Found this forum whilst researching my EGR problems. Hope to solve a few issues while I'm here.
My Astra is the CDTi 1.9 16v engine, detuned 120PS version. It's got 56k on it and was fast approaching a 20k service, when I noticed a massive loss of power one morning. To describe it would be either like having a massive turbo'd petrol engine (foot down at 1.5k revs, waiting, waiting, waiting and then woosh at about 2.7-2.8k revs) or also similar to when the TC cuts the engine power (anyone who's tried driving up a steep snow covered hill with TC on will know that feeling). Either way, I knew the car was not a happy bunny. Within a day both the emissions and the electronics warning lights had displayed on the dash.
So I booked the service early, got everything else done and then got the garage to investigate the power loss and warning lights.
Low and behold, the code reader showed a fault with the EGR.
The technician removed the EGR and manifold and thoroughly decoked them both. (They were very sooted)
With everything put back, I drive away but it's not long before the same issue occurs and the same engine lights show up.
So I take it to a local VX dealrship and blag a quick, free diagnostic.
Their reader displays the same issue, so I bite the bullet and order a new EGR valve. (None in stock at any of my local VX's)
Then I come on here today, only to start reading about the issue with the swirl flaps.. (How much to fix???? )
Anyway... I am clinging on to the hope that the new EGR valve will resolve the issue.. (I read that the EGR valve issue results in bags of smoke, where as the swirl flaps thingy doesn't - I have tonnes of extra smoke at the moment ...)
Occassionally, but only for a few gear changes at a time, the problem disappears, the smoke stops and the power comes back, so I really do think it must be the EGR valve sticking shut and then getting stuck open again.
So, with that out the way, comes my other questions.... if anyone is still reading down this far
I have, lets be honest, a 150PS CDTi that has been robbed of 30PS and a small wedge of torque, thanks to the ECU. What do I need to do to get those hidden ponies back?
Do I need to buy one of these tuning boxes, just to get back what vauxhall decided I didn't need, or can I do something with the ECU to return the engine to the power it was designed for?
If I do have to buy a box, how does it work in respect to my car being detuned to start with? Will it allow me to get the same power as the 150PS guys are getting, or will I still be 30PS behind?
Thanks to anyone for taking time to read and hopefully respond to this little post.