Zafira 2.0l dti turbo issues!!!

[Steve_o]

Hi, this is my first post on here so I'm hoping sombody will be able to help me.

I've just got an '02 zafira 2.0l dti. It has done almost 300,000. Miles as it was a taxi before I got it. The car it's self is in amazing condition, but, the only problem is I don't think the turbo is working.

It's very slow to pull away and is just generally very slugish to drive. I used to have a 1.6l t reg petrol zafira and that had much more guts thatn this has at the moment.

I'm hoping sombody can give me some good advice. I have checked all the pipes for the turbo system and they all seem ok to me.

Before anybody responds, i'm not very familiar with car engines so please can you explain in idiot terms!! Maybe even some pictures would be handy!!!

Thanks in advance...

[smirnoff_rules]

the egr valves r common for that , they can be removed and cleaned

[Steve_o]

I've heard somthing about those. At the risk of sounding like a complete muppet, where are the and what do they look like...

Sorry, I'm a bit thick!!!

[smirnoff_rules]

how to clean egr new method (picture

how to clean egr new method (pictures)
http://i187.photobucket.com/albums/x...8/SP_A0271.jpg
obviously locate and remov e egr valve, not difficult at all
http://i187.photobucket.com/albums/x...8/SP_A0272.jpg
http://i187.photobucket.com/albums/x...8/SP_A0273.jpg
just a couple of pictures of valve when removed note the soot build up!
http://i187.photobucket.com/albums/x...8/SP_A0276.jpg
seperate the valve by undoing 4xtorx bolts
http://i187.photobucket.com/albums/x...8/SP_A0277.jpg
http://i187.photobucket.com/albums/x...8/SP_A0278.jpg
http://i187.photobucket.com/albums/x...8/SP_A0279.jpg
look how bad this looks!
http://i187.photobucket.com/albums/x...8/SP_A0280.jpg
drill a 3mm hole in top of valve as shown
http://i187.photobucket.com/albums/x...8/SP_A0281.jpg
gently tap punch through hole until the solenoid insides come out next pic
http://i187.photobucket.com/albums/x...8/SP_A0282.jpg
http://i187.photobucket.com/albums/x...8/SP_A0283.jpg
http://i187.photobucket.com/albums/x...8/SP_A0284.jpg
what you should have when you have tapped out insides of solenoid now you will see the real cause for the egr complaint these parts will be corroded and cause sticking, believe it or not its not the soot that jams the valve but this corrosion
http://i187.photobucket.com/albums/x...8/SP_A0286.jpg
http://i187.photobucket.com/albums/x...8/SP_A0287.jpg
http://i187.photobucket.com/albums/x...8/SP_A0288.jpg
clean up removed solenoid parts, i use a bench wheel, and reassemble in reverse of removal but lubricate all parts with a touch of grease or the like.
http://i187.photobucket.com/albums/x...8/SP_A0289.jpg
gently tap solenoid parts back into place until flush
http://i187.photobucket.com/albums/x...8/SP_A0290.jpg
you can now depress plunger and notice one hell of a difference. at this point you will have to clean the body of the valve in some form of cleaner.
http://i187.photobucket.com/albums/x...8/SP_A0291.jpg
spray some more grease etc into the 3mm hole
http://i187.photobucket.com/albums/x...8/SP_A0292.jpg
finally reassemble and refit to vehicle, trust me you will be very impressed with the results.

thanx to jon7278

[synkrotronic]

Maybe air mass sensor.
But the better thing is to make a diagnostic to see if any error on ecu memory.If egr valve,clean too air admission "tubes ",sorry don?t know if is the correct term .

Regards

[Steve_o]

Oky, thanks for all that. Sounds quite easy!!

Only one question. If I drill the hole do I need to fill it afterwards or is this just a casing?

[estate]

how to clean egr new method (picture




thanx to jon7278

one small prob with this, it isn't the egr for the 2.0 dti, it's for the 1.9cdti..............

[Meat-Head]

one small prob with this, it isn't the egr for the 2.0 dti, it's for the 1.9cdti..............

a) it's the thought that counts
b) is it a 'low blow'?