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EGR Valve Test - Subaru Outback Legacy 1999 2.5 Liter Engine Failed EGR Test.

I recently had a Test Only Station test my car and every thing passes but the EGR functional test. The EGR valve functions, it holds position under vacuum test and the EGR solenoid switches on and off with changes in rpm’s. There are no OBD II trouble codes for EGR or any other system on my scanner. I am comfortable working on engines, before the test I changed the timing belt, water pump, oil pump, power steering pump, PCV valve, changed oil and filter, and air filters. I find it odd that the only test failed was a subjective test. Then they were eager to perform repairs to make it pass, plus they offered me papers to get a $500 voucher from the State to help with costs, but said it may no cover the repair fees. I told them no thank you and left. I am curious to know your comments regarding EGR test.
Answer:

After the EGR valve holds vacuum, does it open? And if it opens, does it allow exhaust gases back into the intake manifold? You would know it is functioning properly if there is an RPM drop during idle once the EGR valve opens. You can open it manually and look for a change in RPM. If there is no RPM change its a good indication that the valve's passages are plugged with carbon deposits, and restricting exhaust flow. You may use a vacuum pump to open the valve manually at idle, or if the EGR valve allows inserts a tool underneath the valve to prop it open. Make sure the engine is not hot before trying to get your fingers in between the EGR valve and intake manifold. posted by SmogTips Support

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