I was chatting to the guy that maps Saabs about these last weekend as he's just got one to play with as the 9-3 1.9TiD is basically the same as the Vectra.
You need a proper mapper on this one like you say and you need to do an EGR blank and delete in software (will stop the EGR light coming on after the blank). As LGF says the manifold will be properly caked by now due to the EGR, so clean it out and the swirl flaps. This will them be fine and not break as it's down to EGR that deposits all the cack in the system jamming things like swirl flaps and clogging the throttle body. The Saab guy has done all this and is currently playing with different maps with his (ex-race mechanic and tuner) but he is confident of decent figures.
Like all uprating though it will increase wear on parts like the clutch and flywheel, maybe a bit on turbo, injectors and pump, but turbo wear will be offset to a degree by the EGR delete as you won't be passing so much cack through it! Not sure what the life of injectors and fuel pumps are post mapping, but they were two things that were solid on my old Fabia vRS that was mapped to ~170bhp/350NM.
Carl.