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Thread: 2.2dti egr and inlet manifold

  1. #1
    Regular Member ptrehearn152's Avatar
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    Default 2.2dti egr and inlet manifold

    here's one for all you techies, i had/may still have got a prob with my 2004 2.2 dti, yesterday i travelled 2 miles to the depot where i work the car ran like a dream, i left it there for 5 hours and when i stated it up the spanner light came on, it was running very rough and coughing out plumes of white/blue smoke from the exhaust, it died so i restarted and the same again, it did this a few more times (each time it was in limp mode) until finally after some prety fancy dancing with the throttle pedal it cleared and drove home like there was nothing wrong until i got to the end of our close and it died again without warning the spanner light came on again, i coasted onto the drive, tried to start it and it fired up with no probs and no smoke. it has cut out on the odd occassion before but always re-started. this morning it started ok no smoke at all. checking it over all the vac pipes are in good order and the vac valve on the turbo working, the vac on the inlet manifold (the one that works the butterfly's in the manifold) and the one on the throttle body ok (tested by sucking on relavent pipes). took the egr off along with inlet manifold and butterfly rail as all were pretty gunged up, egr is free to move by hand, after a good clean up all re-assembled fuel bled started and took for a test drive and ok, now the questions, if you rev the engine slowly from 0-2500 revs there is a distinct engine tone change, is this normal? 2nd why do these engines get choked up so quickly? this one 55k, my fontera had same gunge at 70k.
    any thoughts anyone?

  2. #2
    Full Member bobssignum's Avatar
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    Vehicle : Signum 2.0 DTi

    Trim : Elegance/Elite

    Engine : 2.0DTi

    Year : 2003

    Mileage : 73350

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    If all your doing is 2 miles to work and back again then the engine is not getting a chance to burn off the excess carbon build up , put some millers inthe tank and take it for a run
    Driving vauxhall,s for 30 + years
    and still loving it

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    It sounds to me that you have a leak off pipe problem. Check to see if there is any diesel arond them. They do suffer from this. Use VX pipe and new t-pieces replace all pipe even to the pump.

  4. #4
    Regular Member ptrehearn152's Avatar
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    thanks guys, only done 1k since i had the car, no leaks around leak off's, didn't think leak off's would create so much smoke, car looks fantastic but not convinced that previous owner took much care of it.

  5. #5
    Regular Member phykell's Avatar
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    Did you take the EGR's solenoid apart to remove any corrosion? Did you clean the MAF sensor?

  6. #6
    Regular Member ptrehearn152's Avatar
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    cleaned maf sensor first with meth's (being very careful) then drounded the sensor bit in carb cleaner and left to evapourate whilst dismantling egr, no corrosion just lots of carbon/oily grime cleaned and put a light smear of assembly grease on the plunger lever/cam, but everything was as free as a bird before dismantling.

  7. #7
    Regular Member ptrehearn152's Avatar
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    anyone any ideas about my 2 questions at the bottom of my original post please?

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