1.9CDTI 150 sub 2k flat spot is very annoying

[hothatch]

The car is absolutely great when above the 2000 mark, but just when is under 2000 is so annoying, the bl**dy thing won't go, is absolutely terrifying on roundabouts and yes that is what i look like when i see a lorry coming.

What are the things to check for, in order to fix it?
I know checking injector clips to see if its blue is one of them.

[vectra 120]

Check all the vacuum pipes m8 clean the EGR out and bost sensor out.


Also you could fit a fiat blanking gasket but some people say that's a big no no


Steve

[hothatch]

Check all the vacuum pipes m8 clean the EGR out and bost sensor out.


Also you could fit a fiat blanking gasket but some people say that's a big no no


Steve

Thanks.

[Chocki]

The two main things I have found with this car is the EGR valve, very common, you loose loads of power below about 2k, this gets progressively worse over time until the car becomes undriveable and you get a fault light.

Easiest way to prove if this is the reason is to completely blank the EGR valve with a bit of tin can, on the oval manifold underneath the EGR valve when viewing from above, you will need some high temperature gasket compound or two bits of gasket sheet, dont worry about having to make it oval with holes for the bolts, but make it rectangular so it fits between the bolts, makes it easy to fit and remove as well if you leave it long enough to stick out.

You will get the spanner light come on and eventually the Engine Management Light, but the car will run perfectly, I've had mine blanked like this for over 11000 miles and some members considerably more than this and no one has had any problems running their cars like this.

The second reason for flat spots is fuel.

I am still amazed at how much difference fuel makes, if I use cheap normal derv, I get a flat spot, if I use V-Power diesel, no flat spot.

But from the sounds of it, your more than likely suffering the EGR problem, also check the swirl flaps linkage is OK, although not as dramatic as EGR faults, it still has an effect on the performance.

[hothatch]

The car has always been like this since i got it when it was 10 months old, thought it was just vectra diesels, but obviously not, which i found out later it affects mainly the 150bhp models.

Using V-Power diesel makes no difference in my car at all, well i don't feel any.

[Vaux-Man-G]

Mate, I had this and it was dangerous. My dad drives at snails pace and even he was scared to drive, in return it was doing the clutch no good either.

In the end a brand new EGR valve was fitted by the dealers and the car has been insanely brilliant since!

Check all the pipes, etc, and if they are all OK, get a new EGR on it....dont ebay it as I did and that too was scrooged.

[hothatch]

Mate, I had this and it was dangerous. My dad drives at snails pace and even he was scared to drive, in return it was doing the clutch no good either.

In the end a brand new EGR valve was fitted by the dealers and the car has been insanely brilliant since!

Check all the pipes, etc, and if they are all OK, get a new EGR on it....dont ebay it as I did and that too was scrooged.

Ok i give it a check. Have your car got blue injector clips? I seen somewhere if its the yellow ones that causes problems too.

[Vaux-Man-G]

I changed the 3rd Injector to the blue one. They were all yellow before but now has the main culprit dressed in blue.

[mark_647]

Clean the EGR and boost sensor and it may make quite a difference.

[hertscol]

a thread on here also about taking off the inlet manifold butterfly valve to the right hand side under the main large intercooler hose. 3 bolts and off. The inlet manifold stays in place, just the butterfly valve comes off as a whole unit - under large pipe in front of the egr slightly to the right.

Once I got into this area, there is a swirl chamber type area direct in front where the egr bolts on. This was full of crud, and scraped it all out, and then the air free flows direct from the egr into the inlet side of the manifold. THIS cured the flat spot for me after all the egr cleans, solenoid cleans, boost sensor cleans, 3rd injector checks etc. Car flies under 2k revs and I hope I have increased the life of my inlet manifold for a longer period of time.