Hi
Some time ago I started to have EGR malfunctions (engine check light) in my 2001 Opel Astra-G 1.6-16V (Z16XE) so I built EGR cheater according to instructions here. Unfortunately it never worked (maybe I built it wrongly :silent: ). When connected, after a while driving it again gave the same fault codes as with the faulty EGR-valve installed. Usually the EML light came on couple hundred miles after the ECU reset via disconnecting the battery.
In the last summer I carried out an ECU reprogramming to disable EGR functions while keeping the old EGR-valve connected. Since that I drove 10 000 km without problems, until the engine fault light appeared again with the familiar fault code 1405 (EGR).
I reset the ECU by taking off the battery for a couple of minutes. Then tested driving without EGR connected at all, but the engine light went on right away. So, obviously ECU still needs EGR-valve to be connected somehow :think: .
After that incident I reconnected the faulty EGR-valve again, and since that I drove at least couple of thousands kilometers until the EML light went on this morning (anything to do with the winter temperature of -22 Celsius :wtf: )
Is it that even with EGR disabled in the ECU, the valve must be connected and functional?
To check whether my EGR is broken or not I tried to check the readings of the valve:
I took the EGR off and measured resistances between wires:
wires A-E for a solenoid about 6 Ohm (solenoind working when feeded 12V between A-E)
B-D 2.81 kOhm, independent on valve position :problem: .
pin C over range (>1 Mohm resistance) against to any other pin :problem: .
Does anybody know what these values should be like? notsure.gif
I still have the blanking plate installed, so based on the carbon formation (the plate is clean) I deduced the EGR-valve never opens so the ECU re-programming was at least partially successful. Every time I have disconnected the EGR-valve from the car I have also cleaned the valve properly, so the problem should not be that it only jams. Based on these weird resistance measurements, I could guess the valve electronics have lost.
If it is right that the Pin C is the sensor position output, and the reading between this and pin B or D should vary as the valve plunger is opened/closed, then it should be possible to emulate the EGR-valve with a very simple circuit, which may be build of couple of resistors because here in my case the ECU only needs to sense the EGR is in place and that it is closed all the time. So I'm guessing that I could solder there a fixed resistor with resistance matching the value with EGR-solenoid closed.
Now I only need to know the resistances. Unfortunately I'm not so good in electronics, but I think you guys here are :thumbup:
Thanks for any help available!
