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  1. steeltips

    steeltips Member

    Messages:
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    Location:
    lisburn NI
    I have an intermittent misfire on a Zafira 1.6 16 v mar 2003

    after getting the erg or egr (i think they call it) valve gasket replaced and updating the ecu after the EM orange light came on one day.

    about a month after that and every month since it will do this

    if i drive for a mile or so first thing in the morning goes in to limp home mode will not go over 30 once restarted it will run fine with orange em light on

    at idle i think its 700 rpm it goes up and down a little bit not very much but not steady getting 300 mpg to a full tank around town 400 on the longer ones

    twice on occasions cuts out at lights on restart will rev-up to 2000-2500 and down below 700 for a bit and cut out again then will go fine for the rest of the day.(light still on)

    Its been to a vauxhall dealer who read the codes (don't have code just misfire) they checked the ecu and wanted to strip the engine head down and re-seat the valves at £500 (i told them where to go as they said they had not performed a compression test)

    I have replaced so far a coil pack, plugs and one of the injectors.

    At this point I'm looking for something else as the cause or at the ecu or ecm as some people call it as the fault. but cant be sure. i want to strip / open it if i can and see if there is anything that could be repaired.

    anybody else with the same problem or had the same problem cured on there car could you help me out and post some thoughts fixes you think it may be.

    i have had many cars all vauxhalls never gave me engine trouble until this one but this one is giving me enough trouble to last a life time and i may have to change my brand in the end.

    i have read posts on threads about the the engineers placing to much trust in the PC to find the correct fault. (i agree they need to use there heads as well a PC is a tool not a be all and end all) i have a quote for you a person designed the computer that designed the car that required a person to design the software to find the fault the the computer found. (or did it) lol

    just be thankful bill gates has not found a way to get to your cars cpu or you would be rebooting it every 5 minutes hitting the start button to stop it and require an encrypted key to start it, every time it crashed you would have to re-install the engine lol

    thank-you in advance for your replies

    Just an update the car stalled today and then went off a plug about a mile later holding in the mileage reset button and turning the key until the inSP reset appears cured the misfire plug.
    thought this strange and sounds more like the ECU problem. 04-03-2009

    happened again 06-03-2009 morning and afternoon
    happened again 07-03-2009 afternoon only
    happened again 08-03-2009 getting to be a real pain


    got this off another site
    seen a few sticking valves on these vauxhall engines too,usually hard to check in the workshop as it will only miss under load.You could try disconnecting the servo hose at the inlet manifold,attaching a rubber hose to the connection and with the engine running allow a litre and a half of brake fluid to be drawn in to the manifold slowly.Mind you will need someone in the car to hold it at about 3000 revs so it does not cut out when you do this.Refit pipe and give vigorious roadtest for about 10 miles.Mind it will smoke a lot so avoid busy traffic!Smoke wont last for long. Ive had this method work on an astra with similar engine code and fault to your zafira.Thats what vauxhall do to try to clean up the carbon that builds up between the valve guide and stem as i know a tech who works for them.Also check when the engine oil has been changed as this leads to valve stick too.

    anybody tried anything like this
  2. markf2

    markf2 Member

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    Location:
    Reading, UK
    Don't know if it will help, but I had a vauxhall a number of years ago that was having an intermittent short from one of the lead caps at the plug end to the head. That would kill the engine straight away after a few misfires and took weeks to locate. In fact, found the fault three days before trading it in.

    After a random period of time the car would start up again and be fine for a while.
  3. steeltips

    steeltips Member

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    Location:
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    Thanks Markf2
    The coil pack has the leads attached and they are brand new Vauxhall don't sell the leads only the coil pack, there one nice earner for them at £145 quid to replace.
  4. steeltips

    steeltips Member

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    Location:
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    OK folks heres another update.The gunk-ed up throttle body with oil vapors (more so around the butterfly flap i guess at idle this would build up pressure or vaccum in the engine and it would start to draw air and oil from the rocker cover) so the throttle body is now cleaned carb cleaner worked a treat also removed and opened the ecu not where i was expecting it at all on the right hand side of the engine head.

    A design fault if you ask me its like setting a TV on the washing machine on full spin i don't think the TV would last to long. anyway opened it to have a look very nice piece of work indeed but a few flaws its filled with a gel like substance there is not one of the wires coated in plastic they rely on the gel to keep them free from one another which is one of the things i noticed a few of the them were very close to touching (if not touching already) I moved them apart and resealed the unit with contact glue. not a very satisfactory job but it will do for now. if you have a hot glue gun i would use that instead unless anybody knows something better.

    when i had the throttle body off a poured 1/2 ltr redex down the inlet letting it soak for a bit before i put it all back together. Went for a run about 10 miles wow the difference did not miss a heart beat no lights flashing at me any more now all said and done i do still have the codes 00301 00300 stored in the ecu (does anybody know how to clear them)

    Also this is how i got the codes holding the brake and acl pedals in wile turning the key until the lights come on. the spanner symbol on the dash will start flashing 10 flash's = 0 BTW.
    I'm still getting these 00301 00300 using that

    watch this space for further updates I'm not 100% on this yet but i am hopeful pray to the vaux com lol
    if this does not work im thinking of getting the ecu retuned does any body know these guys http://www.rk-motors.co.uk/

    23-03-09 still working fine

    31-03-09 Misfireing again took me 6 hours to sort this time i pull and tested every cable/connector/switch/relay/fuse i could find nothing wrong finaly i pulled the battery which has reset everything and it now running again. for now i have had it with this car feck sake
  5. steeltips

    steeltips Member

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    Location:
    lisburn NI
    Came across this today
    The bit that interested me was (in bold)

    Fuel System Treatment, which is poured directly into the fuel tank to clean the fuel injectors, intake valves and combustion chamber. Using a 50/50 mix of fuel, this product can be run through the fuel injectors by way of the fuel rail

    Throttle Body Cleaner that eliminates buildup on the throttle body. The throttle body cleaner also lubricates the throttle plate mechanism and cleans the idle air control bypass

    Instead of mineral oil, the lubricant contains ester oil, which leaves behind a film to help prevent sticking. Induction Cleaner which removes deposits from the front and back of the throttle body butterfly, the intake plenum and runners and the intake valves and combustion chamber without harming the catalytic converter or oxygen sensor.

    the full storie here
    http://www.theautochannel.com/news/2003/09/09/168347.html

    thought it may be worth a try if i could find it to buy
  6. steeltips

    steeltips Member

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    Location:
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    talking to my self i think

    any body
  7. JMacP

    JMacP New Member

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    Location:
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    No, not to yourself...thanks for the heads ups...can't offer any advice I'm afraid but we're looking at getting one..and your posts have given me loads of food for thought...now I've just got to learn what all the acronyms mean...and work out how to test potential purchases under load...

    Hope you get yours sorted!!

    All the best,

    Gordon.:)
  8. steeltips

    steeltips Member

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    Location:
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    Update

    Your welcome gordon
    nope still not sorted :shake

    codes are
    P0300 Random/Multiple Cylinder Misfire Detected
    P0300 Misfire Detected AT Low Fuel Level
    P0301 Cylinder 1 Misfire Detected
    P0303 Cylinder 3 Misfire Detected

    The following also covers P0302 and P0304

    What to check

    • Open or short in engine wire
    • Connector connection
    • Vacuum hose connection
    • Ignition system
    • Injector
    • Fuel pressure
    • Mass air flow sensor
    • Engine coolant temperature sensor
    • Compression pressure
    • Valve clearance
    • Valve timing
    • PCV hose connection
    • PCV hose
    • ECM

    Also getting these
    P0351 Ignition Coil ”A” Primary/Secondary Circuit
    P0352 Ignition Coil ”B” Primary/Secondary Circuit
    P0353 Ignition Coil ”C” Primary/Secondary Circuit
    P0354 Ignition Coil ”D” Primary/Secondary Circuit

    What to check

    • Ignition system
    • Open or short in IGF or IGT1 to 4 circuit from ignition coil with igniter to ECM
    • No.1 to No.4 ignition coil with igniter
    • ECM
    so we are still having the problem but im getting a recorder attached to the car ECM/ECU ie a black box woope so this may shed more light on the problem i hope.

    The AT Low Fuel Level code and yes it can be the same code P0300 is a bright light i think i normaly run the car from full to near empty i dont do many miles but i would take me about 3 weeks to do that and it fits with the trend when the car is under a 1/4 full is when this mostly happens so to that end for a few weeks im going to run the fuel under that to see how it goes finger crossed that the problem is in the fuel tank with the fuel sender unit Praying
  9. greasemonkey

    greasemonkey VXon Frontera Monkey VxON Club Member

    Messages:
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    Location:
    Bury St Edmunds Isuzu Land
    Drives:
    Frontera
    Hi - i would go for the ecu being biffed - very common - especially for individual cylinder misfires - don't think they can be repaired though its worth a try
    regards
    Steve
  10. steeltips

    steeltips Member

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    Location:
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    thanks for the reply greasemonkey leaving that until last or last resort lol i hope not

    just a quick update guys
    5 weeks ago i had the ecu reset by a mate who teaches students about this stuff we put a crecorder on the car for all that time and nothing happened until last sunday i was working about 30 miles from home and on the way back the car would not go over 30 made a noise like a large hole in exaust wow is me i made it home some what later that expected called the mate checked the car crecorder nada he suggested that tha cat may be blocked so we removed the sensor off the top and fired her up the amount of crap that came out the top of the cat was mad. to get her going again i put a hole down the center of the cat and she is running again better that she ever did still no missfires though. question is this a result of un-burnt fuel in the cat and if so would it be wise to fit a new one or could this have been the cause of the misfires in the first place and a new cat would have been the cure.

    Any other thoughts please post

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