The Engine Management System (EMS) light on my sons car was illuminated and a diagnostic check showed that it was the EGR valve that was faulty. While I understand that once faulty it has to be replaced, could someone tell me what the 'worst case' scenario is for ignoring it and what damage will occur if it is driven to & from work (4 miles each way).

Macca, July 2008

The egr valve opens and takes a sample of oily exhaust cruds.. Sends it across the egr valve stem into the inlet manifold for recycling. Sensors relay this info to ecu. Problem is 1.the crud hits the egr valve stem and eventually bakes it on thus causing it to jam and fail. 2. This crud blocks and fouls inlet manifold, head, valves.
Best to block it off.

Roger Bergquist, August 2019

Hi Phil the expert,

Funny. My Vauxhall Astra CDTI 1.7 had exhaust indicator on and accelerating slowly in the fifth gear. I hammered EGR valve a little with a wooden hammer and the indicator went off. So, I guess it will be in need for replacement and/or cleaning but I was surprised that little hammering fixed the issue for now.

KasparsM, May 2014

I had intermittent misfires on my 1.6 twinport after lots of searching on the internet and trying different things e.g coil packs , plugs ,blanking egr e.t.c. and finally joining the eric the car guy site to get advice. it turned out you need to clean the egr channels leading to and around the intake manifold ! hope this helps someone because this cost me loads to solve

le, March 2014

Where is egr valve on astra 1.6 twinport 16v 2004 ?

danny smith, October 2013

the usual problem with all EGR valves is carbon fouling which prevents the valve reseating properly following activation when the engine is hot. Worst case scenario-engine cools-.,EGR valve stuck open- engine runs roughly A sharp tap with a light hammer will often restore normal running. Light wont go off until valve goes through open/close sequence.Next step try a suitable fuel additive to clean the valve. 8valve astra EGR valve is very easy to remove and clean.Unplug wiring, remove the two torx bolts and lift out the assy.Use a slightly curved screwdriver blade to press against the valve stem and lift off its seat . scrape/wirebrush off the carbon from valve and seat.give a good squirt of WD40 etc and refit. remember -light wont go off immediately.

phil the expert., May 2013

Remove egr valve ,make a metal blanking plate using the valve as a template then put egr valve and blanking plate back on the engine -problem solved.I have done this loads of times on Astra 1.4 ecotec engines and it doesnt affect emissions as far as mot tests go.

John Anderson, August 2012

the oil light is going on than off what is the problem because when i looked for the oil it looks ok what is the problem

niti, July 2012

Take the EGR valve out, get a blanking plate for the hole. Best thing i have ever done, feels like a brand new car. If the engine light gets on your nerves, get it programmed to ignore the EGR valve. 1.6 8v Astra.

Terry, April 2012

how do you clean the egr valve on an asrtra

r eringer, February 2012

i would recomend any 1 with egr problems to contact there local vauxhall dealer what vauxhall dont tell you is they can upgrade your ecu to run with out the egr valve it usally cost s £47 quid to test your ecu and update the problem ive had this fault on my astra 16 8 valve and after replacing spark plugs coil pack trottle body and egr valve i had had enough of vauxhall tell me c==p saying its this or that so go fo the upgrade

gary, February 2012

I have a 16 16v Astra on an 02 plate. I have had it cut out on me now and again when i'm driving. Hard to start, but if i leave it , come back after an hour or 2, it starts fine for some reason.
One day when it was running ok and warm. I messed about with the wires on the EGR and it cut out. Is this my problem? I was going to take the ECU off and send it away for repair. But the chance is i have a fault with my EGR
Please help me.
Regards Tony.

Mr A Loughran, January 2012

I Have a 54 plate Astra 1.6i /twinport. Problem i seem to be having getting CO emission readings of 3.20 compared to the Normal 0.2. but the engine seems to be sucking in Air. Each time this happens i get a low squeeling noise could this be down to the EGR valve.

Tonic, January 2012

i have a 02 astra 1.4..the engines spluttery and once i drive it over about 60km or over rev it the power of the car goes way back and its just like walkin speed and takes forever to get up abit of speed then lasts like this until i turn off the engine for a min or two..would you say its sticky valves

Dean, January 2012

I was replacing the EGR valve on my Astra about every 8 months. Was getting quite costly. The last time it started playing up I stripped it off and cleaned it with Wynn's Carb Cleaner, that was about 5 months ago. Was fine. Currently cleaning it again as I type. If I get another 5 months I'll be happy. Will meen replacing it maybe every 2 years instead of every 8 months.

The reason they regulary go faulty is they're working in a very hot and sooty enviroment. Was a Vauxhall mechanic who told me that.

-stevie-, April 2011

Had a new valve fitted to my 53 astra, 7 months later it packed up.....AGAIN
took back to main dealer and was replaced free of charge.
When i spoke to my mechanic about it he asked where i got my fuel from, which "WAS" tesco or sainsburys.

He told me they dont use enough addictives in there fuel and advised using Shell fuel or Asda....18 months later and the car is still going strong.

Andy ghandi, March 2011

My Astra 1.6 16v sxi is "missing " usually around the 2700rpm on the motorway and lower around town. The EGR Valve is suspect according to the local garage . Can I disconnect it to be sure

Chris, February 2011

I had a 1.6i Mk4 Astra which had to have a replacement egr valve at about 58000 miles. This lasted about 10 months until it started to go seriously wrong and the car would keep cutting out and running really roughly. It was an intermittent problem but the car would often cut out and I got so sick of it that, one evening after a particularly bad journey, I made sure the valve was closed and then I disconnected it. It meant that I had to drive the car with the warning light illuminated all the time but I just put a bit of tape over it so I couldn't see it.
The car went on to do another 60000 miles with the valve disconnected and never missed a beat. It passed 3 MOTs with no mention of emission problems and the fuel consumption was totally unaffected.
When it came to selling the car I took it to the main Vauxhall dealer and got them to program out the egr so that the light would go out - this cost me £35 (in April 2009).
I now have a Mk5 Astra and guess what? That damn light has started to come on on this car! I am booking it in with the main dealer to have the egr programmed out as it is not worth replacing at £60 a pop when you can solve all the current (and future) egr problems for about £40.

Astrafan, June 2010

I've had plenty of EGR Valve problems too. My 1999 1.6 8v Astra has had 5 egr valves, and the car has a FULL vauxhall service history. The engine management light has come on again and the fault code is...you've guessed it. Ready for number 6. The last 4 valves have lasted JUST over 12 months before going. I'm absolutely sick and tired of it, and will DEFINITELY not buy another vauxhall. There are too many in-built problems.
It's been explained to me by an independant garage that it's NOT actually the valve that's at fault. The problem is that the engine itself produces too much carbon, which clogs up the egr valve.

Steve, June 2010

I replaced my EGR valve only 5 months ago because it was cutting out, ive now had an ecu light come on saying its my egr valve again, could there be any undelying reasons why im getting through so many egr valves?

Ben, May 2010

my vauxhall astra 1.9 sri diesel was smoking in acceleration and after a week had difficulty starting took to garage they said it was egr valve replaced that but still wont start with out spraying easy start down air flow!! when it is started still smoking then when emissions light comes on cuts out soon after!! any ideas???thankyou.

marcus, July 2009

i have an astra 1.4 16v ecotec engine ticks over fine don't cut out plenty of power but driving slow it is spluttering and holding back a little,don't back fire,if rolling down a hill in any gear you can still feel it spluttering,,,,??????please help!!!!!thanks

jon roberts, December 2008

my astra is fine on tick over and when on the motorway but round the streets doing 30 mph it is spluttering,put new airbox on it as previous keeper put mickey mouse air filter do anyone have any answers PLEASE.

jon roberts, December 2008

The purpose of the EGR (exhaust gas recirculation) valve is to redirect some of the spent exhaust gas back into the engine. The reason why it does this is to keep the combustion process below a threshold, which if exceeded will produce nitrous oxide which is harmful to the environment. This valve is carefully controlled by the vehicle's ECU so that the valve remains closed whilst the engine is under load, such as hard acceleration or driving up a hill where performance would be serously impaired, and cause potential engine damage. The biggest problem with this valve is that it is connected directly to the exhaust manifold, and early versions were prone to sticking open ( a common fault). My Astra has had two replacments from new, the last seems to have done the trick.

My advice is to get it cleaned, or replaced as the engine will not function correctly in its current state.

James Morgan, August 2008

remove thr egr valve and clean it using carburetter cleaner or petrol. tey sometimes just stick

161jr, August 2008

Hi Macca, day to day driving it will have little to ZERO effect on driving or engine life!! it just means the exhaust output might be a bit higher in the "harmful" gasses unless the MOT is due soon ignore it and enjoy the the better MPG as this valve when operating makes the engine use exhaust gasses reused to improve the flow into the engine and make the engine more efficient

nigel, July 2008