5th Apr 2008, 02:13

We have had a 03 2.0 DTi for the last 12 months, it has been back every month, had every sensor replaced, all the valves. We are on our 3rd turbo etc etc, but still nearly every month it loses power, the engine light comes on.

Bought off a Volkswagen dealership who try to tell us its normal for a car of this age to have this many faults, all connected to the same thing. 11 times we are on now on. Sadly bought on finance, so there's nothing I can do; just have to live with a car the dealership have more than me.

5th Apr 2008, 15:41

Forgot to say in my comment above, what have other people done about the faults? Would be very interested to know what we can do as I now have a car that's too dangerous to drive.

15th Apr 2008, 07:37

OK think I found the fault, because there was nowhere for the exhaust fumes to go I took off the maniverter (combined manifold/catalytic converter) and found broken bits of the catalytic converter everywhere, I’m guessing the filings I found blown out of the lambda sensor hole were parts of the catalytic converter, phew hopefully no blown engine, ordered new one couple hours ago and will have it tomorrow, the cost from Vauxhall £600 I managed to get for £340 inc vat+delivery I will fit tomorrow and post results.

Chris.

26th Apr 2008, 05:22

I got a 53 plate Zafira 1.6 and it seems that I have the same problem. Put the computer on it and it came up with a random multiple misfire, but did not tell us what was causing the misfire. It has had a new coil pack, new crank sensor, cleaned the EGR, but have still got the problem.

It looks like it has got to go.

Can anyone help please.

2nd May 2008, 06:08

51 2.0l DTI

I have had a simliar problem, too many, losing power and the engine management light coming on.

I am a mechanic, and have years of experience with many cars, but this one has confused the hell out of me for ages!

I tested egr, I did a fault code read, that showed that the engine was asking for more boost pressure (+2BAR) but the boost was not there (0.01BAR) I changed the Vacuum switches, and this did not work either. The other week, I was using the Zafira to jump start another vehicle, and I could just hear the faintest of 'hisses' from the engine of the Zafira. I traced it to a Vaccum pipe that goes to the boost valve on the Turbo. It had the tiniest of holes in the pipe, which is small itself, and I have now covered that with some good old fashioned gaffer tape, (I will replace the pipe) and hey presto, it was fine!

Until this week!

Driving along at about 85-90...I mean 70mph! officer.

The Engine lost power, the rev counter stopped, and the spanner light came on, as well as the light for the Radiator warning!!! I pulled into a garage to have a look, and could find nothing out of place.

I stopped on the way back home for some lunch, and when I came out, it was working fine when I got back in it!

I was told today by a mechanic friend of mine, that it may be a problem with the alternator, it has a lead that comes off the back of it to the rev counter, and the car is very dependant on the correct voltage, I have not tested it, but I will do, and will post details after. It is a very easy thing for anyone to test, so if you are having the same problems, I would suggest you try it yourself, the voltage should read 14.5-15Volts.

Also, after reading this thread, I see people promise to post details if they have fixed their car, I don't see anyone doing that, if you have fixed it, it is helpful to others to know what has happened? The more we share, the more we can understand what the problem is, before going down the route of guessing and buy and fitting parts in sequence.

Cheers

Chris.

6th May 2008, 14:23

I have had a Zafira Elegance 1.6 2000 model for about two and a half months and am almost at my wits end with it. We had owned it for five days and the engine management light came on - took it to the garage and they replaced the DIS pack and new spark plugs. Six weeks later engine management light on again - took it back where they cleaned the spark plugs!! One week later engine management light on again - took it back - needed new airflow meter. Two weeks later and the "spanner" symbol is now on and off intermittently. Topped the oil up as this was empty (despite having been topped up only six weeks ago - is this normal?) Car is driving OK and just took it on a 400 mile round trip with no major problems. However, it seems to be drinking petrol like there's no tomorrow and temperature gauge seems to stay on zero for ages and then within ten minutes is just over 90. I've read on here and on other sites that the spanner light could mean a faulty EGR valve and I know the exhaust (front drop-pipe) needs replacing - could this be connected? As I say, I am at my wits' end with it and really disappointed as having owned three Astra Estates with none of this hassle, I really thought owning a Zafira was going to be as easy!!!

7th May 2008, 11:59

I too have had the same problem with my 2.0 DTI Zafira with the EMS light coming on. Problems that arise are the car will do no more than 3000 revs when on and there is a noticeable lack of power, the car then goes into limp home mode. However it is not on permanently on goes off on the motorway when driving at speed. I took it to garage and they diagnosed the ERG valve (Costing £350). When I started the car up the light came straight back on!!! Decided to get my money back and take to a reputable dealer. They aslo diagnosed the ERG Valve but also said that the mass air flow meter was faulty, they were right! This cost £290 and I have not had the problem since. They did change the ERG valve as well but put the old one back on as that was not faulty.

Those of you who have suffered with the car not starting in the morning try parking it on a downhill slope, this cured my fault and it starts first time every time.