Hightower (3rd November 2011)
That little pipe I am sure is a connected to create a vacuum that operates the egs valve itself no vacuum = no egr operation.
Disconnect the little pipe and stick a screw in it just to stop and debris ingress and pop something over where it used to connect to the egr valve itself?
It's correct though - the rubber pipe is likely a breather pipe - purpose unknown mine doesn't have one, but another 300tdi down the road does.
The EGR just recycles exhaust gases on the basis that a certain amount of said gas will be unspent vaporous fuel - thus recycling this will result in lower emissions (in theory).
The difference in emissions in negligible at best, blanking this off results in a better low-end torque as the intake system is sealed and continuous - thus providing the turbo with a good flow of cool air.
or so the theory goes.
So on mine, rather than having 2 holes on the backside like in the vid, I have a hole on the front and only one on the back? I've seen one step-by-step saying simply cap the vacuum valve off and this will effectively do the same job?
Like this: http://www.rx7.org/Robinette/egr.htm
EDIT: Says cars after '94 will flash EML so best to do it with the alum method.
As long as you're putting a solid gasket over it, it doesn't really matter.
Have you checked the dreaded auction site? there may well be some blanking plates for sale - you could find out what material is preferred for the plate.
Capping the vacuum valve may to some extent do the trick, but a sealed blanking plate just ensures that it is properly and physically closed.
There are a million and one ways to do it - it's just a matter of what you have time to do.
Ok, going to go with the blanking method I think, but my car isn't exactly popular like an Astra so nothing on eBay - home made job it is.
Just hope I can get the valve off as the big hole in the pic you can see, that nut was stuck solid.
DT2 (3rd November 2011)
They're not too difficult to fabricate. But due to the horrendous coking of the valve parts usually get stuck (fused almost) on a monumental scale
Any special advice for undoing the nut? Tried belting it with a hammer some. Need to try and find something to fit the spanner to give more leverage.
Took me 2 hours alone on mine..... one whole tin of WD and a pound weight hammer, just tapping away, but it went eventually. try tightening slightly (1/16th turn) before loosening.
Brought it into DT here, clamped it in a vice, WD40, big hammer, heat treatment blowtorch until nice and pretty, more hammering, more 12v pulsing, rinse and repeat. Soon started moving again!
Went for MOT last time, the guy looked under the bonnet.."I see what you did there..good call!". Never caused me any issues.
Thinking on, I bought a cheapo 12v impact wrench (think wheelbolts) - it took standard sockets too - one of those is a lifesaver for stubborn bolts. Satisfying too, hearing the flywheel spin up, then "CLUNK!" and off goes the bolt.
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