Help with dodgy zafira, please.

[lance1a]

Vauxhall Zafira 1.8 2001 16V. Came in with misfire/loss of power above 4000rpm under load, lower rpm under load at speed. Diagnosed as misfire on No:1 cyl. Replaced coil pack (4 into 1 rail coil) still the same. Car started to run really badly, was traced to a break in injector harness above engine. Spliced coolant sensor neg into MAF neg and re-earthed onto ecu (bolted onto side of engine), still the same. Checked injector rail for pressure, ok at 3.5Bar and holds fine. Checked with noid lights for pulse on injector harness, fine. Replaced coolant temp sensor (which is routed via the ecu to control cold start/fueling) and shabby harness. Tested for spark, fine. Compression tested at 150-1....150-2.....130-3....90-4.
Low on no 4, but this may be down to the car overheating due to the inoperative temp gauge on the dash (which is linked I assume, to the fault I still suspect with the ECU/CTS side of things). ECU sent away, first place said it was fked and wanted to sell us a new one at great expense, got it back after a big blowup on the phone, sent to another place who said it was faulty, they 'fixed' it and sent it back. Still the same. Replaced plugs (a know issue on these, and Lambda sensor. Injector pulse confirms CPS works.

Any ideas?

This is why I hate cars with electronics on them.
As I am getting nothing on the fault code reader it's a bit of a process of elimination. Engine management light will come on now and then showing a coil related issue, but then go out of it's own accord.
Idles fine, revs fine though there is a slight misfire that can be heard through the exhaust only, motor as sweet as a nut.
Oh....I also checked the timing and a load of other stuff too.

So...at the moment, the car struggles to start, misfiring badly and running on about two cylinders untill a bit warm, then sorts itself out and seems fine. However, driving it will cause it to misfire again. It jerks and surges through the gears. When the EML lights comes up, it shows as a general misfire/coil issue, then goes away.

Any chance someone on here can throw some light?

Cheers

[thinfourth2]

lance1a said:

Vauxhall Zafira 1.8 2001 16V.

Thats the problem right there

[lance1a]

You are not wrong. Checked again this morning. Fault code shows open loop fuel 1 at 23% then again at 43%.

[SClarke]

Did you use Vauxhall coil rail? We have had all sorts of problems with aftermarket.

[lance1a]

Yep it is a Vaxhall part. Am I correct in assuming that if the coil or plug is an issue the ecu will halt fuel flow to that injector thereby throwing up a open loop on that fuel injector?

[t11ner]

Always going to be tricky as most of the symptoms are happening under load but now that it's playing up from cold you need to see which cylinders it's dropping and why. My guess is that it won't be cutting off the injectors due to a misfire in this case as you say that it improves as it warms up - generally if an ecu shuts the injector down it will stay that way until you have turned the engine off and on again. Also, this means that if it plays up under load it would then drop onto three and stay that way even when idling.

The code it's coming up with, is it P0301/2/3/4 etc (general misfire) or P0351/2/3/4 etc (coil misfire)? You have referred to coil issues and misfire issues on the code reads and they can have very different causes.

[lance1a]

Cheers for the reply. I will have to wait for the EML to come on again to read the codes (using a generic reader) and then post up that info. Ta.

[Fastra]

You've not mentioned the eternal EGR valve!

Take all the air in take of and clean out the throttle body with some carb cleaner.
Also clean out the breather pipes from the top of the head to the throttle body.


Mine had similar problems recently, and I couldn't believe the amount of dirt in the TB and crud in the breather pipes. Along with a new EGR valve I managed to sort it - make sure you get a Delphi one too, not the cheap copy ones from ebay - as I found out!

Edited by Fastra on Wednesday 21st April 10:22

[lance1a]

This 1.8 doesn't have one. Well, not if it's supposed be be where it normally is near the ECU on the right side of the head anyway.

[HellDiver]

lance1a said:

This 1.8 doesn't have one.

It should have.

Also check the engine to body earth strap, they can corrode and cause all manner of electronic funkiness.

[Fastra]

lance1a said:

This 1.8 doesn't have one. Well, not if it's supposed be be where it normally is near the ECU on the right side of the head anyway.

Ah....!

Its not been blanked off has it????

Good source of help maybe:

http://www.astraownersclub.com/vb/

and:

Naturally Aspirated models
http://www.astraownersclub.com/vb/forumdisplay.php...

[Fastra]

what engine code is it?

X18xe or Z18xe?

Either way I'm getting results on ebay for egr valves:

http://cgi.ebay.co.uk/EGR-Valve-new-X20XEV-X18XE_W...

http://cgi.ebay.co.uk/Vauxhall-EGR-Valve-Z18XE_W0Q...

[bn9af]

my friend had the exact same problem with his vectra 1.8, is the zafira the 130 bhp version of the engine?

he changed everything under the sun but eventually was traced to a faulty ECU.

from customers feedback theres quite alot of owners who have the same issue and eventually give up and run the car into the ground or sell it to the garage.

[lance1a]

Where is the code on this? I can't seem to find it. It has a build date of 20.12.2000 but is a 2001 model. 1800 ecotec 16V. Is there any visual id? Nothing on Vin plate like Z18 or X18 etc.

[HellDiver]

lance1a said:

Where is the code on this? I can't seem to find it. It has a build date of 20.12.2000 but is a 2001 model. 1800 ecotec 16V. Is there any visual id? Nothing on Vin plate like Z18 or X18 etc.

There should be a flat on the bell housing with the code and engine number. Also on a sticker on the timing cover, but they often come off.

It's probably a Z18XE - they came in around June 2000 build date.

[Fastra]

lance1a said:

Where is the code on this? I can't seem to find it. It has a build date of 20.12.2000 but is a 2001 model. 1800 ecotec 16V. Is there any visual id? Nothing on Vin plate like Z18 or X18 etc.

I think it should be on top of the gear box under the ECU - it is on the 1.6 engine.

[Fastra]

Ahhhh!
According to this:

http://www.migweb.co.uk/forums/engines-transmissio...

there is indeed no EGR on Z18xe engines!

They mention the AFM though as being faulty though!

[Fastra]

Bloody hell!
This is a right can of worms.
Have a read through this:


http://www.vauxhallownersnetwork.co.uk/showthread....

perhaps this helps:

"i have read somewhere that on the 1.8's the MAF can get a poor earth and not work correctly, the guy fixed it by stripping the insulation back and routing the earth off it to another earth point"

also:

"Car back from VX, working fine with new ECU and new MAF. Under 700 quid, so could be worse. "

and:

"- Well finally got the Zafira home today -- all working
- £1,170 out of pocket

In the end it was as simlpe as replacing the Air Mass Meter"

Edited by Fastra on Wednesday 21st April 12:00

[lance1a]

I have already re-earthed the maf and the CTS to the ECU with no result. This thing is doing my bloody head in. Almost 50 hours now and no fix. £150 out of pocket on parts alone and how can I charge a customer if the thing is still knackered?

[Fastra]

Point your customer to the last link I posted.
Considering that 2 people (or more) had similar problems and ended up spending a fortune - it may well be worth cutting your losses and admitting defeat? Although this was with VX dealers who haven't an once of the conscience you probably have!