DB9 Top Gear Track
AO Silver Member
Join Date: Jan 2007
Location: United Kingdom
County: East Sussex
Hang on, are we talking about the same thing. Your picture above shows the EGR split in half, all we're interested in is the solenoid half, forget the valve half for the time being.
The solenoid half is made up of 4 bits; the solenoid housing, spring, armature (actuator/pin) and collar (what I think you're calling the cup) This is what I mentioned in the earlier post, although the collar/cup may appear flush in the housing it only needs to be very slightly misaligned to cause the armature to stick. Put the solenoid in a vice and tap the cup/collar around its face till the armature moves freely. You have given the cup/collar a good clean too?
Once you're happy bolt the solenoid to the valve.
Loose - not close, compact, or tight in structure or arrangement
Lose - to part with or come to be without, as through theft, accident, negligence, etc.