2010 Insignia P0402 EGR Excessive flow

This Insignia lost power and cut out, logging P0402 EGR Excessive flow.
Take a walk with me through this common problem.
Apologies for the abrupt ending but I was mercilessly struck down with Man-flu before I could film the conclusion.
A new EGR valve, fitted and adapted correctly cured this fault.
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Steve
* Disclaimer: Neither Simply Diagnostics nor Steve Scott accept any liability for any loss, injury or damage to any person, property or vehicle as a result of techniques, tools or methods shown on this channel. Always follow the manufacturers instructions and abide by all local and national laws regarding safe working and environmental hazards*

[@phantom2017]

Exactly the symptoms in my 2010 insignia. Now I know what to do. Thanks for this video.

[@andresmejia7741]

Great example...and very clean work Steve ! Thumbs up !!!!

[@ssss-df5qz]

To be fair, when these engines are tip top brand new, setting the faults aside - they are a strong engine. It's a fun diesel in my book.

[@yogibear2485]

A very informative video, best video I've seen on giving good information of car faults, what I was looking for. Keep up the good work.

[@steveguest8028]

Great video,had one of these in today with exactly the same problem 👍

[@wardybasher]

Simple, efficient with a spot on diagnosis, Great stuff.👍

[@JBTaylor86]

Top work steve. 👍🏻👍🏻 I don’t like how you’re not able to select specific date during actuator tests with the Bosch tho.

[@SimplyDiagnostics]

John, it is a tad frustrating but none of the other generic tools do either. Dealer tools are the only way forward.

[@samuesoeilyoriy6581]

the engine in these or at least the block is an old fiat design from the 80s which actually was a great diesel engine

[@ricardocamacho5466]

Well done mate!!!! All the best.....

[@benjaminrich9396]

"Vauxhall and diesel are two words that should never be used in the same sentence together." Hahaha Maybe "back in the day the 1.7 isuzu diesel engine that astras and such had wasn't too bad." :)

[@TheRoverspeed]

It's a Fiat derived GM engine. Also found in Fiats, Alfa Romeos and Saabs. And probably others. Not much Vauxhall about it

[@mrmotorvator5151]

Not a gm motor

[@benjaminrich9396]

@@mrmotorvator5151 exactly

[@mrmotorvator5151]

@@benjaminrich9396 had a few and looked after 250k easily achievable so not exactly shit..il stick to unleaded all the same

[@thomasadamteasdale]

Excellent mate really good video enjoyed the Vauxhall and diesel comment

[@darrenconnolly1412]

Great vid pal, but now I have p0403 code, egr malfunction is this a wiring problem. Thanks

[@chrisbates2343]

Like the Video Mate, Alldata looks good, looks alot more user friendly then Tis2web. Cheers

[@SimplyDiagnostics]

Gratzme Gaming it has its strengths when the vehicle is listed. When it isn’t then you just put a request in for the information you want and wait. It has its weaknesses as well but it’s invaluable to me seeing such a variety of vehicles and faults.

[@Automotive_Solutions]

900 subscribers to go. 👍

[@mashrafshamsaldeen5321]

The thing is I got this code on my 2013 insignia and I have just changed the Egr valve, the car is lossing power and I got that dpf is full. After driving for a bit the dpf massage went off but the code still comes and goes, any ideas ?

[@paulkazjack]

Never had all these problems with cars in the 90's.

[@ivandrago2557]

Why egr position sensor didn't registred slightly open valve, actually it showed less than 1 V. Isn't have to show more than 1 V.

[@rrmech11]

Very interesting Mate

[@mjxfusionz7807]

Wonder if you could help me I have an egr and maf error code and I think the egr could be causing the maf error but I’m not too sure

[@petercambulaso3858]

Can my codes on an Audi A5 2013 tdi still have codes of 1) EGR valve open circuit 2) Exhaust gas Recirculation Sensor A circuit/range performance 3) EGR valve open circuit If it was just totally blocked up ?

[@SimplyDiagnostics]

no, range/performance yes but not the open circuit codes

[@petercambulaso3858]

Simply Diagnostics thanks mate trying to determine weather it’s a clogged EGR or electrical

[@DIETRYING001]

@@petercambulaso3858 gurantee it needs a valve.

[@donnierobertson3088]

Great job

[@mattknights274]

Nice simple process there mate. That engine is a fiat 2.0l unit not a vauxhall produced engine.

[@SimplyDiagnostics]

Matt Knights 😁

[@davehughes6501]

The 1.9 cdti was sourced from fiat, the 2.0cdti was jointly developed by both.

[@TheGeekazoid]

how did you lift the valve with egr out of the car

[@SimplyDiagnostics]

Probably a PWM controller, don't remember this specific job.

[@newry123]

If you put a new egr valve on does it need programmming to car

[@newry123]

Thanks

[@newry123]

Does a new egr valve for an insignia need coded or programmed to the car or is it just a case of putting new one on. Cheers

[@SimplyDiagnostics]

Most component replacement requires some form of adaption or coding these days. Best advice would refer to technical information for the vehicle being worked on. Hope this helps.

[@newry123]

Thanks

[@Ollie_77]

You wouldn't believe the nightmare I'm having with this exact issue on my insignia. Same fault code. Egr valve has been replaced. Same problem. Car goes into "limp mode" several times a week. I have to restart engine to get it working again.

[@Prot0n]

Did you ever figure this out? I’m having the same issue

[@BrandonMorrison-yi2vr]

​@@Prot0nsame question to you 😂😂

[@1988csh]

I have had the same error on my 2012 2.0 CDTi Astra. My car seems okay apart from start/ stop doesn’t seem to work anymore. A Vauxhall specialist told me I have a stuck open EGR then they told me I must have a EGR cooler leak however that was 2 months ago and I haven’t lost any coolent, they want to replace this at a cost of £1500. Are you based in the north west?

[@Matthewjhunter1]

Just had mine changed and just got that p0402 code dunno what to do

[@125sm3]

Great video, new subscriber.

[@SimplyDiagnostics]

125 SM thanks for subscribing 😁

[@ryanrepairs6944]

Do all data diy have vauxhall I can never find it mate

[@SimplyDiagnostics]

Yes they have comprehensive OEM info on Vauxhall/Opel

[@ryanrepairs6944]

@@SimplyDiagnostics great thank you!

[@jhauna1]

Hey steve what scanner are u using fir this diag? Hope u can give some detail on it, thanks brother

[@SimplyDiagnostics]

Hi Bannie, it's the Bosch KTS 590

[@FlorinFrent]

Hello , it would be awesome if u would explain how to readapt the new EGR . Thanks.

[@SimplyDiagnostics]

The next vehicle I see with this fault I will show the process. It's normally just a couple of button presses with a scantool. Some vehicles (not all & not this particular car) also require a software update or patch. There are also vehicles that only the OE dealer tool should be used for this process to avoid irreparable damage to controllers and components.

[@FlorinFrent]

@@SimplyDiagnostics thank you !

[@edwardsteele4022]

what do you mean by their engines? are they that bad? im looking into buying this car

[@meller1965]

So are you saying opel/ Vauxhall and diesel engine do.not mix

[@DibroTeam]

I have the same error, it's shows 1 ,2 time per month but I tried to clean it today and now i have non stop this error. I don't know what to do now.

[@SimplyDiagnostics]

I'd say it's either stuck open or thinks it's stuck open. There are a few reasons why this may be happening. Suggest getting it booked into your nearest specialist for an assessment. Hope this helps.

[@DibroTeam]

@@SimplyDiagnostics Thank you very much!

[@DibroTeam]

I changed egr with new but now i have same error. Two days was fine. What is possible to have this error p0402-51

[@DibroTeam]

After few weeks i don`t have solution. I found that I have this fault after regeneration, when my DPF% was below 30 or around 20/35 %. When dpf goes More than 35% i don`t have problem with errors to next regeneration.

[@slipperymud]

Hi Mate you said after you have given it a clean you have to reset the EGR positions or it will have the old readings still. I'm just a DIYer . So if I clean the EGR will I still have to take it to a service station to reset the positions of the EGR ? is that correct? I've only got one of those cheap blue tooth OBDII connectors modules that just reads data. or will the computer reset itself when I clear the error ...............Cheers

[@SimplyDiagnostics]

It's always a good idea to reset the adaptions after cleaning. OBD tools won't normally do this function. Try it and see how you get on.

[@garybrown5500]

Engine & DPF. Another two words that shouldn't go together (or EGR). Todays diesel engines would be fantastic compared to the old stuff if it wasn't for these!

[@DIETRYING001]

easily fixed though and essential in my opinion. modern engines are basically forced to digest their own shit! diesels especially.

[@atos.nympha3451]

My egr is brand new but I still get this code

[@AKMCars]

Cleaning it out didnt work for you?

[@Bob-nu3xe]

call me old school but i would "because the way the engine is performing" clean the EGR valve and I would have been done by the time this guy had worked it out on his fancy telly! cost? a bottle of white spirit £1!

[@SimplyDiagnostics]

That's all well and good on a vehicle with such easy access, what happens when it's a 4hr job to even get to it? Is it not better to prove its the component before stripping? Cheers

[@Bob-nu3xe]

@@SimplyDiagnostics Hi the EGR valve clean on the Vauxhall is 45 minute job if it was a 4 hour job then yes it would be better to make sure the prognosis was correct

[@georgebenson6279]

Dpf troubles are way too frequent on these . Some blame the egr but it's dpf bullshit

[@mrmotorvator5151]

Thought these were pug motors

[@gazzaoco]

Great video mate I've got insignia 2,0 ecoflex and done 188k How much to reset the bcm

[@podi7777]

Worst car ever... Spend thousands on this crap