Hi, sorry this is a bit of an essay!...
Just bought a Vectra 1.9 cdti 150 08plate diesel. I knew nothing about vectra's but bought it as it seemed decent enough and anyway, was a shed lot cooler than my Mondeo!
Got it home, all good, but began to notice there was quite a bit of black smoke coming out of the exhaust. Funnily enough the EGR light came on about the same time.
Had a man diagnose my fault codes, it was P0400, EGR valve blocked. He cleared the fault code, but obviously that didnt solve the problem..
I followed the advice on the forum, took off the EGR valve which was caked with soot and cleaned it with Carb cleaner. The solenoid plunger was free and moved well when I pushed it in, so that was OK. When putting the EGR valve back on I noticed the inside of the Intake manifold was even more caked up with soot, almost seemed to be completely blocked. Gave that a clean as best I could.
Started the car up, lots of black smoke, and then lots of frigging white smoke! Had a drive and noticed bad lack of power/turbo until 2,500-3,000 revs.
After a bit more driving...
The white smoke has died off but the black smoke is still there on high revs, its enough to make drivers behind pull back when it happens . The other issue is on cold start, low revs the car tends to stall, and idelling is generally very rough. And the EGR light is back on.
1 more thing!... I took a look at the swirl bar (actuator) and it has fallen off. The swirl valves are kinder stiff to move but will. Valves 4 & 1 have a bit of soot build up around them. Valve 3 does move on revving.
This is what I'm thinking of getting done:
1. Re-attach swirl bar
2. Blank off EGR valve
3. Check turbo boost & intercooler hoses for splits / holes
4. Carb cleaner through air intake to clean out manifold ?
Will this be enough? Or will I need a new manifold?