Neither Myself or CavMK3OC.com and it's owners can not and will not be held responsible for any damage done to your
vehicle by performing this modification.
Any modifaction posted in this section has been tried and tested, and fault can not be assigned to the original
postee.
Any mods performed are at your own risk / leisure.
If you have any questions, please do ask.
Hello all.
This is a 'how 2' blank off your EGR valve.
This modification was performed on a 1993 Vauxhall Cavalier 1.8i LS, with a C18NZ engine.
This modification WILL work on other engines.
However it is best you research this modification for your own engine,
if you plan to perform this modification on an engine other than the CxxNZ engines.
The parts you will require are:
x1 "Gasket" Part Number: 92061674
£8.57 for EGR blank or £30+ for a new EGR valve, you decide.
The Parts, Sales man. May tell you that the above part numbers are for the C16LZ2 engine.
I assure you, these parts do fit a C18NZ engine.
Tools required
Old cloth or rag
Rubber bung
'Philips head' screw driver
13mm Spanner
13mm socket with the appropriate ratchet
Plenty of Carb Cleaner.
Estimated job time: 30 - 40mins
Step 1:
Disconnect the air box pipe from the the top hat.
Remove the top hat from the intake / injector assembly.
Removing the top hat, will give better access to the 13mm bolts, holding the EGR valve inplace.
Step 2:
Disconnect the small rubber pipe connecting the EGR valve to the top hat / intake.
The rubber pipe may break or split, be careful when removing it.
There will be a small outlet on the top hat whewre you removed the pipe, plug this outlet with the rubber bung.
Step 3:
Remove the EGR valve from the intake manifold.
Remove the 13mm bolts and lift the EGR valve away from the intake manifold.
Its a tight fit to get onto the 13mm bolts, you will only get a few degrees of turn on the bolts with a spanner.
YOU WILL NOT be able to get a normal socket / ratchet into the space given.
Step 4:
Clean the intake surface of debris, and excess carbon build up.
Its not recommended you rub the surface with fine grit paper, as this may introduce metal filings into the engine.
Use plenty of carb cleaner and a rag to remove excessive carb and debris.
DO NOT be tempted to dislodge large amounts of carbon build up with a screw driver or other tools, you may damage
your engine by doing so.
Step 5:
Once the manifold mating surfaces are clean, line up the EGR blank (Lock plate) and gasket.
Screw the bolts down.
Its best not to over tighten the bolts as you may need to move the gasket, after an engine test.
Once you are satisfied the EGR blank is in place and secure, start the engine up and allow to idle for a few mins.
Check for any leaks in the EGR blank.
If no leaks are apparent, blip the accelerator a few times looking for leaks when the engine is under load.
If none are present, you have succesfully completed the EGR blank mod.
Re-attach the airbox - top hat pipe.
Take the car for a drive checking for unusual noises.
Hope this helps
Adam
