2004 Vauxhall Zafira warning light then car goes into get you home mode

Could try this from another forum , quite common ,

hi i also have a 2.0l dti 2003 i had the same problem with my spanner light going on and off whilst driving putting car in limp mode.diognostic fault was p0400 egr valve.i had the problem for nearly 2 years but couldnt afford new valve.so i cleanedthe valve without taking it off.the valve sits just behind the radiator at the top in the centre.all i done was took off the plastic grey cap to the left hand side of the valve it was almost packed solid with carbon i scrapped off all the carbon from inside the plastic cap and all what the cap was covering there was a dog leg shaped piece of metal which when the engine is running and you rev it up moved back and forth this was clogged with carbon restricting air flow i cleaned all around this and sprayed with wd40 after i put the cap back on and took it for a run. 3 weeks later the light still hasnt come on. i took it back to garage to clear fault code and mechanic said it had cleared the code itself meaning the cleaning i done had worked.i would recomend to anyone on trying this first as it takes no more than 20 minutes and you dont have to take anything to bits.i went on youtube first to find the egr valve and saw the egr valve working so i new what i was looking for before i started.i hope this helps others as i was quoted £208 upwards plus fitting.im not saying this is everybodies answer but it is a very quick and easy place to start. goodluck

adam
September 2009