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EGR valve cleaning.
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08-02-2012 9:17pm#1I did a bit of a job on the Astra today which I said I'd take a few pics of as a bit of a 'how to' perhaps.
As most of us know there are several problems associated with modern diesels and I started having one of them over the last week or two.
I developed an intermittent EGR flow fault and after some further diagnostics, was happy that it wasn't the EGR valve/solenoid itself but likely to be a clogged pipe or EGR ports.
So, on my day off, back under a bonnet again:rolleyes: to strip the EGR system and give it all a clean.
On my engine(Opel 1.7cdti) this is actually a more involved job then the majority of other engines due to the EGR valve being part of the throttle body housing, but it still may give people a better idea of what's involved.
Start stripping, battery, battery tray, IC pipes etc had to come out;
The black housing behind the throttle body is the EGR housing, As I said, on other engines this is much more accessible and is separate to other parts;
When I stripped the EGR/throttle body housing and intake pipe, I was actually shocked at how much build up there was.....and how the engine was running as well as it was before now:eek:
Intake pipe;
EGR housing;
Before starting on the above build up I checked the EGR valve/solenoid as it can be the case that gasses/deposits can get up through the valve and into the valve spring and solenoid, causing them to stick, leading to failure.
In my case, they were spotless and moving freely;
Sign of the engines origin;
In the vast majority of applications, the solenoid/actuator housing can be removed from the EGR valve;
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So onto cleaning.
I used an old screw driver to scrape the heavy stuff off and unblock the EGR ports and then, for the EGR housing its self, used a wire brush to remove the remaining deposits.
Much better;
EGR housing/valve/solenoid back together;
Now for the more awkward part, The badly blocked intake pipe and even more so, the inlet manifold itself.
The first goat the pipe;
After getting some of the heavy deposits out, onto the trick to get the remaining stuff out.....leave it soaking in oven cleaner:D
While that was soaking I moved onto the inlet manifold. Ideally, this would be removed and cleaned throughout but in my case, most of the common rail system has to come out to remove the manifold, which, I really wasn't inclined to do this time.
The build up in the manifold;
My plan for not letting lots of loosened carbon deposits get in through the valves and make a mess of everything was to hoover while I removed the deposits...so, out of the garage and around to the house to use the hoover(the wife wasn't home luckily:P)
Seal around the hoover to make sure all loose carbon get removed;
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The inlet manifold looking a bit better;
And, after a hour of soaking in the oven cleaner, then intake pipe looks a little better;
After putting everything back together off I went for a test drive with the diagnostics attached.
Immediately, throttle response is noticeably improved, boost is building faster and smoother and top end/high rpm, where the restriction would have had the most effect, is vastly improved. She used to fly up to 120kp/h and then start to die off(triggering limp home mode over the last week or so), now the same acceleration gets up to 155-160kp/h(on a private road:P) before tailing off. No doubt economy will be improved too.
Cleaning an EGR like this would give most diesels a marked improvement as the deposit build up, especially when used a lot in the city, often leads to many of the EGR issues that modern diesels suffer from, and with the latest craze for diesels, will become even more common.
If you have a go at cleaning it out yourself you may well save yourself a good few quid on future repairs.0 -
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