2003 Vauxhall Zafira from UK and Ireland - Comments

I too have had constant problems with the fuel gauge - it goes up and down constantly during each journey I take - with the light coming on for a period of time then going off and the gauge going back to a quarter of a tank.

I also have had problems regarding the oil levels - I thought the engine was making a strange noise I checked the oil levels (bearing in mind there was no light indication to warn me) I found the level on the dipstick was below the minimum - I filled it up. then continued to check it regularly - each time the dipstick looks low I never get any indication from the warning lights - I have been told there are no faults with the car coming up on the computer.

I also have a warning light which occasionally flashes on and remains on until the engine is turned off this is an orange light with a picture of a car with a spanner through the middle - each time I have taken it to the garage they cannot find any fault and nothing is shown on the computer readings (strange)

And to top it off my alarm has decided to continually go offs - this first occurred whilst driving - then continued to go off in three spurts lasting about ten minutes - for quite a few hours until my only solution was to disconnect the battery until the morning and take it to dealership - has anyone else had any similar problems - I am at my wits end - I love the comfort and the space in the car, but the computer is wearing me down and the continual amount of faults I am having.

I left a comment on the 30th of October 2007 it read.

30th Oct 2007, 12:42

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.

Any how I decided to replace the coil pack this worked and the car ran like a dream right up until last week, it now has the same problems its undriveable, I’ve ordered another coilpack and if it works I’m still able to get my money back for the old coilpack because its under warranty, I will post the results, the reason I write this because now I have done extensive research on this problem and come to the conclusion that Vauxhall cannot not know that the coilpack gets damaged too easily probably due to inadequate parts and we the mugs that buy there crap cars have to pay, I’ve seen a lot of reports of faulty maf but the 1.6 engine does seem to have one only a air intake sensor where the mass air flow sensor is on the larger engines, I saw a post which said they were combined but I don’t this is the case, if the new coil pack doesn’t work I will try the earth lead trick, but once again I find this amazing that gm with create a car with deteriorating wiring looms!

I will keep you posted and have results in 2 days. Hopefully this can save some of you from being ripped off by Vauxhall dealerships, p. s anyone reading this with the same problems who thinks this is a complicated job to change the coilpack clean the egr its not its easy.

Coil pack arrived a few hours later, I went about the task of replacing it and cleaned other parts, i.e. sensors and carb, unfortunately the same problem it refused to start, I checked for fuel, (pressure), sparks and lots more, it was only when I removed lambda sensor and tried to start up that it started obviously very noisy but it ran OK except when I revved it up lots of filings flew out from where the lambda sensor hole is, now I don’t know what the filings are but I’m not going to jump to conclusions and say piston rings/bore etc, there seem to be piston pressure but this will have to be tested, when I replaced the lambda sensor the car started straight away but it soon stopped I would imagine part of the exhaust is blocked hence exhaust gases being unable to escape, if you know what these silver filings are for sure could you let me know, I was wondering if it could be part of the cat disintegrated!?

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.

OK I fitted the maniverter, ripped my knuckles to shreds but saved a small fortune, zafira was tested, the zafira now works fine but the sooner I get rid the better.

Just to let you know the zafira now seems OK made a larger run and alls fine, to the person who has the dodgy fuel gauge this seems quite common on the zafiras anything below 1/4 tank and its anyones guess, also the warming light that comes on with a picture of a car and spanner is a service indicator meaning vauxhall want it returned to them for a service but you can stop the light coming on yourself this is normal.

Chris.