Hi guys,

Recently I replaced the EGR solenoid as I accidentally broke a plastic tab on it.

I noticed that my idle became better and more consistent (my car has always been idling quit poorly).

To test the EGR system a bit better, I installed a piece of a coke can between the EGR tube that leads to the intake manifold and the intake manifold itself.

The idle has become better again yet not perfect.

It seems the EGR is somehow not working properly.
What is the most likely culprit?
Is it worth fixing/repairing?
With the piece of coke can blocking the entrance of the exhaust fumes, is there still a way it can be creating a bit of a rough idle? ie, could the issue be a split in some vacuum line, or the EGR valve itself allowing un-metered air into the engine?

I've tried cleaning my EGR thoroughly but it's just so hard to get right in there. The carbon deposits are so hard to remove on the pin.

When it is closed, I can still suck a very small amount of air through the valve - I don't know if they are meant to be absolutely air tight or not.

Perhaps Mal can advise? I've always thought about replacing mine, but don't want to dump money on a new one if it has nothing to do with my lumpy idle/slight miss.

I've already done leads, plugs, rotor, cleaned TB. By the time I throw an EGR valve and an oxygen sensor at it, I will have poured a fair amount of money into it.

Does anyone know if the EGR seals COMPLETELY? Has anyone got a brand new one to try and suck some air through?

I've tried cleaning my EGR thoroughly but it's just so hard to get right in there. The carbon deposits are so hard to remove on the pin.
Just while we're waiting for an answer, whats a new EGR valve worth anyway?

To be honest it seems like completely disabling the EGR might be a better option?
Though illegal....

Flyboy,
For what its worth, I can tell you I did fiddle with the EGR on my TP carby wagon some time ago. I'm not sure if the EGR's are the same.
From the leakage test point of view , the EGR passed the in-situ check given in the manual. I took it out and cleaned the carbon deposits off the small bleed hole using wire and a 1mm drill bit. I then checked for leakage with a 100psi air supply and found that the valve did leak slightly. The car had done about 280,000 km. I could not quantify the amount of leakage. I did install a blocking plate to help with the diagnosis. My guess is that the high temperature exhaust gas would give the seats and seals a hard time so how much leakage is OK i dont know, but I reckon some leakage is to be expected. If you still have other worries, block the EGR and try to eliminate the other worries.
I pensioned the TP off and took on a TW.