2.0l DTI LS estate, spanner light problem.

[mick 1986]

i recently bought the above car and the spanner light has came on a few times but i just turned car off and waited for around a minute, problem solved, not!
on friday on the motorway the spanner light came on and the engine management light (underneath the fuel gauge) came on, so i took it to a local garage for diagnostics. it came back with fault code
P0100 and
Mass or Volume Present
Air Flow Sensor
Circuit Range
Performance
the garage told me that the same fault code was on a 05 DTI vectra earlier this month and the EGR valve was shot, at £260 for a new one i want to be certain its the faulty part.
if i keep below 3K RPM the light wont come on, its sluggish when first started but after around a minute at tick over its ok, if i go over 3K RPM after the engine is warmed up properly the light comes straight on and the engine wont rev above 3K RPM and its flat, no power at all.
i havent checked anything as i dont want to be muckin around with bits that wont make a difference, i have been told to strip and clean the EGR valve but dont know where it is.
sorry for the long listing but wanted to list everything. anyone had the same fault and fixed it or think anything might fix it, advice would be much appreceated.
cheers, mick.

[bobssignum]

Hi mick before you go ahead and buy a new one , take the old one out and give it a clean with some carb cleaner , also while your there also clean your boost sensor .
you can find a how 2 for this on line here on the forum . also check your vacuum hoses for splits or perishing on the connectors .
All very common fault,s with the dti,s and easily fixed.If you need any more help come back to us and i see what can be done

[_ZS_]

Could be the AFM as well, my Astra had the same problem and it was the AFM that was goosed.

[Ste]

A code from the MAF can be EGR related, or can be the sensor too.

I would clean the EGR valve (good How to on here, by all accounts) and then maybe a clean of the MAF with carb cleaner too.

[mick 1986]

just been out and taken sum pics of the engine as im a bit stuck.

in this photo, what is the large black pipe at the front of the engine and what does it connect to? i only ask as it is split!

can anyone highlight the EGR valve in this pic or tell me where to look please?

or if the EGR valve is at the back of the engine can you highlight the area to look in this photo please?
also i took the air flow meter out and had a look, it looks brand new not a sniff of dust or dirt, i know that doesnt gaurentee it works but i would seriously dout it not working. i also done the air box mod and the filter was pitted on one half so a K&N will be purchased as soon as the light is sorted.
cheers again, mick.

[deano1]

hi the black hose is from the intercooler to the turbo and could be the cause of your problems get another one on before doing anything else i had same problem but with the other side pipe.

[mick 1986]

if its from the intercooler the turbo could be running without cooling, right?
i hope its not as the turbo could be snookerd aswell!! cheers.
do you know where the EGR valve is?
and the boost sensor?

[deano1]

hi mate the pipe just sends air to the turbo the spilit will cause the spanner light to come on at 3000 revs as i say replace the hose first it will drive ten times better with that pipe done.

[mick 1986]

ok mate, will try a quick fix first with a pipe bandage and then replace if it sorts it. what is the purpose of it sending air to the turbo? thanks again.

[mick 1986]

cheers deano1,
she now!!! thanks again for all the contributions. i will be back on here if it does it again, but a quick spin up the motorway with the engine above 80C and the light never came on, even above 3K RPM.

but can someone still point out the EGR valve and the boost sensor for a clean up, cheers.