Wow , two days off and Ive been hard at work on the vectra and Ive got well skinned knuckles to prove it !
Firstly instead of stripping the manifold to clean it I took off the battery and cover along with the TB and used a very long serving spoon ( I know ) to take out around half a cup full of sludge out from the manifold. Then I used some carb cleaner to blast the residue I couldnt scrape out.
Maybe It was a bit Heath Robinson but it took all of 1 hour not the 4 or so inc cost of gaskets etc if I had decided to pull the manifold off.
So to keep my manifold in its new (semi ) clean state I invested in a catch tank and took it from the top of the breather system and did a fairly neat install away at the rear of the engine bay.
I then decided to tackle the bl***y egr once and for all as Id bought and fitted a Fiat restricting gasket ( square one with four holes goes between egr and manifold) and it had really done sod all.
I then went to work with an old can and some metal shears creating a new gasket for the smaller diamond shape (up pipe to egr) and drilling from 4 mil upwards and using op com to reset the error light to work out how small I could make the next restriction without an error being logged.
It transpires Its 10 mil with the above mentioned Fiat gasket allready in place. I do wish I hadnt gone up just one mil at a time
So with the manifold and hopefully the swirl valve flaps clean and moving well and with the best restriction possible with no error code it now works a treat. No flat spot / lack of power and it spools up nice and early close to 1100 rpm and on boost is fantastic.
Some pics of the catch can install just cos I like the look of it
Then I did a complete service including brake bleed , cleaned and painted the calipers black to tidy them up and then decided I wanted to take off the intercooler to wash it through with cleaner as it must be clogged up in the small vanes wiht the crud that was blowing through from the pcv system.
This was scuppered by the air con rad not lifting out of its seat in the intercooler on the left as the pipework would not budge and the top torx screws for the intercooler are hid away under the slam panel and i could only figure need to be accessed via the small hole in the slam panel that would require a very long thin torx screwdriver that I dont have
Another pic of this part I hope someone reading can help as id like to try to clean the intercooler. The yellow circles are where I found the top torx screws and the red circle is the side of the air con rad that wouldnt lift out.
All I can say is good luck to anyone else suffering the lack of power issue.