[madscientist]

It is normal. The vent holes are there to allow the EGR valve to vent vacuum pressure, allowing it to modulate its position. With no power applied to the valve, it defaults to the open position. If you tried running the smoke test again, but with the key in the on position, the vent should be closed on a properly functioning valve.

 

[madscientist]

From what you've described it sounds like the valve is working, but does have a slight leak. I'd take a good look at the gasket between it and the manifold as well as all the connections. If they are all good, the valve may need to be cleaned or replaced if it is causing problems.

The good news is that since it got significantly harder to blow with the key on, the rest of you vacuum system is probably in pretty good shape.

 

[madscientist]

OK just checked to be 100% sure.
Nothing should come out the vent holes. They are just atmosphere to the diaphragm free side. If you suck on the nipple, or put a hose on it to do the same, it should hold, no leaking. If so, it is scrap. Won't function and leaks vacuum.

-chart-

Good catch Chart. I was looking at the diagrams backwards. If it is leaking on that side the diaphragm is probably blown.