EGR Valve - Kia Forum
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post #1 of 19 (permalink) Old 07-04-2009, 04:57 AM Thread Starter
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Default EGR Valve

Hello All

I've had this problem for a while, it's quite slow and black smoking. Decided to remove the vac hose from the egr valve and what a difference it made.

Removed the valve and checked it. The plunger was very stiff in operation, so gave it a clean and refitted. When the vac was re-connected it was back to how it was.

Ordered a new valve from Kia, fitted it, and.... No change.

The egr is still open at idle.

So I'm thinking it must be a solenoid sticking that controls the vacuum (if there is one)

What do people think.

Any advice would be appreciated.

Regards
Darren
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post #2 of 19 (permalink) Old 07-04-2009, 05:30 AM
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Welcome to the forum.

You are certainly on the right track.

There is a solenoid valve that controls the vacuum to the EGR actuator - the EGR being open at idle will most certainly make it rough - track the vacuum line from the EGR and it should lead you to the solenoid.

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post #3 of 19 (permalink) Old 07-07-2009, 08:46 AM
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Originally Posted by ron1004 View Post
Welcome to the forum.

You are certainly on the right track.

There is a solenoid valve that controls the vacuum to the EGR actuator - the EGR being open at idle will most certainly make it rough - track the vacuum line from the EGR and it should lead you to the solenoid.
Hi Off the top of my head it is located on the fire wall on the drivers side if in the UK
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post #4 of 19 (permalink) Old 07-07-2009, 04:07 PM
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Hi, I found this forum last night, and spent two hours reading to get some ideas, about my 2000 Sedona 2.9TD which was running badly and putting out clouds of black smoke, when the engine was under load.

Today I checked air filter, Intercooler for blockages, hoses around the turbo for splits etc.

Then I found the cause and a cure.
I blanked off with a piece of sheet aluminium, the hose that comes out of the EGR valve and goes into the inlet manifold. She now runs beautifully, loads of power and no smoke.

I appreciate that the 'proper' thing to do was to go down the road of replacing the EGR valve, then if that didnt work look at replacing the solenoid, then look into the ECU to see if it was sending the right signals to the solenoid etc etc. but my way seems to work a treat, and cost me less than a cup of tea.

I hope this helps somebody out there with a smokey Sedona.

cheers
Kev
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post #5 of 19 (permalink) Old 07-09-2009, 03:49 PM
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Right move. All the EGR system does is introduce dirty hot exhaust gas back into the inlet manifold to reduce emissions at cruising speed. Diesels do not like hot dirty air, they like clean cool air that's why they have an intercooler. I blocked the EGR valve off on my O3 Sedona and cleaned the 100ks worth of black treacley goo out of the inlet manifold. You want to clean the intercooler as well if a high miler and change the oil, oil filter and air filter about every 6000 miles.

Happy motoring.
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post #6 of 19 (permalink) Old 09-14-2009, 02:39 PM
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Question Kia Sedona 2.9TDi black smoke & poor acceleration

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Originally Posted by Striker View Post
Hi, I found this forum last night, and spent two hours reading to get some ideas, about my 2000 Sedona 2.9TD which was running badly and putting out clouds of black smoke, when the engine was under load.

Today I checked air filter, Intercooler for blockages, hoses around the turbo for splits etc.

Then I found the cause and a cure.
I blanked off with a piece of sheet aluminium, the hose that comes out of the EGR valve and goes into the inlet manifold. She now runs beautifully, loads of power and no smoke.

I appreciate that the 'proper' thing to do was to go down the road of replacing the EGR valve, then if that didnt work look at replacing the solenoid, then look into the ECU to see if it was sending the right signals to the solenoid etc etc. but my way seems to work a treat, and cost me less than a cup of tea.

I hope this helps somebody out there with a smokey Sedona.

cheers
Kev

My Sedona 2.9TD 2000 also has black smoke and poor acceleration.
I've changed the fuel, oil and air filters plus full oil change, tried redex in the diesel and then fuel injector cleaner, all to no avail.
My last resort is to blank off the egr valve but as a complete novice could someone advise me whereabouts this should be blanked off?
I've located the EGR valve assembly which has two bolted sections, one of which is underneath and I can't get to with a spanner.

The other section (located on the side) has a rigid metal hose attached to it that comes out of the EGR valve assembly and round into the intake manifold (not sure of the air flow direction though??)

Could anyone advise where the EGR should be blanked ie at the valve end or at the intake manifold end as I don't have a clue (please please don't tell me it's the one underneath the valve that needs blanking otherwise it's another trip to the Kia garage ££££

Any diagrams labelled so an idiot can understand them would be extremely appreciated.

Cheers
Norm
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post #7 of 19 (permalink) Old 09-14-2009, 05:34 PM
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Originally Posted by stormin65 View Post
My Sedona 2.9TD 2000 also has black smoke and poor acceleration.
I've changed the fuel, oil and air filters plus full oil change, tried redex in the diesel and then fuel injector cleaner, all to no avail.
My last resort is to blank off the egr valve but as a complete novice could someone advise me whereabouts this should be blanked off?
I've located the EGR valve assembly which has two bolted sections, one of which is underneath and I can't get to with a spanner.

The other section (located on the side) has a rigid metal hose attached to it that comes out of the EGR valve assembly and round into the intake manifold (not sure of the air flow direction though??)

Could anyone advise where the EGR should be blanked ie at the valve end or at the intake manifold end as I don't have a clue (please please don't tell me it's the one underneath the valve that needs blanking otherwise it's another trip to the Kia garage ££££

Any diagrams labelled so an idiot can understand them would be extremely appreciated.

Cheers
Norm
Norm, just undo the rigid metal hose that runs round to the inlet manifold at the EGR valve end. fashion a blanking plate out of a thin piece of sheet metal (someone on here used a coke can). My mechanic used a sheet of cardboard on a Shogun which worked long enough to prove the problem before it burnt through !) Just slip it onto the two bolts, then rebolt the hose up. Dont touch anything underneath the valve.
Once you have removed the air filter box etc so you can get at it, it should take all of about 5 mins, and no money.
Once I did this this I revved the engine and still got clouds of smoke. I feared it hadnt made any difference, but that must have been soot built up in the exhaust, because once I drove the car it was fantastic.

Doing this, transformed my Sedona. I hope it does the same for yours.

Good luck
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post #8 of 19 (permalink) Old 09-15-2009, 02:31 PM Thread Starter
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Hi There

Just to check it, you could remove the small rubber pipe on the front of the EGR valve.(same effect as the coke can trick). This stops the valve operating.

Just a thought

Regards Darren
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post #9 of 19 (permalink) Old 09-15-2009, 02:40 PM
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Thumbs up Kia Sedona 2.9TDi black smoke & poor acceleration

Quote:
Originally Posted by Striker View Post
Norm, just undo the rigid metal hose that runs round to the inlet manifold at the EGR valve end. fashion a blanking plate out of a thin piece of sheet metal (someone on here used a coke can). My mechanic used a sheet of cardboard on a Shogun which worked long enough to prove the problem before it burnt through !) Just slip it onto the two bolts, then rebolt the hose up. Dont touch anything underneath the valve.
Once you have removed the air filter box etc so you can get at it, it should take all of about 5 mins, and no money.
Once I did this this I revved the engine and still got clouds of smoke. I feared it hadnt made any difference, but that must have been soot built up in the exhaust, because once I drove the car it was fantastic.

Doing this, transformed my Sedona. I hope it does the same for yours.

Good luck
Hi Kev,
Thank you so much for your speedy response....I managed to block the EGR off with several layers of an empty Red Bull Can using the gasket as a template (one piece seemed too flimsy). I'd already purchased new gaskets (£3.63 from Kia) so fitted them as well.
She now runs like a dream with full power resumed and only a small amount of smoke but this is probably down to the fuel injector cleaner that is still in the fuel.

Just one other point though, would it make a difference to which end of the pipe you block off as the front one is more accessible? Just a thought for future ref.

Thanks again!
Norm
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post #10 of 19 (permalink) Old 09-16-2009, 03:41 PM
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Quote:
Originally Posted by westj66 View Post
Right move. All the EGR system does is introduce dirty hot exhaust gas back into the inlet manifold to reduce emissions at cruising speed. Diesels do not like hot dirty air, they like clean cool air that's why they have an intercooler. I blocked the EGR valve off on my O3 Sedona and cleaned the 100ks worth of black treacley goo out of the inlet manifold. You want to clean the intercooler as well if a high miler and change the oil, oil filter and air filter about every 6000 miles.

Happy motoring.
For the CRDi version, is the EGR valve sat in the middle of this picture ( just to the left of the open air intake on the air-filter box) :
http://tinyurl.com/bs335
If so, are we talking....like two pairs of bolts and the rubber hose on the diaphram ?
Also, is there any special brand of snakeoil to clean the valve and inlet manifold with ?
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