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Thread: Z19dt egr cooler pipe fractured

  1. #1
    VIP-Member ianwat23's Avatar
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    Vehicle : Vectra Sri 120 navi

    Trim : Sri

    Engine : 1.9 cdti 120 bhp

    Year : 2006

    Mileage : 38550

    Default Z19dt egr cooler pipe fractured

    Would anyone know if the egr cooler pipe has a weakness causing it to crack under the heat jacket thing?
    for around 2-3 years now Iíve always had a strong smell of exhaust smoke when the car was at a standstill with the engine running.
    I had looked all over the engine and exhaust trying to find the fault but never had any luck. Tonight Iíve found the fault and it is a metal concertina pipe that fits into the egr valve onto the cooler just above the gearbox. I only noticed it as Iíve jet washed the entire engine bay and the mix of diesel and engine cleaner has cleaned away the junk on the block and rear pipes. I thought it was the clamp so I tightened it a bit more but the leak was still there I reached around the entire pipe and could feel the gas escaping under the thermal heat blanket thing, so I lifted it as high as it goes and I can feel what appears to be a small crack on the pipe bulge.
    Any help would be great as I need a new one but was wondering if a good second hand part would do the job or will it be false economy to do so.
    Ian
    1.9cdti 120/190 @littleteapot remap with sports button. F40 gearbox conversion,UHP4,aux in mod. Auto headlights wipers, auto Tint rear view,door mirrors,Rear interior light,Cool Glove box,lock conversion for flip key,De-locked,6000 HID's,vxr grille,19" alloys and boot spoiler,signing chrome fog lights,rear electric window conversion with auto close.

  2. #2
    Regular Member petrolcan's Avatar
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    Vehicle : Signum

    Trim : Elegance

    Engine : 1.9 CDTI (120)

    Year : 2006

    Default

    On the assumption that your EGR is mapped out, whip out the cooler and blank it at both maifolds

  3. #3
    VIP-Member ianwat23's Avatar
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    Vehicle : Vectra Sri 120 navi

    Trim : Sri

    Engine : 1.9 cdti 120 bhp

    Year : 2006

    Mileage : 38550

    Default

    Quote Originally Posted by petrolcan View Post
    On the assumption that your EGR is mapped out, whip out the cooler and blank it at both maifolds
    the car has been remapped and had egr delete courtesy of @littleteapot. Will the egr blank which I fitted between the egr valve and the cooler pipe fit the manifold connection?
    1.9cdti 120/190 @littleteapot remap with sports button. F40 gearbox conversion,UHP4,aux in mod. Auto headlights wipers, auto Tint rear view,door mirrors,Rear interior light,Cool Glove box,lock conversion for flip key,De-locked,6000 HID's,vxr grille,19" alloys and boot spoiler,signing chrome fog lights,rear electric window conversion with auto close.

  4. #4
    Regular Member petrolcan's Avatar
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    Vehicle : Signum

    Trim : Elegance

    Engine : 1.9 CDTI (120)

    Year : 2006

    Default

    Quote Originally Posted by ianwat23 View Post
    the car has been remapped and had egr delete courtesy of @littleteapot. Will the egr blank which I fitted between the egr valve and the cooler pipe fit the manifold connection?
    I'm pretty sure it will. For reference, this is the kit that's fitted to mine https://www.ebay.co.uk/itm/171737850225

  5. #5
    VIP-Member ianwat23's Avatar
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    Vehicle : Vectra Sri 120 navi

    Trim : Sri

    Engine : 1.9 cdti 120 bhp

    Year : 2006

    Mileage : 38550

    Default

    Bit of an update. I was going to buy the kit listed above but they couldn’t get it to me next day so I’ve bought a replacement end pipe from the same scrapyard I got the fuel pipe from. It cost a tenner but it’s in near mint condition. i did ring the dealers and they wanted £120ish but said I could have it for cheaper at £110 as they only sell the egr cooler with both end pipes. I fitted the replacement pipe at the side of the road where I got it from as I had removed the heat bag that surrounds the pipe so more fumes got into the car. Now the pipe is changed for the first time in years I can jave the heaters on at a standstill and not gassmysely or the family.
    Cheers for all the advise on this. If this pipe or the other breaks again I’ll just buy the delete kit and have the faults gone totally.
    Ian
    1.9cdti 120/190 @littleteapot remap with sports button. F40 gearbox conversion,UHP4,aux in mod. Auto headlights wipers, auto Tint rear view,door mirrors,Rear interior light,Cool Glove box,lock conversion for flip key,De-locked,6000 HID's,vxr grille,19" alloys and boot spoiler,signing chrome fog lights,rear electric window conversion with auto close.

  6. #6
    Regular Member northpole's Avatar
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    Vehicle : Vectra C

    Trim : SXI limited edition

    Engine : 2.0 16v DTI

    Year : 2003

    Mileage : 140000

    Default

    I would suggest if you plan on keeping the car for a while to get the delete kit anyway.. than put it on when you've got the time for it and when it's warmer that way you make sure it can never happen again

  7. #7
    Midlands - Head case Organiser Dog_Book's Avatar
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    Vehicle : Vectra Estate

    Trim : VXR

    Engine : Z28NEH

    Year : 07

    Default

    I was advised when mapped these have an inclination to fracture due to the extra heat and gases from increased boost so was advised to blank the exhaust manifold which i did. The blanking oval is a different shape to that which goes under the EGR valve.
    Vectra VXR estate 2007 Sapphire Black
    Teapot Tuned 245/300
    Eibachs B8's, fully loaded factory options

  8. #8
    Regular Member Morty1977's Avatar
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    Vehicle : Vectra c

    Trim : Exclusiv

    Engine : 1.9cdti 43,000

    Year : 2009

    Default

    Quote Originally Posted by ianwat23 View Post
    Bit of an update. I was going to buy the kit listed above but they couldnít get it to me next day so Iíve bought a replacement end pipe from the same scrapyard I got the fuel pipe from. It cost a tenner but itís in near mint condition. i did ring the dealers and they wanted £120ish but said I could have it for cheaper at £110 as they only sell the egr cooler with both end pipes. I fitted the replacement pipe at the side of the road where I got it from as I had removed the heat bag that surrounds the pipe so more fumes got into the car. Now the pipe is changed for the first time in years I can jave the heaters on at a standstill and not gassmysely or the family.
    Cheers for all the advise on this. If this pipe or the other breaks again Iíll just buy the delete kit and have the faults gone totally.
    Ian
    How did you do this ? It looks very hard to get to

    Sent from my SM-G935F using Tapatalk

  9. #9
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    Vehicle : Saab 9-3 (Vectra C in disguise)

    Trim : Linear Sport

    Engine : 1.9 TiD 150

    Year : 2005

    Default

    I blanked mine at the turbo end using a steel core plug, some fire cement to make the core plug seal and then an oval blanking plate over the top to keep everything in place (my flexi pipe went porous between the turbo and the cooler under the cloth, looked like swiss cheese with all the holes.
    Utter pain to do with the rad pack in place
    should have taken the bumper off, rad pack out and doing it that way, doddle on another car in comparison.

  10. #10
    Regular Member justin32's Avatar
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    Vehicle : Vectra c SRI Facelift

    Trim : SRI

    Engine : 1.9 CDTI 150

    Year : 2006

    Default

    Quote Originally Posted by ianwat23 View Post
    the car has been remapped and had egr delete courtesy of @littleteapot. Will the egr blank which I fitted between the egr valve and the cooler pipe fit the manifold connection?
    No it doesn't fit. Althought they look the same size the manifold one is slightly bigger

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