Vectra C SRI 150 CDTI jerks at around 2000 revs after changing EGR valve, Manifold & throttle body

[Sums]

Hi

I have a 54 plate vectra which has chip box installed, it jerks at times at the rev range of 1500-2500 rev (95% of the time it jerks at 2000 revs) I have done around 20,000 miles in this car in a year of owning it and has been perfect.

Recently it started to go on limp mode a lot and after checking, it left me a deep hole in the pocket due to changing inlet Manifold, EGR valve and throttle body to solve the problem. Manifold and EGR valve are brand new and from Vauxhall, whereas throttle body is second hand from a vauxhall breaker. Throttle body was changed after all the manifold and egr valve job as it was still going on limp mode.

Now that limp mode problem is solved, it still jerks at times. Sound like turbo as it sound like sequentional dump-valve noise (kushhh kusshhh kussshh) and you can feel the jerking too. Car does not lose any power what so ever and pulls really hard at any revs like it should, just jerks.

What could be the problem? It doesn't happen all the time, just say about 1/5 times when you are at that rev range.

Thank you in advance :-)

[LADmachining]

I have a similar issue on both my Astra CDTi 150 and Signum 150.

The car often 'stumbles' around 1800-2000rpm, especially on very light throttle, or after releasing then applying the throttle.

On the Astra, this problem only started to surface since the EGR valve was replaced under warranty back in May. The EGR is of a newer design, with a different shaped valve and plunger.

The Signum had the valve replaced by myself, again of the newer design, in July, after which this is experiencing hesitation around 2000rpm, but not to the same extent as the Astra.

I have read on other forums that this is a known issue with the 'modified' EGR valve that is now being fitted.

[lesj]

This any help

Field Remedy: 1849
Subject: Engine Z19DT/H - Jerking
Models: Engines: Option:
Vectra-C 2004...2005,Signum 2004...2005 Z19DT| Z19DTH,Z19DT| Z19DTH
Complaint: Customer complains about a kind of jerking at steady state or at slight acceleration.
Cause: The problem is caused by high EGR-rate in combination with component tolerances.
Production:

Remedy:
In case of customer complaint reprogram the ECU with new software as of TIS 2000-CD, Version 67.
If the problem occurs with the new software again, contact ETAC for further information.
Please note:
A replacement of any parts (injectors, high-pressure pump, EGR valve, ECU, etc.)is not necessary.
FunctionalGroup: J - Engine
Complaint Group: 18 - Poor Drivebility
Trouble Code: None

[Marky]

It seems that most people with the 1.9 Diesel (120 or 150) have this problem.

Cleaing or replacing the EGR, Throttle Valve and Inlet manifold seem to help but doesn't always solve the problem.

Also semi blanking the EGR may also help.

And as LesJ says above its worth checking that you have the latest ECU software.

I have read on other forums that this is a known issue with the 'modified' EGR valve that is now being fitted.

Thats interesting, where have you seen this. I think most people have been swapping the old EGR for the new style one.

[LADmachining]

This any help

Field Remedy: 1849
Subject: Engine Z19DT/H - Jerking
Models: Engines: Option:
Vectra-C 2004...2005,Signum 2004...2005 Z19DT| Z19DTH,Z19DT| Z19DTH
Complaint: Customer complains about a kind of jerking at steady state or at slight acceleration.
Cause: The problem is caused by high EGR-rate in combination with component tolerances.
Production:

Remedy:
In case of customer complaint reprogram the ECU with new software as of TIS 2000-CD, Version 67.
If the problem occurs with the new software again, contact ETAC for further information.
Please note:
A replacement of any parts (injectors, high-pressure pump, EGR valve, ECU, etc.)is not necessary.
FunctionalGroup: J - Engine
Complaint Group: 18 - Poor Drivebility
Trouble Code: None

Interesting info Les. Unfortunately, my vehicles are model years 2007 and 2008, so fall outside of the range of this field remedy.

The ECU software on each is already at the latest version.

Further investigation required. The Astra is still under warranty, so it will be going back again before it runs out to try and get it sorted.

[Sums]

This any help

Field Remedy: 1849
Subject: Engine Z19DT/H - Jerking
Models: Engines: Option:
Vectra-C 2004...2005,Signum 2004...2005 Z19DT| Z19DTH,Z19DT| Z19DTH
Complaint: Customer complains about a kind of jerking at steady state or at slight acceleration.
Cause: The problem is caused by high EGR-rate in combination with component tolerances.
Production:

Remedy:
In case of customer complaint reprogram the ECU with new software as of TIS 2000-CD, Version 67.
If the problem occurs with the new software again, contact ETAC for further information.
Please note:
A replacement of any parts (injectors, high-pressure pump, EGR valve, ECU, etc.)is not necessary.
FunctionalGroup: J - Engine
Complaint Group: 18 - Poor Drivebility
Trouble Code: None

Nice one mate, will give that a shot

Any idea where I can get this done from?

[LADmachining]

This will be a Vauxhall dealer job, or finding someone with a TECH2 and programming access to Vauxhall TIS (technical information system).

[lesj]

Nice one mate, will give that a shot

Any idea where I can get this done from?

Afraid its a dealer job unless you can find an indie that has paid for the Vx link.
My local dealer quoted £60 for a full software upgrade.

[Sums]

I put my old EGR valve back in last week and since then done 1000 miles, its perfect. No jerking what so ever. So the new EGR valve from Vauxhall is the problem

[lesj]

New EGRs are slightly different, hence the software update thats available. So that all ties in. Okd EGR old software or new EGR and new software