Egr Solenoid Rebuilding? (Page 1/10)
Kitskaboodle AUG 17, 04:38 PM
I know there is a thread here on finding an alternative egr solenoid for the V6 but I’m surprised there isn’t more talk & effort put in to rebuilding the original one. Even if you have to buy a new, cheap and generic egr valve to pirate parts from.
I have seen a thread or two over the years of some who have dissected one and posted pics. Again, I’m surprised more people (who need one) are not going down this path.

Your input??
Thanks, Kit

[This message has been edited by Kitskaboodle (edited 08-17-2022).]

tnkgnr AUG 17, 09:59 PM
I recently took mine apart to figure it out and was surprised at how simple it is (and saw the other threads about it here). It's just an electromagnet that attracts a metal disk - rewiring one isn't hard. I've had three examples now where the metal winding is shorted, but the vacuum switch is fine. Seems if you just connect up any old solenoid that controls the flow of vacuum it should work. I searched for the cheapest EGR out there, and found one for $9 on a Mazda, part #911-707. Will caveat that I don't know if it works, as my check engine didn't seem to activate with the original unplugged. Of course its not real pretty, but a motivated person could package it up okay I think.

Rewinding...
Kitskaboodle AUG 17, 11:29 PM
I did a test on my 85 GT today. I put a vacuum gauge in-line with the hose that goes to the egr valve, warmed up the engine, revved it to 2500-3000 rpm and the vacuum gauge barely read 2.5 hg. I heard the minimum is at least 5 hg. Despite no codes, I think my egr solenoid is not allowing vacuum to get to the egr valve. And my Nox is way too high.
Kit
Mike in Sydney AUG 17, 11:59 PM

quote
Originally posted by Kitskaboodle:

I did a test on my 85 GT today. I put a vacuum gauge in-line with the hose that goes to the egr valve, warmed up the engine, revved it to 2500-3000 rpm and the vacuum gauge barely read 2.5 hg. I heard the minimum is at least 5 hg. Despite no codes, I think my egr solenoid is not allowing vacuum to get to the egr valve. And my Nox is way too high.
Kit



Check your EGR valve and the connections on the vacuum lines. To check the EGR valve, disconnect the vacuum line from the valve. Feel under the valve and push up on the plate / diaphragm. While holding the diaphragm up, place your finger over the port on the EGR valve. Release the diaphragm. You should feel the vacuum suck your finger against the port and the diaphragm should stay in the up position. It it doesn't or the diaphragm slowly returns, you probably need a new EGR valve - which are still available from Summit, Rock Auto, etc.

You should also check you vacuum lines and the rubber connectors. Sometimes the plastic lines age and split. I found that my problem was a bad connector at the EGR solenoid valve. I replaced it and resolved the problem.

It the problem is a split or broken vacuum line Rodney Dickman and the Fiero Store sells replacement sets.
Kitskaboodle AUG 18, 09:12 PM
Hi Mike, those are all good points & suggestions. Before I took my egr solenoid off this afternoon, I checked all the connections and everything looks good. However, I probably need to verify the full integrity of the hard lines that go under the plenum. As an fyi I just changed the cat, new 02 sensor, new egr valve, Seafoamed engine and Seafoam in the the gas tank and it failed with high Nox. Going on the basis that my egr solenoid is BAD, I decided to take off my egr solenoid, take it apart and try to see what is the issue. I heard the coil winding wires often break/ have contact issues. Mine look “so-so” with only a small amount of corrosion. I’m going to resolder the leads onto the connectors, clean everything up and then apply 12 volts and see if she “clicks”. My gut feeling is one of the components in the potted square box is bad.
In that case it will be time to look for another unit. Taking one apart has been a great learning experience! Here is a few pics of the disassembly:
Kit[img]https://images.fiero.nl/userimages/Kitskaboodle/ 35F79F7D-0E46-49DF-B417-C3FCE130B817.jpeg[/img][img]http s://images.fiero.nl/userimages/Kitskaboodle/985616A9-52D1-4B54-904E-3FCAEF81A37B.jpeg[/img]

[This message has been edited by Kitskaboodle (edited 08-18-2022).]

Kitskaboodle AUG 18, 09:17 PM
More pics..,
Kit
shemdogg AUG 18, 09:18 PM
Not a permanent fix but if you need it to pass smog you could borrow the one I have from the motor I pulled. If you want to swing by and see if mine makes any difference on your motor, send me a pm.

shem
Kitskaboodle AUG 18, 11:01 PM
Thanks for the offer Shemdogg! 😀
My 86 GT has a good one if I need to do that. I’m hoping that my “refurb” fixes my problem. If not, I’m hoping to get one soon from a local yard.
Kit
skywurz AUG 18, 11:51 PM
There are some stone like filters in the inlet of the solenoid that seem to get clogged. The last one i messed with had perfect vacuum but it was not making it to the egr. After i punched out the filter stones everything worked properly
Kitskaboodle AUG 19, 08:50 AM
Stone like filters?
Is that located in the long round filter portion?
Kit