Engine noises when temperature is more than 20°C

[Bymoe]

Hello everyone, 

I have some strange problem with my wifes Insignia 2.0CDTi 16v (160PS) inc. ecoFLEX By now I have been in 5 garages to get down to the problem, but  no one has an answer for me. 

When I start the car and the outside temperature is 20°C or more as per dashboard, the engine has no power, makes ugly rattling noises <1500rpm. No matter how long I drive, the issue remains. The next time when I start it, if the temperature is less than 20°C, everything is fine again. 

There are no error codes saved. So far we have cleaned the air intake incl. EGR, cleaned the complete fuel system, got a new clutch kit, incl. flywheel. Nothing helped. 

I wonder if there is any sensor, valve, or whatever, that could cause this behaviour? Any help is welcome. 

Please see Sound Sample, for a better description of the sound the engine makes. Let me know if you need any more info or have any questions.  

Thanks

Edited March 26 by Bymoe
Car model added