how to clean z19 egr valve (proper method)

[jon7278]

how to clean egr new method (pictures)
http://i187.photobucket.com/albums/x...8/SP_A0271.jpg
obviously locate and remov e egr valve, not difficult at all
http://i187.photobucket.com/albums/x...8/SP_A0272.jpg
http://i187.photobucket.com/albums/x...8/SP_A0273.jpg
just a couple of pictures of valve when removed note the soot build up!
http://i187.photobucket.com/albums/x...8/SP_A0276.jpg
seperate the valve by undoing 4xtorx bolts
http://i187.photobucket.com/albums/x...8/SP_A0277.jpg
http://i187.photobucket.com/albums/x...8/SP_A0278.jpg
http://i187.photobucket.com/albums/x...8/SP_A0279.jpg
look how bad this looks!
http://i187.photobucket.com/albums/x...8/SP_A0280.jpg
drill a 3mm hole in top of valve as shown
http://i187.photobucket.com/albums/x...8/SP_A0281.jpg
gently tap punch through hole until the solenoid insides come out next pic
http://i187.photobucket.com/albums/x...8/SP_A0282.jpg
http://i187.photobucket.com/albums/x...8/SP_A0283.jpg
http://i187.photobucket.com/albums/x...8/SP_A0284.jpg
what you should have when you have tapped out insides of solenoid now you will see the real cause for the egr complaint these parts will be corroded and cause sticking, believe it or not its not the soot that jams the valve but this corrosion
http://i187.photobucket.com/albums/x...8/SP_A0286.jpg
http://i187.photobucket.com/albums/x...8/SP_A0287.jpg
http://i187.photobucket.com/albums/x...8/SP_A0288.jpg
clean up removed solenoid parts, i use a bench wheel, and reassemble in reverse of removal but lubricate all parts with a touch of grease or the like.
http://i187.photobucket.com/albums/x...8/SP_A0289.jpg
gently tap solenoid parts back into place until flush
http://i187.photobucket.com/albums/x...8/SP_A0290.jpg
you can now depress plunger and notice one hell of a difference. at this point you will have to clean the body of the valve in some form of cleaner.
http://i187.photobucket.com/albums/x...8/SP_A0291.jpg
spray some more grease etc into the 3mm hole
http://i187.photobucket.com/albums/x...8/SP_A0292.jpg
finally reassemble and refit to vehicle, trust me you will be very impressed with the results.

[John35]

great guide.....just don't delete the pictures from photobucket or we will never see them......

[DeanF]

Some one has been really busy, Great work, This will be appreciated by many im sure

Dean

[nutron]

So it is the solenoid not the valve itself, well that's just a disgrace. If mine went I think I would probably measure the voltage and replace the valve with a shop bough one.

The old DTI engines were vacuum controlled so they didn't suffer this problem. They tended to clog up around 60K but you could easily clean and put back most of them for another 60k.

[jon7278]

the voltage isnt the issue here measure the voltage of any defective valve and the readings will meet vx's criteria, the fact of the increased resistance on the solenoid due to the corroded parts is the issue i guess by drilling the hole in the top of the solenoid vents condensation somewhat, i dont know i pester vx technical everyday for updates but info is scarce. this is a temporary measure and i am sure vx will sort this asap once the have a 100% fix for it. i agree it is disgusting and as a vx master tech i have the ****ty job of explaining the situation to unhappy customers! it seems to me that the z19's that are used to pop to the shops etc are the most effected and the ones that do alot of motorway driving or are driving hard seem to be ok.

[moorlander]

how often would you need to clean the valve ? every 12months ?

[jon7278]

if your car is still in warranty then you will be able to get the new one when yours is faulty, but if yours is out of warranty then i would clean it every 12 months like you said, i had a vectra b 2.0dti i was cleaning the manifold/egr/swirl flaps every 6 months.

[ditchp]

mine going in for a ''CLEAN'' on thurs so all is ok before irmscher trip, great how 2 mate

[John35]

Is the 120 EGR the same as the 150....

[jon7278]

slight differnce in pipework attachments but the cleaning process is the same