Vauxhall DPF Nightmare: Black Smoke & Power Loss Issues

Hey there! I've got some experience with cars (not a pro, but I've dealt with my share of issues). Had almost the exact same problem with my 2017 Vauxhall Astra diesel last year. Same symptoms, black smoke, rough running, power loss, the works. Took it to my trusted workshop in town and, yep, turned out the DPF was internally damaged. Cost me around 1550€ to get it sorted with a new unit. Best decision ever, car's running like new now. Before I share more details about what my garage did, how many miles/km on your Insignia? Do you mainly do city driving or longer trips? Any engine warning lights besides the DPF one? These details would help me figure out if you're dealing with the same issue I had. DPF problems can be tricky, and knowing more about your driving patterns would help a lot.

Thanks for the reply! My Insignia's got 28784 KM on the clock and had its last service about 2 months ago. I do mainly city runs with occasional motorway trips on weekends. The only warning light I'm getting is the DPF one, no other engine lights showing up. Would be great to hear more about how your garage handled it. It's a bit worrying that it might cost that much, but better to get it sorted properly than let it get worse, right?

Hey again! Yeah, those symptoms definitely sound familiar, almost exactly what I experienced with my Astra. Given your mileage and driving pattern, I'm even more convinced it's similar to what I went through. Listen, here's what my garage found with my car: the DPF had actually developed internal cracks that were causing incomplete regeneration cycles. The city driving probably isn't helping your case either, it was the same issue that contributed to my problem. Those short trips don't let the DPF get hot enough for proper regeneration. When they fixed mine, they did a full diagnostic first (cost about 80€), which confirmed the DPF damage. They also checked the sensors and pressure pipes just to be sure, always good to rule out the cheaper fixes first! The new unit they installed was a genuine Vauxhall part (I didn't want to risk it with aftermarket options). One tip though, since you're doing mainly city driving like I was, try to take it for a good 20-30 minute motorway run at least once a week. I've been doing this since my repair, and it's made a massive difference. My fuel economy is way better now, and no more issues with regeneration. Have you noticed if it's getting worse with time? That's what happened with mine before I bit the bullet and got it fixed.

Thanks so much for all that detailed info, it's really helpful! Yeah, it's definitely getting worse week by week. The fuel consumption especially is becoming a real pain. I'll take your advice and get it checked out properly. Think I'll start with a diagnostic test first, just like you did. At least that way I'll know exactly what I'm dealing with. The price tag for a full replacement is a bit scary, but sounds like it's worth it in the long run. And thanks for the tip about the weekly motorway runs, I'll definitely start doing that. Actually, there's a nice stretch of motorway not far from me that would be perfect for this. Might as well start this weekend! Really appreciate you taking the time to share your experience. You've helped me make up my mind about getting it sorted sooner rather than later. Cheers!