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System Testing: Montero

  1. Check hoses for correct routing and condition. Cold start engine and run at idle. Observe the secondary EGR valve for operation as engine speed is increased to 2500 RPM. There should be NO secondary EGR operation after cold start. If secondary EGR valve operates, replace thermo valve.
  2. Warm engine until coolant reaches 131°F (55°C). Increase engine speed to 2500 RPM. Observe the secondary EGR valve. The secondary EGR valve should operate. If secondary EGR valve is inoperative, check EGR valve and thermo valve. Replace as necessary.
  3. Detach Green-striped hose from thermo valve. Connect vacuum pump and apply vacuum. If no vacuum is available, valve is okay.
  4. Disconnect Green-striped hose from fitting at carburetor and connect vacuum pump to hose end. Apply 5.9 in. Hg vacuum while opening sub EGR valve by hand.
  5. If idle speed becomes unstable, secondary EGR valve is okay. If idling speed remains stable, valve is NOT okay. Replace EGR valve as necessary.
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