I sprayed carb cleaner into the IAC bleed hole and around the butterfly, then replaced plugs and wires, coolant temperature sensor. Runs smooth for 15-20 seconds on a cold morning, then rough high idle about 1300 - 1600. It seems to stick in one place or another, occasionally as high as 2500-3000 rpm and will increase when I push in the clutch to shift, even though I already took my foot of the gas. This afternoon it was warm so I turned on the AC on the way home and the idle dropped to normal (1000 with AC on) and smoothed out. I get vacuum to the orifice in the EGR vacuum line, but at idle no vacuum through the EGR solenoid. Could this be the problem? When should I be getting vacuum to the EGR valve and how can I check this out? I don't want to just keep buying parts til I get lucky.
You didn't waste any money on what you replaced, so don't feel bad about it. The egr valve can be cleaned and may be the cause. Make sure the passageways are clear after you remove the valve.
February, 22, 2007 AT 7:40 PM
I took your advice and decided to take apart the egr valve and clean it. Went to the parts store to buy replacement gaskets first and they can not match my EGR valve. I looked everywhere I could find on the WEB and the picture of the egr valve for my 2002 saturn 1.9 L, SOHC, does not match the connector or anything else. Mine has a part number 21210000 on the top of the diaphragm, is more square, doesn't have any electrical connection on the top, and the connection to the exhaust tubing is in the horizontal. No idea how to figure this out.
February, 22, 2007 AT 8:17 PM
Before anyone blows a hole through me, I am a meager service writer. :)
I'm throwin this out here anyway:
Are we looking at the right part?
February, 22, 2007 AT 9:32 PM
Boy do I feel stupid. My EGR valve is just where you said and looks just like it. Thanks so much. I think the " valve" I was looking at is part of the AIR system during engine warm-up. I'll give it another try. What should I look out for when I try to clean the EGR valve?
February, 23, 2007 AT 5:25 AM
Any black carbon build up. Get a good intake cleaner to spray it out. Anywhere the air flows through should be looked at and cleaned as well. Use rags, pipe cleaner etc. On the engine side. On the egr there is pintle that may be sticking spray it out good. A google search on cleaning egrs may expose a little more.
February, 27, 2007 AT 7:53 PM
I pulled the egr valve and it was pretty clean. A thin film of fine carbon, but no chunks. The pintle (has a little torx head in it) was moving freely. It has some light spring pressure that I could push in with a small screwdriver. If I shake it it rattles a little. I sprayed it with carb cleaner, but I want to check it out before I put it back on. How do I go about testing it off the engine? Can I apply some voltage to it to make it move in (open)? If so, how much and which contacts? It has 5 electrical contacts in the connector.
February, 28, 2007 AT 3:54 AM
By chance did you check for any codes in the computer?
Here's the connector view:
I can't say that a rattle should be present, short of a piece of carbon in there, but if you cleaned the pintle, That's about the best you can do on those as I understand.
February, 28, 2007 AT 6:10 PM
The only codes so far have been cyl 1/4 misfire and 0507 high idle. I replaced the cleaned egr with no change. I replaced the IAC, which did not appear gummed up, but still no change. I replaced the PCV just for kicks, no change.
The engine will still jump up to 2500-3000 rpm with the clutch in after driving for a few minutes and when this happens the car will maintain speed in gear or even speedup. I have plenty of power and it seems to rev up fine without a flat spot or top-out.
If I turn it off when the idle is that high and restart it immediately, then it starts running at close to about 1500-1600 RPM. This might mean there is a timer involved. It also will rise by itself if I just let it sit in idle.
I still did not replace the Throttle position switch, MAP, or O2 sensors, but I'm not getting any codes for them.
February, 28, 2007 AT 6:54 PM
Po301 and po 304?
What code # (s)
February, 28, 2007 AT 8:10 PM
Sorry, yes P0301 and 0304, then 0507. Nothing else so far.