EGR Blanking
Refer to "EGR" for tools and removal instructions of the EGR Valve.
Right two years I've had this Zafira and it's coked up two EGR valves each costing £80.00 a piece (mainly due to high oil consumption which is common on this engine), so after some advice ferom the guys over at Vauxhall Owners Network I decided to blank off my EGR valve. Like always I will share with you all my progress and outcome of my work.
First job is to remove the EGR by unplugging the electrical connector and then remove the two star bolts holding the valve on (SEE EGR FOR FULL INSTRUCTIONS).
I looked on eBay etc for a valve blanking plate but was unable to locate one, I know people say use a can of drink and cut it up but the thought of driving round with a cut up Pepsi can bolted to my Exhaust manifold didn't seem right. So I got a piece of 3mm Low Carbon Steel (see pic) removed the gasket from the EGR and carefully marked out the shape using a pencil. the following pics show my progress as I fabricated (to the best of my ability) a plate using a hack saw, set of files and a 8mm steel drill bit, if you have managed to purchase a blanking plate then ignore this section.
I looked on eBay etc for a valve blanking plate but was unable to locate one, I know people say use a can of drink and cut it up but the thought of driving round with a cut up Pepsi can bolted to my Exhaust manifold didn't seem right. So I got a piece of 3mm Low Carbon Steel (see pic) removed the gasket from the EGR and carefully marked out the shape using a pencil. the following pics show my progress as I fabricated (to the best of my ability) a plate using a hack saw, set of files and a 8mm steel drill bit, if you have managed to purchase a blanking plate then ignore this section.
OK that's the fabrication aspect of this job over with, it took about an hour and was 2 degrees outside so bloody freezing, however there is always that feeling of self achievement when doing a job like this, if you are going to make your own plate ensure (as in the above pic) that the plate is carefully cleaned and sanded to provide a flat sealable surface.
Refitting
Your first job is to refit the gasket as this will provide a tight seal between the manifold and the plate (see pic).
PS I did the put gasket the right way round in the end hahaha.
PS I did the put gasket the right way round in the end hahaha.
Refitting
Simply place blanking plate over the gasket and fit a bolt into the hole closest to you, lightly tighten with fingers to locate hole.
See told you I fitted the gasket properly in the end.
See told you I fitted the gasket properly in the end.
Refitting
Now bolt on the EGR using the other hole, ensure that the EGR's piston which usually goes through the hole in the gasket is free to move without obstruction and that the plug adaptor on the EGR is within distance of the electrical connector.
before tightening up ensure that the connector is plugged in, now tighten the valve nicely.
before tightening up ensure that the connector is plugged in, now tighten the valve nicely.
EGR is now blanked off.
Since completing this job I have taken the car out and got it well up to operating temperature and I must say it runs like a dream, no sluggish accelerating, no stuttering at 30mph in 3rd or 4th, no hesitant turning over and because the ECU still recognises the EGR's existance no warning light on the dash, now iv'e tried this on my wives Zafira I will do my own Astra hahahahahaha.
UPDATE!!!!!!!!!!!
OK It's been 3 months since I done this job and I must say WOW!!! No more burnt gases entering the combustion chamber, purrs like a kitten even with 100. 000 mls on her clock, no more jerking, lumy idle, heitating.
UPDATE!!!!!!!!!!!
OK It's been 3 months since I done this job and I must say WOW!!! No more burnt gases entering the combustion chamber, purrs like a kitten even with 100. 000 mls on her clock, no more jerking, lumy idle, heitating.