1999 Vauxhall Zafira Elegance from UK and Ireland - Comments

I have a Vauxhall Zafira, 2.0DTI, and I too have been experiencing the same problem as many others. It has had the engine management light, coming on now and again, during motorway journeys, then loss of power. The problem has slowly got worse and worse, and this summer, on our way back from holiday, the car decided to crawl along the motorway at 55mph with the light permanently on, and me terrified at the wheel, that we would break down in the fast lane of the M5.

My husband, a mechanic, has been trying to diagnose the problem for ages, and has finally decided its the EGR valve. It's good to see we're not alone, and so many helpful people have posted their problems on this site. Good luck!!

Zafira 1.6 club

I too have had many of these problems

I had the egr valve replaced about 2 years ago under warranty

and also a coil pack, my car has been faultless ever since, but recently it seems to be developing the same fault intermittently.

I was thinking of buying an egr valve and fitting it myself, is it just a matter of unbolting the old one and fitting a new one or is it more involved?

I have a 2001 2.0 dti (Opel grey import) with the cold-starting problem. The Vauxhall dealer diagnosed a faulty ECU and recommended replacing the unit (costs: testing £170, replacement ECU £669 + labour to swap unit). Instead, I sent the suspect ECU to an independent tester who says it is not faulty according to his bench test, but suggests I now send him relay unit for testing. Another Vauxhaul dealer (my regular one for servicing) tells me the common faults are the injector leak-off pipe (I see previous comments with that fault) or the injector bridge seals (inside the engine) I'm not at the end of the road yet, but I advise anybody to check other owners comments for similar faults before going to a dealer.

Since purchasing our '02 Zafira 1.8 Comfort we have had nothing, but drama after drama. Seems as though there is now a club for unhappy Zafira owners.

After purchasing our Zafira left U.K. to go to Germany, 3 days before Xmas the engine management light came on along with the ESP light. Spent a small fortune at the local German Opel dealership (who informed me that the car was S**T in his best English).

Approximately 2 months later same fault. Airflow meter changed

Another couple of months down the road, leaving the house to drive back to the U.K. the car got very nervous and illuminated both Engine Management and ESP lights.

After leaving the car overnight, or starting the car after rain or damp weather both of these lights come on guaranteed.

ESP light will come on if cornering/braking first thing in the morning.

I have inspected the airflow system and have found that the airflow sensor (when unplugged with engine running) will illuminate both Engine Management System and ESP lights.

Since the Airflow sensor has been changed a number of times I feel pretty gutted to have been duped into buying an otherwise faultless car by a Vauxhall dealership.

After 139,000 of trouble free motoring in my 2052 Zafira 2.0 DTI Elegance I have just burnt out my third starter motor in 3 months. The engine seems fine, but then runs very poorly and then there is a severe burning smell.

You go to restart it and then nothing. My mechanic who has been excellent all the way along replacing each SM under its 1yr warranty reckons it could be an electrical fault.

Has anyone else had this problem?

After several years of generally trouble free motoring my 2000 Zafira Di Comfort has just died. The engine just cut out and would not start. My local garage (not Vauxhall) checked the car over and reported the error code to a local Vauxhall dealer. They said the failed part was unknown to them!! They then suggested replacing the fuel injection for £1600. My garage then went to a Vauxhall repair specialist who said that failing injection was known fault with diesel Zafira's and would cost around £1000. I was thinking about buying a new one before this incident, but I'm not so sure now.

Makes very interesting reading! Wish I'd have found this site before buying my 2.0 diesel Zafira elegance. (Y plate)

3 weeks ago the car lost power and the spanner light came on had to have complete fuel injection system replaced, everything cleaned through etc etc etc cost in total 2,300 euros (£1,586) (living in France now)

I can't let you know the mileage it's done because --- its back at the garage with the same/similar fault today, total loss of power, spanner light on!!!

I'd said before I'd never have another Vauxhall since a dreadful Cavalier in the 80's, I went and fell for it again. Absolute last time I ever touch one with a barge pole!

Miffed lady in France.

Hmmmmm stumbled across this site. Wot a nighmare we have been having with this car!!! 51 plate, bought for 3,800 and we have never been out the garage. Same thing no power misfiring ect. So far spark plugs, 2 coyl packs, a new battery and now its in and they are still trying to find the problem. Anyone got any advice? also is joining the AA maybe a good thing? Email me on kaz_23_@hotmail.com cheerz.

High

Bought secondhand Zafira 2.0 dti elegance. Stumbled across this site. I have seen my engine management light come on, but have yet to experience power loss. Car at the moment starts well so it seems like I have more suprises in store for me. It seems that there is no real definite solution, but I will continue to check out this site with interest.

OH NO WHAT A NIGHTMARE I HAVE ALSO BOUGHT A SECOND HAND 2002 ZAFIRA CLUB AND YOU GUESSED IT LOOSES POWER WHEN SLOWING DOWN AND CHANGING GEAR AND ALL LIGHTS COME ON. CAN ANYONE ADVISE ME WHAT THE ERG IS AND WHAT THE BEST COURSE OF ACTION IS APART FROM LOBBING OUTSIDE VAUXHALLS HEAD OFFICE ANY ADVICE APPRECIATED denisejack2005@yahoo.co.uk.

Hi I have a zafira 1.8 16v w reg (2000) its done 160.000 miles it uses a lot of oil, but the main thing is that it hesitates when accelerating I have changed the camshaft sensor, fuel filter, spark plugs, oil, air filter... does anyone know what the problem is... i really would like to know without going to a dealer!!!

Stumbled on this site and pleased I did!..yes i,ve also joined the zafira fan club!.was driving my 1600 16v 04 home from south wales when the famous engine "spanner light" came on then loss of power as I was overtaking at 70mph, (very dangerous with my wife and 3 kids with me).pulled over and turned engine off for 5 minutes, re-started and all seemed fine until 10 minutes later I tried to go over 60mph when the same thing happend!.surely vauxhalls should be brought to task over this!enquiries suggest the EGR valve is the fault?.

Any advice or help would be gladly recieved!.many thanks,

dempseyian@btinternet.com.

Thank god we stumbled on this site... Have a 2002 Zafira Club 1.6i and the EMS and spanner light came on recently when going round a round-a-bout. Bought a fault code reader from Ebay (around £25-£30) plugged it into car and diagnosed no faults... The tool will now be permanently in the car just in case. All else seems well with the car... at present...

I have a zafira 1.6 03plate, started having problems with engine, starts OK and idles, when throttle pushed it staggers to rev, had engine management light up and bought a odb2 reader, reader showed fault, but code unavailable, erased fault and engine returned until throttle pushed then the same problems, took out egr and cleaned and tested with 12v it works fine, changed the lambda sensor £70 with lambda tool £11, no difference, cleaned sparks and carburettor body, no change, thinking problem may be coil pack, but at £50 this could become expensive, has anyone else had the same problems, I really don't want to go to dealers because I know there a rip off and change things just incase it is that! etc, then when problem reoccurs you've paid out for nothing.

I have had a Vauxhall Zafira 2.0TDi 52 plate since new. About a year ago the spanner light came on whilst on the motorway and it lost power. Over the year the frequency has increased -on an hour motorway journey it comes on 3 - 4 times and causes loss of power. Turning the engine off and on clears it temporarily. It always occurs at high speeds, usually on the motorway. I've taken it to the Dealer and had a diagnostic check which cost £80 and hasn't resolved the problem. The Vauxhall dealer have not been helpful and I am at a loss as what to do other than sell it. I won't drive on the motorway anymore because it's too dangerous.