2.2 DTi. At 50 MPH spanner warning light comes on and car goes into limp mode

[Saggy]

Hi.
I have a 2003 Vectra 2.2 DTi Automatic. At 50 mph (exactly) the spanner warning light appears on the dash and the power drops off (I think this is the car going into limp home mode).
If I turn off the ignition and restart the car, the light is not on and the car drives fine - until I hit 50 mph again.
Any thoughts on what the problem could be? I know people mention EGR and other things, but wouldn't that throw the warning light on straight away, and not wait till 50 mph?? Any ideas would be welcome. I'm reluctant to get VX to do a diagnostic but may have to.

thanks

[Saggy]

Actually, the car has a real loss of power right from when pulling away until it hits 50 mph, and then the limp mode kicks in. Hope it's not the swirl valves!

[bobssignum]

OK mate firstly check all your hoses connecting your turbo to to the manifold and intercooler (the two large one,s in front of your engine ) secondly check your vacuum hose and connectors for splits. next take out your boost valve and clean it with carb cleaner spray. remove egr valve and de-coke it .
All of these can cause the problem you describe, if you go as far as removeing egr valve and boost sensor also remove manifold sensor is fitted to this will give you an improvement in performance.

[craigbarlow18]

bob, when you say remove do you mean remove and clean or just remove?

[bobssignum]

Sorry about that should of been remove and clean

[AndrewTi]

All spot on advice, but all I'll add is be very gentle with the boost sensor, it's a delicate bit of kit. A liberal spray with the cleaner and agitate it with a soft, small brush.

[Saggy]

Thanks guys. All sounds like good advice (and hopefully not too expensive!). It'll give me something to do on Boxing Day!! I've checked and a replacement EGR is almost £200, so I'll definitely try cleaning it first.

[craigbarlow18]

saggy, good luck getting egr out, mines stuck fast had 2 attempts at removing it and failed each time

[bobssignum]

Craig your supposed to remove the retaining bolts first.

[craigbarlow18]

lol, i did, well two of them.#


tried giving it a twist and pull, it just wont budge. tried with warm engine and cold engine