Below is a copy of my post on the Astra Owners Network forum, thought this could help people here too !
Well after following the guide on this forum to clean my EGR which got he soot off and made little difference it didnít quite do the trick so I thought I would post the following.
I take no responsibility for any damage to your car/EGR if you try this. I am not even a hobby mechanic but was able to get my car back on the road by completing the following.
Credit to Jon7278 @ vectra-c forum for the photos.
When you have the EGR off the car youíll have the following
Then undo the torx screws
Youíll then see the following
Drill a hole in the top of the plastic shroud holding in the solenoid as follows, 3mm should be enough
Using a punch or similar hit directly the centre
You can then take out the solenoid
Donít lose the spring !
Youíll end up with this
Put together like this
Clean all of the corrosion off
At this point I greased the inside where there are moving parts, place back in
And hit back in with a hammer
Ending with this
Spray some grease through the hole at the top and your done.