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How2: Remove and clean EGR - ZAFIRA A

Discussion in 'All Model Vauxhall / Opel / GM / Holden How2' started by Steve-Pillock, Apr 12, 2013.

  1. Steve-Pillock

    Steve-Pillock Member

    Messages:
    44
    Likes Received:
    9
    Location:
    Fife
    Drives:
    Audi A4 Tdi, Mazda 323f 1.5, Zafira A Dti
    This is my first Vauxhall Guide and i have very little mechanical knowledge so i use terms such as thingy.

    If you cannot or do not want to blank off your egr and just wish to clean it here are the simple steps to follow:

    Time: 30 - 45 minutes

    Tools Needed:

    Socket Set
    Torx T30
    Wives/Husbands Toothbrush
    (optional) carb cleaner

    [​IMG][/URL]

    Firstly in the engine bay remove these two bolts with a T30 and remove the yellow oil cap

    [​IMG]

    Lift the engine cover off

    [​IMG]

    This is the egr here, remove the two clips that i am pointing to with your thumb and forefingers

    [​IMG]

    Shift them out of the way so you have access to the two bolts

    [​IMG]

    As you can see my two bolts were rusted and not much use to anyone so i hammered on a 11/32 socket onto the top bolt and a 9/32 onto the bottom bolt and they came off. Some models have a 13mm bolt. Anyway pull the EGR valve off and it should look like this:

    [​IMG]

    Next take your wife/husbands toothbrush and clean all of the black deposits out of the round hole and the top ovalish hole. Plenty of sooty crap should come out. (optional) you can use carb cleaner too but i managed with just the toothbrush and patience.

    [​IMG]

    Re-fit everything in reverse and take it for a test drive. Dont forget to put your wife/husbands toothbrush back and blame the dirt on the kids.
     
  2. Steve-Pillock

    Steve-Pillock Member

    Messages:
    44
    Likes Received:
    9
    Location:
    Fife
    Drives:
    Audi A4 Tdi, Mazda 323f 1.5, Zafira A Dti
    I meant to say this is on a Z18XE Dutch Imported Opel Zafira. The 1.6 EGR is located a few inches higher than the 1.8 but its the same process. Also the 1.6/1.8 egr valves are interchangeable.
     
  3. DrewKrewUK

    DrewKrewUK Electronics Technician

    Messages:
    405
    Likes Received:
    78
    Location:
    Shildon
    Drives:
    Vauxhall Zafira 1.8 16v Comfort 2001
    Nice clear-cut guide. Most grateful. My UK spec Zafira A Z18XE didn't have an EGR valve unit fitted (but at least I knew where to look to see if it did lol)
    Thanks!
     
    Last edited: Feb 23, 2014
  4. acriduk

    acriduk Well-Known Member

    Messages:
    392
    Likes Received:
    41
    Location:
    uk
    Drives:
    1.6 Zafira B
    Do not use carb cleaner!!! You will damage the internals of the valve it is too strong. There is a proprietary EGR valve cleaner made by Wynns. BTW it won't be long until it fails again. Just blank off hole and be done with EGR all together. I did mine 2 years ago and it has not caused an issue
     
  5. Rwspakde

    Rwspakde New Member

    Messages:
    5
    Likes Received:
    1
    Location:
    Indonesia
    Drives:
    2003 Zafira CD Z18XE
    Steve, sorry for bumping on an old thread (you've probably even sold the car lol). Anyway, why did you clean it? Were you having fault codes or getting the eml on? Great guide btw; very clear. Dank u.
     

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