X12SZ help with gaskets, heater, coolant and EGR valve

[fandango]

Hello guys, quick introduction here. My friend has a 1996 Corsa B 1.2 8v X12SZ and recently had few problems, which I took the initiative to repair for him, mean while I decided to register in the forum and ask for some question that without a doubt you will be familiar with.

This car is a work horse and used for his job but recently had an oil leak after 1 year owner ship, which turn out to be oil sump. The guy before him tried to repair a small hole with some gunk and also it's so battered that even a new gasket couldn't seal properly. I've ordered new sump, its here and in few hours I will be fitting it. I also want to help him increase his fuel economy so I modified his air box, plus disconnected the EGR valve. A good clean up of the spark plugs, Lambda sensor, Air flow meter also should help with the task.

My first question is EGR Valve. I've disconnected the plug and as expected the engine light came on. I'm not sure which made more difference disconnecting the valve or me making a DIY ram air induction, the car pulls very well in the high rpm's and adds good noise. Response of throttle has been improved. Would the EGR Valve disconnected help with fuel economy or is it still operating at minimum?

Second question is about the sump gasket. Never had to remove something in such short period but can I reuse the sump gasket that has been fitted for 1 week? Also do you recommend fitting it dry or oiling it to form a better seal?

Coolant. I'm also going to replace it. In Haynes manual it say remove the bottom hose but on this radiator both hoses are at the top. Any idea? I want to drain the system completely and check why the heater is not working either. During winter he complained it just blows warm air. Could it be a blocked air filter? Maybe the pipes are blocked? I read somewhere maybe his dial on the dash is not working and there is a handle I need to move. And last I'm planing on using 40/60 (coolant/water) ratio this should be ok even in the winter yes?

Last question is manifold to exhaust gasket. I will remove it again in order to move the exhaust out of the way so I can lower the oil sump. It's held on two bolts on springs (clever idea!) but ever since I removed it the exhaust is blowing. It has some crap around it like metal flakes from a wire brush. I will clean it but do I need to buy a gasket or can I just use some LocTite sealer? I cant figure what the original gasket reassembled.

Thank you so much for your help!

p.s How the hell do you remove the clips on the water hoses? I'm getting the screw type from B&Q

[jordyp]

you need the egr valve connected mate, its the exaust gas recirculation valve which helps with emissions, and no you cant re use a sump gasket, or head gasket or pretty much any except exhaust manifold and downpipe gaskets, and sometimes inlet manifold gasket, number 3 it should be ok in winter, have you tried cleaning pollen filter? and last.....i had the same problem, at first i thought it was ok and i changed gasket and it was a right pain so try put them exhaust putty on it and try it mate, and get some plumber plier things and should be a good one...hope that helped

[fandango]

Hey, car has been finally fixed. Thanks for the reply Jordyp, I went to main dealer and I'm glad I bought the exhaust gasket. There is no way a putty would fix the huge hole I had as the gasket reassembles something of a very big heavy wire brush all rolled up like this

http://www.bridgat.com/files/Exhaust_Wi ... Gasket.jpg

Also on a closer inspection the oil sump gasket was in perfect condition so I decided to refit it and after test driving the oil leak is finally gone. Replacing the coolant was HARD! Who the hell decided it's a good idea to use such hose clips. I even tried angle grinder on those. Anyway I flushed the system and proper screw clips were installed. Engine is nice and cool now. The only thing I couldn't fix is the heater
Overall I'm quiet surprised how easy it's to work on this car for amateur mechanic like me

[jordyp]

the gasket can look ok but your better just changing it cause it wont be long till its leaking again bud. and change the pollen filter on it mate its under scuttle panel