Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
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HOMESERVICE MANUALSCHEVROLET1995SPORTVAN G20, 5.7 KREPAIR AND DIAGNOSIS (SINGLE PAGE)ENGINE MECHANICALAUXILIARY EMISSION CONTROL SYSTEMSEGR FUNCTION TESTINGEGR FUNCTION TESTINGLINEAR EGR
1995 Chevrolet Sportvan G20, 5.7 K
Linear EGR
1995 Chevrolet Sportvan G20, 5.7 KSECTION Linear EGR
- Install scan tester. Ensure P/N switch is operating properly. With engine at normal operating temperature, command EGR pintle position to zero percent. Increase engine speed to 2000 RPM. If scan tester reads actual EGR pintle position at greater than 3 percent, EGR valve is stuck open. Replace EGR valve.
- If scan tester reads actual EGR pintle position at 3 percent or less, command a 25 percent position step increase (i.e. 0-25 percent, 25-50 percent, 50-75 percent, etc.). Observe MAP sensor reading and actual EGR pintle position for 3 seconds. EGR should increase by about 25 percent and MAP reading should also increase.
- If actual EGR pintle position is stable and within 10 percent position of desired EGR pintle position command after 2 seconds, go to next step. If actual EGR pintle position is not as specified, go to step 5).
- MAP reading should have increased when EGR pintle responded. If MAP did not respond, check EGR passages and EGR valve for blockage. If MAP responded, set desired EGR pintle position to 100 percent. If EGR pintle position sets to 100 percent, EGR is okay. If not, replace EGR valve.
- Turn engine off. Check EGR electrical circuit and connecting components. Turn ignition on, check 5-volt reference voltage on harness connector terminal "D" (Gray wire). If 5-volt reference voltage is not present, check ECM. If circuits are okay, replace EGR valve.
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.