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Hot exhaust, melted EGR valve, no exhaust restriction

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Old 07 Mar 2011, 03:40 am
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Default Hot exhaust, melted EGR valve, no exhaust restriction


My first post here. Be gentle.

My friend's 2001 PT Cruiser keeps melting EGR valves. The exhaust air is hot. No exhaust restriction, catalytic converter is fine, same problem even with catalytic converter unplugged. The mechanic is at a loss about what the problem could be.

FYI: Tropical climate, as my username implies, around 90F every day.

Any suggestions? No engine codes, other than a very recent P1193 (IAT Circuit High) which is probably unrelated and came after the EGR problems (and maybe from when the engine was worked on to replace the last EGR valve).

Many many thanks.
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Old 07 Mar 2011, 01:44 pm
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Default Re: Hot exhaust, melted EGR valve, no exhaust restriction

I'd guess the valve is being held open for some reason-
It's probably not designed for constant, full flow.
The IAT is then getting TOASTED by the exhaust flow.

I doubt the exhaust is getting too hot.

Why? No idea.

install a restrictor until you figure it out
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egr 2001 exhaust hot

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