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EGR Valve Replacement Leads to Other Issues

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    2 years ago we got an error code suggesting that there’s an issue with the EGR valve. yet the engine runs fine. stopped at the shop and had the code cleared.. it’s now been another 2 years and again the code has resurfaced. We’ve learn that this is actually a false error code due to several small issues one being the poor fuel we’re getting from third world counties. So we though best to just have the EGR replaced anyway. doing so last week, has proven beneficial and the van is running better.. but still hesitating.

    Looking at the EGR, shows that yes there is some caked up carbon on the valve and fittings.. which is causing the valve to hesitate and even get stuck open or closed. This seems to suggest that the EGR is a flawed design and will need to be replaced every 3 years.

    Last week while having the van worked on, I thought best to replace the 30K miles NGK spark plugs wit another set of the NGK plugs.. but once the package was home, we heard others complain about bad plugs or counterfeit plugs.. doing more research, we concluded that both sets (the used and new plugs) are both counterfeit. I contact rock auto about this and they claim that don’t sell counterfeit parts.. Yet in the same breath.. Rockauto doesn’t have a physical warehouse and order their parts from third party suppliers. We even got NGK involved in this and based on our finding.. it’s 100% true that our New and old plug are counterfeit. NGK just happens to happens to be the target at this point.

    Knowing that we’re going to have to switch to a different brand.. we’ve selected the autolite plugs based on David Freiburger (hot rod magazines Editor) suggestions. Not only have we replaced the EGR valve with a new one, we replaced the spark plugs and purchased a new set of performance TRQ coil packs.. The van is running better as the red head coil packs are designed to offer a 15% increased performance rate with better throttle response.. We’ll have more data after a few more weeks of driving.


    A few days ago, I thought I may have missed something while cleaning and tuning the van with the new plugs and coil packs. So I thought best to remove the airbox and the intake tube just to get a look at the throttle body.. sure enough.. there’s a small amount of carbon build up on the flapper as well as inside the throttle body. I clean what I could with throttle body cleaner. and the van runs better but we’re still getting hesitation.

    Mind you 2 weeks ago, I had the trans serviced at a shop that claim they would use the BG products flush and fill and the low viscosity ATF fluid. for those two weeks the van shift very smooth.. but this fell out of that smoothness once we replaced the EGR valve. We come to the conclusion that 90% of what we’re experiencing has everything to do with poor fuel that’s bene acquired from third world counties. But I have a plan..

    2 days ago, we found out or confirmed that our 2.0L GDI I4 can run on either regular gas or E85. So we’ve switched up to run just the eFuels from now on and what a difference.. with the new plugs, new coil packs, new EGR and now running on the eFuels.. the van has some pep to it again. yesterday and for the first time in 4 years, I left rubber at the store while leaving the parking lot.. the van just wants to go.. calculating some stats, we’ve concluded that this 162 Horsepower 142 torque stock van is now running 189 horsepower at 156 torque and we’re planning on doing more tweaks in the near future.

    Main thing learn here, is you car/truck can run on the eFuels, best do it.. the only drawback.. less than prefect fuel economy. But we’ll take that as a trade off for more horsepower etc.

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