As I mentioned in my introduction, I've got a late 2002 Astra 2.0 DTi. I understand it has effectively a Vectra C engine which is why I'm here.
I bought it knowing it was running in limp mode. That's not as daft as it seems, although I'm beginning to wonder, as I paid comfortably under £2000 for it.
I bought an interface for my laptop and Vauxcheck from Gendan. Error codes were P0100 and P0400, MAF and EGR. I replaced the MAF and cleaned out the EGR, absolutely no difference and the same error codes. I was reluctant to replace the EGR, largely because of the price but also for some unknown reason I had a feeling it was't faulty. As it turns out I was right but I'll get to that.
I bought a vacuum gauge, checked the pump output then plumbed it into the system. No problems.
Next I took the inlet manifold off to de-gunge it. It wasn't too bad and must have been done before. When I came to refit the upper manifold I noticed a few nicks out of the lower face which I cleaned up with wet & dry on a lump of steel bar. The upper face had big chunks out of it which I built it up with chemical metal as a stopgap until I got another manifold. There were a few nicks on the EGR face too but that cleaned up OK.
Cleared the codes, started up and 30 seconds later - EML. Just EGR this time, no MAF.
Beginning to despair I bought an upper inlet manifold from a scrappy and a brand new EGR.
Still no difference, if anything it's worse, The throttle pedal has absolutely no effect until it's been running for 30 seconds or so then it will rev to 1500. After a bit longer it will go to 1900 and longer still to 2900. Then the EML goes out, the turbo cuts in and it revs to about 3500. As soon as I put load on the EML comes back on and it's in limp mode again. Before all the "fixes" it would rev to 1900 immediately and the rest as before.
I've run out of ideas and everything that's been suggested hasn't helped yet. Are there any geniuses around?
Sorry for such a long screed as my first proper post.