Blanking off the EGR Valve (V6)

[Gnome]

Just done it tonight, and will report back at the end of the week if everything's ok.

Saw a guide on VVOC, and thought I'd have a crack. I'll put a post on here, so that VxON members can see how's it done too.

Basically, you've probably heard of the common problems with cracked manifold and EGR pipes.

A costly repair, and annoyingly, can strike at any time - good reason to treat your car carefully from first start-up. I don't go above 3000rpm until the temp gauge is about 90.

Anyways, I digress.
I took a trip to Dave Jordan this weekend, and he replaced the rear manifold and EGR pipe on my V6 vectra. The manifold was definately cracked, but not sure on the EGR pipe - got it changed anyways.

Dave spotted the EGR valve itself was blowing as well though.
First sign being that, after changing the above, there was still a noticeable "spitting" noise when the car was warming up, and under load.

The EGR valve servces the purpose of feeding warm air from the rear manifold, back in to the intake, to keep emissions down (apparently), and aid car warm-up.

It's not needed. The proof being that the Omega's don't have it as far as I'm aware, or the newer Vectra's.

So, you can simply blank it off. You can't simply remove it, as it'll set off your Engine management light.

Here's what I did:

Left car to cool down - about 2-3 hours.
Removed the connector from the EGR valve, and un-did the two torx bolts (size 45).
Be careful not to drop the bolts or gasket.
Get the gasket, and trace it on to some sheet metal. In my case, I used a pepsi max can!
I cut it out, and carefully drilled the holes for the bolts. Obviously, you won't need to cut out the holes in the middle which would serve as airways for air going in and out the valve.
I then simply placed it between the bottom of the EGR valve, and the gasket.
Simply then bolted it back in place, and re-connected the connector.

That's it. Took me about 30mins in total. Dead easy job...

[whitebullet]

Just done it tonight, and will report back at the end of the week if everything's ok.

Saw a guide on VVOC, and thought I'd have a crack. I'll put a post on here, so that VxON members can see how's it done too.

Basically, you've probably heard of the common problems with cracked manifold and EGR pipes.

A costly repair, and annoyingly, can strike at any time - good reason to treat your car carefully from first start-up. I don't go above 3000rpm until the temp gauge is about 90.

Anyways, I digress.
I took a trip to Dave Jordan this weekend, and he replaced the rear manifold and EGR pipe on my V6 vectra. The manifold was definately cracked, but not sure on the EGR pipe - got it changed anyways.

Dave spotted the EGR valve itself was blowing as well though.
First sign being that, after changing the above, there was still a noticeable "spitting" noise when the car was warming up, and under load.

The EGR valve servces the purpose of feeding warm air from the rear manifold, back in to the intake, to keep emissions down (apparently), and aid car warm-up.

It's not needed. The proof being that the Omega's don't have it as far as I'm aware, or the newer Vectra's.

So, you can simply blank it off. You can't simply remove it, as it'll set off your Engine management light.

Here's what I did:

Left car to cool down - about 2-3 hours.
Removed the connector from the EGR valve, and un-did the two torx bolts (size 45).
Be careful not to drop the bolts or gasket.
Get the gasket, and trace it on to some sheet metal. In my case, I used a pepsi max can!
I cut it out, and carefully drilled the holes for the bolts. Obviously, you won't need to cut out the holes in the middle which would serve as airways for air going in and out the valve.
I then simply placed it between the bottom of the EGR valve, and the gasket.
Simply then bolted it back in place, and re-connected the connector.

That's it. Took me about 30mins in total. Dead easy job...

i take it then that the car does not run rough or any adverse affects to blanking of the egr, ive wanted to do it for a while

[Gnome]

No, it ran sweet over the quick run I did.

Looking at the thread on VVOC, lots of people have done it.

Folks reported that it actually ran a bit smoother, and some got slightly better mpg figures too...

As I said, I'll report back at the end of the week, and let you all know. ;)

[jimbobthegreat]

I did mine yesterday using same method, works a treat

[whitebullet]

look like i'll be blanking of the egr valve then when this rain and wind stops

[jimbobthegreat]

I did mine in the rain lol!! had no choice really it was a quick "off with the valve and quickly run to the shed to make a gasket" scenario lol!

[Gnome]

Superb!

Run to work today (about 12 miles), was sweet as!
Didn't really notice a difference in "smoothness" on the throttle, but that annoying "spitting" sound is now gone!

Lucky for me, my folks bought a house with a 1 and a half size garage.
As I'm the only one in the house that can drive, the garage is mine! :D

[Gnome]

Well, quite a trip today, and it's held up very well.
Clocked up about 80 miles today, and all is well.
Best 45p I ever spent! :D

[fluffsri]

sounds good! ive had a blanking plate made for ages and not got round to fitting it. will have to do it now. Omegas do have the EGR as i got one fron a scrappy to replace mine but the plug is 180 degrees out the cable fitted with a bit of a stretch.

[Gnome]

Deffo worth it.
Thank you for the correction on the Omega. Thinking about it, I think Dave Jordan may have told me that the other week when I went to see him...

Do any of you 2.6 or 3.2 owners have them?

[SilverGSi]

if you`ve used a coke can(similar) to make the gasket, you`ll find it wont be long before it burns through, so I`ve read.Use a thicker metal.

[Gnome]

if you`ve used a coke can(similar) to make the gasket, you`ll find it wont be long before it burns through, so I`ve read.Use a thicker metal.

Why?

It's ally, and ally has a 600+ degree melting point - it's what the pistons are made of...

[Gnome]

I also wouldn't expect the exhaust gases that would normally travel through the valve to be that hot either!

[Dogudders]

I did this the other day to sort out my blowing egr valve. Used a decent bit of ally and some gasket sealant, works a treat. No more annoying blowing noise :Cool2:

[poolieboy]

sorted now used a baccy tin lid runs 100% better now,feels a lot more responsive ,done about 250 last week to and from work still got plenty left in tank, well more than usual.

[yinyan]

can you tell me were it is.lol.any pics etc.sorry not long had vectra..

[Gnome]

V6?
Have a look here: http://www.vvoc.com/forum/showthread.php?t=38556

[b3rt]

I have a 2.o dti, i have been advised through these forums that the problems starting could be my EGR, i am going to clean it.

Is it worth blanking it off?

[michaelcaine22]

can this be done on a 2.2 dti ?

[m/port lad]

But the egr pipe can still leak and the coke can method can burn to as the hot exhaust gases can burn a hole through as its very thin metal.
Most people on vvoc are now taking the egr pipe off and cutting the nuts off the pipe, then placing two 5p's in each nut with some exhaust paste and bolting them back on, and it wont burn through as its 3/4mm thick.


Best 45p I ever spent! :D
And it only costs 20p LMAO