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[JeffBarre]

My 2002 2.2 dti is very hard to start, when it runs the tickover is lumpy but does improve after a while. Wont rev past about 1200. The management light comes on but code reader says no codes. When its warm if you turn it off and restart it will rev a couple of times and then its back to no revs. Egr is clean, vac pipes checked only thing left is to pour petrol over and light a match . HELP !!

[martin42]

Check leak of pipes,common fault on dti's could be crank sensor causing fault

[andymp]

If the management light has come on there will be a fault code stored, but a basic hand held code reader such as the ones on ebay wont read them. You need vaux check or op com to read it.

[joff]

EGR is clean but what is the inlet manifold and butterfly valves like, on mine after 100k the inlet manifold was full of carbon and the small sensor at the rear of the manifold was also full of carbon.

[joff]

You will know if it's the crank sensor as the rev counter and speedo will go to zero with engine running.

[JeffBarre]

Stripped and checked every vacuum pipe and they are all perfect. This all started after the crank pulley went and a new one was fitted. I think the garage ran it out of fuel. Have bled system and put a primer  in the fuel line. I thought I had found it at first with a broken vac tube but when I repaired it no improvement. I cant see any damage caused by the fan belt the only think in its path is the Maf but I cant see that causing this fault

[AndyStobbs]

Think you can forget about vacuum system. If it wont tick over properly you've got a fuelling issue, or a mechanical issue.

[aaronjb]

A friend had almost identical issues - his fuel filter had collapsed and blocked the fuel flow almost completely (and eventually completely); has it been changed recently?

[JeffBarre]

Not long had fuel filter by garage who did pulley. I have stripped it and made sure they did it right !! I thought crank sensor but Im told if thats gone the rev counter wont work but mine does.

[joff]

When the crank sensor went on the brothers 2.2dti the speedo and rev counter would go to zero, as soon as the new one was fitted all was fine, have you taken the primer out to see if it is restricting flow at all. Had fuel feed issues when I had Vauxhall service the wife first 2.2Dti never had them service any of our car after that always do it myself. At what stage do you fit the primer and is it before or after filter?

[JeffBarre]

I do appreciate your help. I fitted the hand primer to make sure the fuel system was bled through properly. It is fitted between filter and pump. The fuel passes through nicely. The rev counter and speedo work fine. Im not a great believer in coincidence and the car ran perfectly before the crank pulley went. Any other ideas gratefully received.

[AndyStobbs]

Think you had better take a fuel sample at the injectors, just to be sure there isn't a load of swarf in it. If the garage ran it dry then bungled bleeding it there may be pump damage.
 I'm not sure that I've worked on a 2.2 dti, how is the fuel
Injection quantity controlled?

[joff]

There are a few vac pipes down under the air filter housing which go out to the pre-heater for coolant, there is also a small fuel feed pipe to the heater which is same bore/size as the vac pipe. Has any of this been damaged by the pulley going, did the belt snap?

[Elite Pete]

You will know if it's the crank sensor as the rev counter and speedo will go to zero with engine running.

Mine didn't

[Elite Pete]

Get the codes read first