mentalasanything
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Registered: 27th Jan 04
Location: Hengoed Drives:Corsa Sport
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Right, the story goes a bit like this. Are we all sitting comfortably???? Then I'll begin.
Last Monday my Engine Management light came on and me car died. Did a diagnostics test and came up with code 1405 - EGR Valve.
Took it to my local garage, put it on tek2 and it showed EGR valve, they replaced it and it was all hunky dory......FOR ABOUT 25 MILES.
Same prob again and same fault 1405. Took it back to garage and was runnin really bad, worse than my lawnmower, neways, they took the EGR back off and it was jammed open with this sorta stuff, corrugated aluminium :-
Garage instantly didnt want anything more to do with the car sayin it needed the head stripping. I pulled all this stuff out of the port of the EGR valve replaced the EGR and all works perfect.
My question is, does anyone know what it is and/or where it came from, help needed!!!!!
Cheers, Lee
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Adam-D
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Registered: 11th May 02
Location: Cheshire
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no idea
looks kinda like a old timing belt?
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Adam_B
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Registered: 13th Dec 00
Location: Lancashire
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baffles from the exhaust maybe
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mentalasanything
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Registered: 27th Jan 04
Location: Hengoed Drives:Corsa Sport
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Naaah, way too thin and small 2 b timing belt, its metal and it was in the little pot and the port, where the EGR valve sits.
Dnt think its exhaust baffles, they wouldnt come up exhaust, thru valves and in to chamber, would they?
[Edited on 0505-0707-2004200420042004 by mentalasanything]
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PaulW
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Registered: 26th Jan 03
Location: Atherton, Greater Manchester
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doubt it will be exhaust baffles in the EGR... but it does look like it tho... 
there really is nothing that can cause that tbh unless they did a shite job & jammed it up to get more cash out of ya!
out of interest, have you checked the condition of your air filter & air pipes leading to the throttle-body??
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Siberia
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Registered: 9th Oct 03
Location: Leprechaun Land Drives : Zafira GSI
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i was gonna say bits of induction kit.... but i'm not to sure of the EGR's location/function.
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PaulW
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Registered: 26th Jan 03
Location: Atherton, Greater Manchester
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EGR is on the manifold just after the head. its about 2-3ft of exhaust tubing before the cat, so if it was exhaust baffles, then it would of have to of gone through the cat & really been sucked up!
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Siberia
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Registered: 9th Oct 03
Location: Leprechaun Land Drives : Zafira GSI
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oh so its on the exhaust side? doubt its induction kit then cos the engine would be shaged if all that aluminium went through it.
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PaulW
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Registered: 26th Jan 03
Location: Atherton, Greater Manchester
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true - only thing I can think of is they stuffed it up or jammed it to get more money! wouldnt be the first time I seen this done 
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Siberia
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Registered: 9th Oct 03
Location: Leprechaun Land Drives : Zafira GSI
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have to say from the pic its doesnt look like its been living in the exhaust for too long.
jesus would they go to that much hassle to get a few extra quid..............
sad!
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Daniel_Corsa
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Registered: 21st Apr 04
Location: Wigton, Cumbria
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But if they wanted more money out of you why would they tell ya they wanted nothing more to do with the car surely they would have known what the problem was and fixed it if that were the case
April '06' Corsasport Feature Car  | Aug '08' Total Vauxhall Feature Car | Spring '09' Fast Car Feature Car
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CorsAsh
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Registered: 19th Apr 02
Location: Munich
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Hmm, corrugated fasteners as used in furniture assembly...
and whats been found in your car...
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Greasemonkey
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Registered: 17th Apr 02
Location: Drives a Tractor
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Thats fooking weird mate, i seriously cannot think what that is dude, i know nothing about EGR cos im lucky enough to have a rev all over the place C16XE. this is my theroy. Some thing has come in ya inlet (bits of induction kit?). and gone down the exhaust gas recirculation system which plumbs exhaust gasses back into the lower inlet manifold from the exhaust. This is the only link between the two that wont shagg ya engine, look for things that have broken up in the EGR system? just an idea
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Siberia
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Registered: 9th Oct 03
Location: Leprechaun Land Drives : Zafira GSI
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its aluminium though? bits them size surely would destroy the engine internals?
next thing ya know he'll find a small bird in his EGR
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mentalasanything
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Registered: 27th Jan 04
Location: Hengoed Drives:Corsa Sport
User status: Offline
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its not induction kit/pipe, had a look at this. You may be right about them jammng stuff in, when we said to them "you fcuked it up you must ave put those bits in, he chucked me out!!!
Its too soft tohave caused damage, bout th thickness of 3 layers of foil
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Greasemonkey
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Registered: 17th Apr 02
Location: Drives a Tractor
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the link between the exhaust and inlet manifold on the EGR system is a straight link it dosnt pass through the engine?
If these dudes aint stuffed that shite in there i would point my finger to something in the EGR although i dont have a clue what it is
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OzzySRi
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Registered: 18th Jun 02
Location: Sydney, Australia Drives: Corsa C 1.8 SRi
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u sure it aint hardened carbon. could have formed over time somewhere and finally dislodged?
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mentalasanything
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Registered: 27th Jan 04
Location: Hengoed Drives:Corsa Sport
User status: Offline
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quote:
Originally posted by Greasemonkey
.....If these dudes aint stuffed that shite in there i would point my finger to something in the EGR.....
Naah, the EGR is just a u-bend with a gate that opens and closes, nothing in there, It aint carbon either, its a thin soft metal, uniformly corrugated.
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Siberia
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Registered: 9th Oct 03
Location: Leprechaun Land Drives : Zafira GSI
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if the car continues to run alright then they must have shoved that crap into the part
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mentalasanything
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Registered: 27th Jan 04
Location: Hengoed Drives:Corsa Sport
User status: Offline
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quote:
Originally posted by Siberia
if the car continues to run alright then they must have shoved that crap into the part
Damn right
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greebo2
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Registered: 21st Aug 03
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the only thing it looks like to me is shredded up piece of corrugated ally air ducting, intereresting that it's blackened has it been burnt or had carbon deposited on it? Very very strange. I'm a bit suspicious that they claimed it needs the head stripping, although it's kind of
too obvious to fool anyone although I suppose the average garage customer would just take their word for it. If you really think they stuffed it in I'd report them to trading standards.
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Mattb
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Registered: 2nd Feb 03
Location: Under your sisters bed
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that looks like nothing out of an engine anywhere trading standards i think should at least be informed 
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mentalasanything
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Registered: 27th Jan 04
Location: Hengoed Drives:Corsa Sport
User status: Offline
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quote:
Originally posted by Mattb
that looks like nothing out of an engine anywhere trading standards i think should at least be informed
My sentiments exactly, I cant think of anywhere at all that it could have come from! Trading standards methinks.
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greebo2
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Registered: 21st Aug 03
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If you were to cut a piece of corrugated air duct off - say about two inches long, then cut strips of it lengthwise, then flattened it out, then burned it with a blow-torch or similar to blacken it, you might end up with something that looks like this stuff. I can't see how it could possibly be produced by some fault within an engine. I've been trying to imagine how I would make some of this if I needed to.
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greebo2
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Registered: 21st Aug 03
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and the thing I'm missing of course is it's been exposed to exhaust gases as it's been in the egr valve location, so that explains the blackening; so what you've got is some cut up flattened strips of corrugated ally that have been put in by the looks of it. If you're going to report to trading standards would be useful to have a second "expert" opinion to back you up, for example a statement from a main dealer saying that there are no circumstances under which such material could be produced in the location it was found by an engine fault. Just a thought.
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