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[dtnorth]

I have a, just hit 100,000 miles 2002 2.2 sport auto and last week the engine management light came on and it felt like clutch slip in a manual.

This manifests as a judder and very lumpy running.

After reading these forums I attempted to clean out the EGR valve
however I couldnt get the bugger off due to lack of the correct TORX
bit to remove it.

Incidentaly, does anyone know the correct size of TORX
bit required to remove the EGR?

Having given up on my attempt to remove the EGR, I removed every pipe and hose in sight in order to clean them out.

About 75% of them were filled with gunk and muck to the point where
nothing could get through them.  Water, Air, Oil etc...

God only knows how the bugger has been able to run at all..

Anyhoo, I cleaned them all out but to no avail. The car still judders , but only after its heated up.

Does this look like a dying Gearbox or something else.

[Dazzler]

I am a little confused at your problem...... Is the car running lumpy/rough when just idling or only when its being driven?

[dtnorth]

Oops, as an addendum to the hose/pipe cleaning.  One from the right hand top back side of the engine, just right of the EGR leading into the gearbox.

This was all but blocked with gunge.

The other hose lead from the air filter into the top right hand side of the engine , and this basically fell to bits
in the removal attempt and was completely clogged.    

Anyway, as a result after the first drive test which didnt go well on Saturday, it is now running like a dream.....

I hit 70 mph on 2000 revs very quickly and smoothly....    with no lumping and no cost....  

Incidentally, its a 2002 2.2 sport saloon with more mileage than it deserves.

[dtnorth]

A wierd and wonderful thing.

After "de-filthing" all of the various hoses and pipes leading from various parts of the engine . "2002 2.2 Ecotec" the car runs like a dream.

No more auto slip, no more racing in the wrong gear, and the engine is barely audible. Reminds me of why I first enjoyed the bugger.

Im curious though, the 2 worst hoses/pipes were as follows:

1 leading from the air intake, after the filter, perhaps 10 cm's wide leading into the top of the engine on the left hand side. This had almost calcified andd felt like licorice and snapped on removal.

The second about 1" thick coming from the top right feeding into the gearbox.

Both were completely blocked with crap.

Anyhoo, it solved my prob....

[dtnorth]

Oops.   Not 10 cm's  , I meant 10 mm.....

[Marks DTM Calib]

Has it had good regualr oil changes or the 20K Vx spec ones....

[dtnorth]

Just the normal service schedule oil changes

[tunnie]

Just the normal service schedule oil changes

I change the oil in mine every 3k, sometimes even more often.

Made hell of a difference, its a lot, lot smooth and makes much less noise at idle.

Since the 2.2 takes almost exactly 5L of oil, its very cheap to do an oil change.

You can get 4 x 5L GM 10/40 Semi Synth for £33 odd

Filters are about £1.06 ish...

You can do an oil change for under a tenner!!!