22nd Mar 2007, 03:22

I too have a Zafira 2.0TDI, firstly the problem with the car starting in a morning is more than likely down to the spill tubes on the injectors perishing. I have had this problem for around a year now and have tried everything, while looking around the engine and moving tubes I found that the small spill tubes (takes the excess diesel back to the pump) were very hard. When I tried to take them off they literally came apart in my hands. I have replaced all the tubing from the injectors to the pump (about £4 worth) and all seems OK now. The car now starts after the first turn which it has not done for over a year now.

Secondly the problem with the engine management light coming on and you loose half the power, this is happening to me and I was at a loss as to what it is. I also have an Audi and when I bought it I took it in for some work and they told me that the air mass meter has stopped working, I had not noticed as there seemed enough power, but not quite enough. After they replaced this it was like driving a new car. I will get this replaced and see if it fixes the fault.

15th Apr 2007, 02:39

We have just bought a Zafira 2.0 l dti, 2002 plate. It has had no problems up to now. I parked on a steep driveway overnight and it would not start the next day, despite the fact that I had half a tank of fuel. Luckily, I had a friend who was able to bump start it down the hill and it started almost immediately. I can only assume that the fuel leaks back into the tank allowing an air lock into the fuel line. Next time I will be parking downhill!

26th May 2007, 06:15

I have a 2.0 DTi Zafira Elegance (X-reg). 67000 miles. On a cold start, the glow plug light comes on, then goes out as expected, the engine starts after about 4 cranks, then the Engine Management Light comes on. I rev the engine (to 1100 rpm) a couple of times and it goes out. Hot starts no problem. If left for a couple of hours, it refuses to start straight away, and when it does I have a cloud of smoke coming from the exhaust for a few seconds.

4th Jul 2007, 19:17

Oh no! Just been given a present Vauxhall Zafira 2002 reg with 82k miles and full service history 1 and 1/2 days ago. It was bought for 4500, and the missus today said it lost power while slowing down at the junction. I stumbled across this website and well disappointed, 1 with vauxhall, 2 with the bloody dealer who sold it to the person who gave it to us (Arthur Daley comes to mind).

I am a japanese man myself, as I know these cars are nothing but trouble, but thought they may have changed their ways.

Get Vauxhall, they know about this and are to blame.

11th Jul 2007, 12:06

Guess What? Same issues here too.

Zafira club 1.6 2002, 47k on clock.

When coming off motorway, engine cuts out. Sometimes restarts after around 10 minutes, but last time had to call RAC, who reset the management system (free of charge) Worked for a week, until I had to use motorway again. Same thing happened.

I have just bought a code reader off ebay, so I don't get ripped off by vauxhall like some of you guys.

Just to note, the RAC guy said it could be either the ECU, or the pedal box sometimes sticks, but both of these are expensive, and I want to know exactly what the problem is before I hand over my cash.

12th Jul 2007, 00:03

"Uphill starting problems". I am glad that I am not alone with not being able to start my Zafira 2.00 Dti (2002) model when parked uphill after several hours. It went back to Main Dealer under warranty twice and they did not fix it. Various mechanics have looked at it and replaced the crumbling injectors lines, but still no better at starting. Consigned my self to leave it pointed downhill every night. Also, the Engine Management light used to come on constantly and it would not rev over 2,000 revs and would cough and splutter. A new sensor was put on and seems to have cured it, but light still comes on now and again. Come on Vauxhall, there is a serious problem with this car which needs looking at.

12th Jul 2007, 11:54

Came across this site because I too started to get the annoying 'engine management' errors and rev problems...however, it is a known problem (as some have said) but most Vauxhall dealers don't know it!..

Found out about about field remedy 1590 from an independent dealer... it actually involves changing the throttle valve adjustment by means of making a small hole in the bore and then reprogramming the ECU.. total cost about £50.

Hope this helps..

13th Jul 2007, 06:45

I have a 2003 2.0 DTI Zafira with 58000 miles. On long journeys, completely at random, the intermittent engine management light on with loss of power problem. Sometimes the light stays on and power stays low, which I fix by stopping and starting the engine, even while doing 60 on the motorway. I daren't take to the garage in fear of excess charges and no guarantee of fixing it.

What amazes me is that loads of other have the same problem. Is there a fix, or what is causing it?

Oh, I had the car serviced, which had no effect.

23rd Jul 2007, 15:18

Hi there.

Got a question.

I am thinking about buying a code reader from eBay, but need to know what to do with it. Where do I plug it in on the car, and how do you translate the code to matching the problem?

My engine management has been on a lot recently, and when I now turn on the ignition, the engine management keeps on flashing and car doesn't start. It has also been losing power for ages.

Anyone help please.

3rd Aug 2007, 06:30

My 2003 Zafira 2ltr diesel suffered with the spanner warning light and loss of power when showing 68000 miles on the clock. The fault was intermittent, but progressively deteriorated. The main dealer were unable to confidently locate the source as the diagnostic failed to reveal the cause. They suspected the EGR valve and quoted £460 the replace with no guarantee of success. Another month down the road I took the car to an independent mechanic who was able to run the diagnostic with the car running under fault. The EGR valve was the culprit and was promptly replaced for £100 less than the main dealer price. I am told this is a common fault with this particular car, the Achilles heel of an otherwise OK people lugger. The car has been running without fault for two weeks since the repair. I am still going to replace the vehicle due to its poor towing ability (1050kgs max).