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Thread: EGR cooler *you'r fired*

  1. #1
    Regular Member Razzemup's Avatar
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    Default EGR cooler *you'r fired*

    Hi,

    My ERG cooler have gone bad and I am loosing coolant. I want to bypass the cooler and factor out the hole ERG system. I know about the blanking plate and the remap but not about the cooler.

    Has anybody bypassed the cooler? Just wonder what I need to do as the exhaust gas is still going through the bad cooler? Is it just a bit of hose and forget about it?

    Thanks for any help.

  2. #2
    Full Member Leemarksmith's Avatar
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    Vehicle : Vectra

    Trim : SRi (VXR Styling)

    Engine : Z19DTH (Re-mapped)

    Year : 04

    Mileage : 110k

    Default

    Did you solve this...

    Anyone else, does the cooler removal throw up the EML?

  3. #3
    VIP-Member Z80's Avatar
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    Vehicle : Opel Vectra GTS

    Trim : Elegance

    Engine : 2.2 DTi 16V

    Year : 2003

    Mileage : 75 000

    Default

    Depending on your engine, you will be able to remove the EGR or not. On CDTis, it seems you just have a warning light, but no limp mode, and you can even plug an EGR faking circuit to avoid the warning. I think you should then just connect the coolant hoses using a piece of silicone tubing, as there's probably a pump sending pressure in the circuit somewhere, so it should be better not to obstruct it.

    On a DTi, you won't be able to remove the EGR without immediately throwing limp mode (even if it's still wired). I think the ECU relies on the MAP sensor to monitor the intake manifold pressure at idle. I'm studying an electronic solution to fool it, hoping it doesn't also use the temperature sensor that's built inside these Bosch DTIs' MAP sensors (we're really not gifted with these engines)...

  4. #4
    Full Member Leemarksmith's Avatar
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    Vehicle : Vectra

    Trim : SRi (VXR Styling)

    Engine : Z19DTH (Re-mapped)

    Year : 04

    Mileage : 110k

    Default

    It's the cdti 150... I'm gonna get the EGR mapped out but I think the pipe through the cooler is letting out exgaust gasses from the turbo end, have no water loss... So its the EGR cooler pipe I'm thinking of removing?

  5. #5
    VIP-Member Z80's Avatar
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    Vehicle : Opel Vectra GTS

    Trim : Elegance

    Engine : 2.2 DTi 16V

    Year : 2003

    Mileage : 75 000

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    You'll have to plug to both tips, then. Unless it's different on the CDTi... The DTi EGR valve is cooled by the engine coolant, so of course, the pipes can't just be left unplugged...

  6. #6
    Regular Member Penfold101's Avatar
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    The EGR cooler on the 1.9 CDTi's is just a hose type affair - doesn't connect with the engine coolant at all as far as I'm aware...

  7. #7
    Regular Member nutron's Avatar
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    Vehicle : Vauxhall

    Trim : very

    Engine : Z19DTH

    Year : Nosey

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    The EGR charge cooler is prone to failure as I have posted before and if you are blanking the EGR, it should be blanked at both manifolds. Failure of the cooler results in over pressurizing of the coolant system, cavitation of the coolant system, loss of coolant on shut down into the EGR cooler, which would dump into the engine on start up, causing clouds of steam for a short period.

    The EGR cooler can be bypassed without blanking the EGR by removing and mating the feed and return coolant hoses onto the cooler. This will give a short term solution but only short term. The exhaust gasses will then pass uncooled into the intake, causing higher intake manifold temps and reduced performance but no loss of fluid or over pressurization of the coolant.

    The best thing to do is blank at both manifolds and bypass the EGR cooler with the coolant pipes. Contact Courtenay as they have had to do this and are working on a kit to remove the cooler completely.

  8. #8
    Regular Member Penfold101's Avatar
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    Well there you go then - learn something new every day...

  9. #9
    Full Member Leemarksmith's Avatar
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    Vehicle : Vectra

    Trim : SRi (VXR Styling)

    Engine : Z19DTH (Re-mapped)

    Year : 04

    Mileage : 110k

    Default

    Well I've got 2 oval blanking plates, 1 holed and one totally blank, plus a blank square one on its way to replace the holed fiat type, so.......

    Can I use the blanked oval turbo side of the cooler, then just use the others on the EGR side, its getting mapped soon anyway, then just leave the cooler in place and the coolant pipes, but no exhaust gasses are then passing through?

    I don't beleive the cooler is specifically playing up but I have noticed exhaust gasses coming from that area and don't fancy replacing it, no coolant loss or pressure issues however...

    The seller of the oval blanks says it can fit both sides of the cooler pipe so assume there correct? Fingers crossed... Just hope I can then get to it without rad removals
    Last edited by Leemarksmith; 13th February 2013 at 18:51.

  10. #10
    Regular Member nutron's Avatar
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    Vehicle : Vauxhall

    Trim : very

    Engine : Z19DTH

    Year : Nosey

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    That does not sound like it has ruptured internally then, more that you have an exhaust gas leak from a joint. Have you noticed it picking up later in the rev range?

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