AMC Coupes/Sedans/Wagons 1975-1988 Repair Information

Exhaust Gas Recirculation (EGR) System

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OPERATION



See Figures 1 through 7

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Fig. Fig. 1: Common EGR system components1975-79 8-cylinder engines



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Fig. Fig. 2: Location of the EGR system components1975-79 6 cylinder engines



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Fig. Fig. 3: Typical EGR system used on 8 cylinder engines1980-88 models



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Fig. Fig. 4: EGR system used the 4-151 engine



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Fig. Fig. 5: EGR system component locations1980-82 6 cylinder engines



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Fig. Fig. 6: Location of the Exhaust Gas Recirculation (EGR) valve



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Fig. Fig. 7: Some EGR valves may be tested using a vacuum pump by watching for diaphragm movement

The Exhaust Gas Recirculation (EGR) system consists of a diaphragm actuated flow control valve (EGR valve), coolant temperature override switch, low temperature vacuum signal modulator, high temperature vacuum signal modulator.

All 1977 and later California units have a back pressure sensor which modulates EGR signal vacuum according to the rise or fall of exhaust pressure in the manifold. A restrictor plate is not used in these applications.

The purpose of the EGR system is to limit the formation of nitrogen oxides by diluting the fresh air intake charge with a metered amount of exhaust gas, thereby reducing the peak temperatures of the burning gases in the combustion chambers.

EGR Valve

The EGR valve is mounted on a machined surface at the rear of the intake manifold on the V8s and on the side of the intake manifold on the sixes.

The valve is held in a normally closed position by a coil spring located above the diaphragm. A special fitting is provided at the carburetor to route ported (above the throttle plates) vacuum through hose connections to a fitting located above the diaphragm on the valve. A passage in the intake manifold directs exhaust gas from the exhaust crossover passage (V8) or from below the riser area (Sixes) to the EGR valve. When the diaphragm is actuated by vacuum, the valve opens and meters exhaust gas through another passage in the intake manifold to the floor of the intake manifold below the carburetor.

Coolant Temperature Override Switch

This switch is located in the intake manifold at the coolant passage adjacent to the oil filler tube on the V8s or at the left side of the engine block (formerly the drain plug) on the Sixes. The outer port of the switch is open and not used. The inner port is connected by a hose to fitting at the carburetor. The center port is connected to the EGR valve. When coolant temperature is below 115°F (46°C) (160°F (71°C) on the 8-304 with manual transmission), the center port of the switch is closed and no vacuum signal is applied to the EGR valve. Therefore, no exhaust gas will flow through the valve. When the coolant temperature reaches 115°F (46°C), both the center port and the inner port of the switch are open and a vacuum signal is applied to the EGR valve. This vacuum signal is, however, subject to regulation by the low and high temperature signal modulators.

Low Temperature Vacuum Signal Modulator

This unit is located just to the right of the radiator behind the grill opening. The low temperature vacuum signal modulator vacuum hose is connected by a plastic T-fitting to the EGR vacuum signal hose. The modulator is open when ambient temperatures are below 60°F (16°C). This causes a weakened vacuum signal to the EGR valve and a resultant decrease in the amount of exhaust gas being recirculated.

High Temperature Vacuum Signal Modulator

This unit is located at the right front fender inner panel. The high temperature vacuum signal modulator is connected to the EGR vacuum signal hose by a plastic T-fitting. The modulator opens when the underhood air temperatures reach 115°F (46°C) and it causes a weakened vacuum signal to the EGR valve, thus reducing the amount of exhaust gases being recirculated.

REMOVAL & INSTALLATION - EGR Valve



  1. Remove the air cleaner assembly from the carburetor.
  2.  
  3. Unfasten the vacuum line from the top of the EGR valve.
  4.  
  5. Loosen and remove the two screws which secure the valve to the manifold.
  6.  
  7. Remove the EGR valve, complete with its gasket.
  8.  
  9. Installation of the EGR valve is the reverse of its removal. Always use a new gasket. Tighten the valve securing bolts to 13 ft. lbs.
  10.  

Valve and Passage Cleaning

  1. Remove the EGR valve.
  2.  
  3. Use a wire brush to clean all the deposits from the stainless steel pintle.
  4.  
  5. Press down on the pintle to open the EGR valve and them release it to close the valve. Replace the valve assembly if it will not close fully.
  6.  
  7. Inspect the manifold passages. If necessary, clean them with a spiral wire brush.
  8.  

On 6-cylinder engines, deposits will build up most rapidly in the upper passage. If the deposits cannot be removed with the wire brush, use a9/16in. (14mm) drill bit. Rotate the drill by hand, after coating it with heavy grease.

  1. Install the EGR valve with a new gasket.
  2.  

 
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