Let me introduce myself with a list of problems!

**signum_jon** · 14th January 2011, 15:38

Firstly, as a new bod, a big hello to everyone here!

Secondly.......help!!!

I bought a 2003 2.2 Dti Signum a few days ago and it's giving me grief already :-(

This is what I've noticed:

Fuel consumption is about 33mpg
Puffs of black smoke out the exhaust
Tries to stall when pulling away
Whilst driving I often get a juddering sensation (like a misfire)
Whilst driving it will judder and then just cut out, but will restart okay
Spanner comes up on the dash every few miles, goes into restricted power mode and then clears itself after about thirty seconds.

Spent a few quid putting it on diagnostic and the following fault codes showed up:

P0638 Throttle Control Circuit Positive Deviation

P0703 Brake Switch Circuit Malfunction

P0704 Clutch Switch Signal Incorrect

P0380 Glow Device Circuit Low Voltage

Anyone had these problems before? Any suggestions for things that I can do myself instead of paying labour charges would be gratefully received!

Oh, btw - I also have a bulb failure warning on the dash, and the centre display tells me to check the rear brake light bulbs, but have replaced these even though all the correct lights are working, have also removed the light units and cleaned all the contacts to be extra sure?

Thanks

Jon

**bobssignum** · 14th January 2011, 16:20

Hi jon
ok first one p0638 relates to your boost sensor , what is probably the case is that it has become covered with carbon deposit . easiest way to solve this is to remove the inlet manifold then remove thesensor and clean with carburettor cleaner , relatedto this you will probably find the egr valve , and the manifold itself will almot definnetly need a clean as well , all relatively straight forward just have a look in the how too section of the forum for guides
p0703 no info at the moment
p0704 no info at the moment
p0380 relates to one or more of your glow plugs is faulty only cure for this to replace them have a look on ebay plenty on there going for a lot less than what the stealers will charge you.

**dh.dti** · 14th January 2011, 16:32

In addition to the above...

Have a good look round all the Boost & vac pipe work for splits etc... it's sometimes easier to spot anything a miss if someone holds the revs around 2.5 k while you have a good look

hth

**bobssignum** · 14th January 2011, 16:41

Jon in a addition to my earlier post can you post a pic of your engine bay with the engine cover off this way we can see what vacuum valve and t p s set up you have as these vary

**signum_jon** · 14th January 2011, 21:12

Originally Posted by bobssignum

Jon in a addition to my earlier post can you post a pic of your engine bay with the engine cover off this way we can see what vacuum valve and t p s set up you have as these vary

Thanks for all the advice so far- will get the engine cover off tomorrow and take some pics.

Have ordered some Bosch glow plugs from ebay, so will get those in as soon as they arrive, and see if that cures one of the faults.

Cheers!!

Jon

**Dazzy2006** · 14th January 2011, 21:18

Originally Posted by signum_jon

Thanks for all the advice so far- will get the engine cover off tomorrow and take some pics.

Have ordered some Bosch glow plugs from ebay, so will get those in as soon as they arrive, and see if that cures one of the faults.

Cheers!!

Jon

Regarding the glowplugs - be VERY VERY careful when changing the glowplugs as they are prone to snapping - make sure you spray plusgas on them for a few days beforehand and the day you change them get the engine HOT and hopefully they will come out ok.

I'm not trying to put you off but i've been quoted £700 to have a snapped glowplug removed and helicoiled

**troutybrown** · 14th January 2011, 21:26

http://www.vectra-c.com/forum/showthread.php?t=70471

Have a look at this thread its all the How to's and should help.

**signum_jon** · 14th January 2011, 23:21

Originally Posted by Dazzy2006

Regarding the glowplugs - be VERY VERY careful when changing the glowplugs as they are prone to snapping - make sure you spray plusgas on them for a few days beforehand and the day you change them get the engine HOT and hopefully they will come out ok.

I'm not trying to put you off but i've been quoted £700 to have a snapped glowplug removed and helicoiled

Top Tip! Thanks as this is my first diesel and I would probably have attacked them in the same way as a normal spark plug.

Jon

**signum_jon** · 15th January 2011, 11:27

Originally Posted by signum_jon

Thanks for all the advice so far- will get the engine cover off tomorrow and take some pics.

Have ordered some Bosch glow plugs from ebay, so will get those in as soon as they arrive, and see if that cures one of the faults.

Cheers!!

Jon

Picture of engine as requested - EGR valve looks new? (assuming I'm looking at the right bit?)

Jon

**the-wizard** · 15th January 2011, 11:32

Here's the others!.

P0703 Torque Converter/Brake Switch B Circuit Malfunction

P0704 Clutch Switch Input Circuit Malfunction

just noticed your recent post so you may have a split boost or vacum hose, or if there's one or two small valves near the front r/h side near the radiator i believe they can be removed / parted & cleaned.