Help! FJ80 EGR Vacuum Problems

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I have a 1992 FJ80 that I am trying to get smog tested for the first time (now stationed in CA). Tail pipe emissions are really clean, but it failed because the EGR was not getting a vacuum signal.

I found a problem, the vacuum ports in the throttle body were gunked up. I cleaned them, and now I get vacuum to the EGR VM. I took it in again, but it still fails. I need to get this sorted out ASAP.

What is the driveway procedure for testing EGR vaccum? (How do I know it is fixed?)
i.e. what conditions would activate the EGR?
How do I test the EGR VM and the solenoids?

If anyone could scan the FSM for those few pages, it would be greatly appreciated.

I tried a Chilton, but it was misprinted, the EGR section was omitted so I returned it. I am selling the 92 so I don't want to buy a FSM and shop labor is really expensive in this area.

Thanks,

Jule
 
any 3FE guys there?
 
FSM online

Check this out. For $10, you can get a one day subscription and download all or bits of the FSM.

http://techinfo.toyota.com

BTW, I'm doing my HG right now on my '96 FZJ80. I had a similar problem in the past with EGR related codes turning on the check engine light. I had a wrencher friend look into it a while back and he cleaned out the EGR pipe, and port at the base of the EGR valve itself. The light stayed off long enough to get it inspected but came back on shortly thereafter.

Upon removal of the intake during this HG job I noticed the EGR port where it empties into the intake was completely clogged. This is a 13mm port, or about 1/2 inch. I'll be curious to see how it affects my performance to have this working correctly and the entire intake (top and bottom) vatted and cleaned real good.

If you have not yet replaced your HG I would recommend it as PM, and have the entire intake cleaned.

D
 
It would help if you let us know exactly how it is failing. Now that the ports are clear is it failing at the tailpipe, or is it failing in the functional inspection? If it's failing at the tailpipe, what wre the readings, if it's failing functional, what exactly is the guy telling you??
 
Tailpipe emissions: pass
Function test: Fail, no vacuum signal to the EGR system.

After the first test, I found that the vacuum ports on the throttle body were clogged. I cleaned them and would get vacuum to the EGR VM on the "P" port.
 
I think that you need to see the egr valve open at a certain rpm, that's controlled by the modulator. Pull the bottom larger hose off the bottom and see if you get a pulsing air flow from there when you rev the engine. If you do then I'd replace the Modulator.
 
Jule said:
If anyone could scan the FSM for those few pages, it would be greatly appreciated.



PM me your email address and I'll sent it to you.

Also, check you see that the EGR is not rusted out. I have that problem and had to replace the valve.
 
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lol
 

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