My car(1.6 8v 53 plate Astra) was jerking a bit, and cutting out now and again. Other than these symptoms the car ran very well indeed.
The ECU indicated a 0400 fault code by doing the "pedal" test, by counting the flahes ans pauses of the symbol, a car with a spanner.
Befre buying a new EGR because of the cost approx.£65 (genuine GM part) I decided to try cleaning it.
This is what I did.
1. Remove the wiring connector from the unit.
2. Remove the EGR valve from the manifold after undoing the two Torx 45 bolts. Incidentally, Torx 45 is the same size as the oil draInplug on my car. I purchased this little tool, with a 3/8 drive square drive, from Halfords a good litrtle buy, in my opinion.
3. The thin metal gasket appeared to be stuck to the body of the EGR valve. After carefully removing it I cleaned it using some brake cleaning fluid.
4. I carefully removed any carbon from the base of the valve and around the piston by freely soaking it with brake cleaning fluid.
5. I connected a small 9v battery across terminals a & e. It is actually marked this way on the body of the vale at the connector socket.
All I had was some small sparks but no movement from the central piston.
I decided to try this same metod but this time use the car battery. More power. Connecting the +ve to a and the -ve to e, using a couple of wires and two croc clips, I got the piston to move down appprox. 3mm. Reversing the polarity had no effect except again some small sparking. With the piston down, i.e. in it's open position, I kept soakinig the unit with more brake cleaning fluid and carefully cleaning the conical shaped end of any carbon etc.
The only way I could get the piston to return i.e. close, was to push it lightly back. I repeated this processs a few times.
6. After a final clean and wipe round I replaced the unit, using the existing gasket and the 5pin wiring connector.
7. I took the car for a test run and in my opinion pulled a lot "sweeter".
It has been nearly two weeks now and in excess of 150 miles I have had no feeling of jerking, no cutting out, and no symbols apppearing at all.
It may be I may have caught it in time, being so intermittent, or I may just have been lucky. Time will tell.
I am not advocating this as a definitve repair or cure, but I thought it was worth trying before spending all that money in the first place.
I was also curious to know what It looked like at the "business end" of the unit.
I am aware of blanking off the EGR, as a cure, and was indeed going to try it, but was assured by my main dealer, that it does not work with a 17200272 valve. It always pays to check in my opinion.
I hope this may help and encourage others to attempt cleaning their EGR valve before parting with a lot of hard earned money.