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I am having starting problems with my 16 valve Zafira 2.0DTI. I have searched this site and taken note of a few pointers, but am looking for some new ideas. The facts are as follows:
- The car starts almost first turn after the “glow-plugs” have been used.
- When the car decides that the glow plugs are not required (on a warm afternoon) it’s an absolute pig to get started and WAS taking around a minute to get going.
- Once running, the car runs as close to a dream as a diesel Vauxhall can!
- My “Leak-off” pipes did appear to be perished (a couple of the inlet nuts were coated in fuel) so I replaced them. This does appear to have improved things a little and the car starts after about 10-20secs of cranking (with a plume of smoke).
- Fuel filter was done on the last service I did, about 3 months back (all new seals fitted).
- While I was replacing the “Leak-off” pipes, I tried to tighten the injector inlet nuts, but they were as tight as could be.

My feeling is that if it starts first turn when the “Glow-plugs” work, then surely the fuel must be present and the fault must be something else…though I’m no mechanic and know less about diesel motors than I do petrol.

I’m off to look for any leaks in the fuel system.

Any help is appreciated.
My zafira is almost the same as above. Except i have just had the pump replaced.

If i disconnect the coolant temperature sensor, the glow-plugs turn on. I was told that the coolant temperature controls whether or not the glow-plugs are turned on. And if the sensor is disconnected the relay interprets that as cold
So the two questions are :

1. If i by-pass the wire to the coolant temperature sensor with at simple on/off-switch, i can probably trick the relay into thinking cold = glow-plugs on :) . After start i switch the sensor back on. Q: Would that mess up the computer in the long run or perhaps do some other damage ??

2. Is it possible to change the "default-glow-plugs-on" temperature via the computer in the car ?

Please forgive any bad writing/language. Danish is my 1. language
 
Discussion starter · #43 ·
The ecu doesn't just get the info for the cold start from the coolant temp sensor it also uses the oil temp sensor and the air temp sensor
regards
steve
 
Hi Guys
Firstly – many thanks to all those who have posted before – although this is my first post I have lurked for sometime and taken advantage of many of the DIY ‘fixes’ that have helped me save money from main dealer repairs!!

We have a 05 Zafira Breeze 2.0DTI. Predominately the car has been used by the wife for ‘pottering around’ and has been trouble free despite our worry that the fuel consumption has ‘overall’ been pretty poor - <400 miles per tank.

A couple of weeks ago – during the really cold spell – the car developed a cold start problem and the EMS warning light came on. My local independent changed the Glow Plugs and the Glow Plug relay and at my request checked the leak off pipes. They reported that they were fine.
The work undertaken has cleared the EMS light and reduced the poor start effect by 50% ish. However, on cold start first thin in the morning or if the first run of the day is just a short one, the engine starts okay but is very ‘chuggy’ for 15 seconds or so and there is a plume of smoke from the exhaust. At all other times – when the engine has been thoroughly warmed – the start is fine.

Looking for some guidance before it goes in for its MOT & service. My independent thinks we should look at the fuel flow meter next OR is it a possibly a vacuum fault and an injector seal. Really looking to solve this one as even when driving (what I would assess as combined driving) I should be getting circa 500 miles per tank and the max ever achieved is only 430 miles!!!
 
Many thanks in anticipation
 
Ian

Edit: meant to say earlier that the car - when driven from cold - has a propensity to surge in 2nd gear on acceleration; I thought it was Turbo lag. Even when warm it tends to be a bit 'lumpy' in 1st and 2nd. Thus my inclination was toward the fuel flow sensor..........
 
cold starting

I have a 2003 dti vectra 2ltr and it is hard to start when left for a few days but run daily it is fine.I have had the inlet manifold and egr off and cleaned up fit new leak off pipes checked vacum pipes all ok fit a non return valve in the pipe from tank to filter and no differance had opel had a look and they fit a non return in the return pipe why????.When i do get it going there is a cloud of black smoke not too bad but getting peeved off now.Would changing the filler cap make any differance?as i am not getting any feed back when taking it of.
Thanks in advance for the advice will try anything.
 
Zafira Y20dth Fails to start unless vacumn is disconnected ?

Hello every one My zafira y20dth will not start and stay running unless i disconnect one of the vacumn pipes to the air cut off valve actuater ,(the Black plunger above the egr valve) it gets sucked in and the engine just cuts out if i pull the vacumn lead off it the engine starts and runs ok but i have no power at all and occaisionally goes into limp.At first I was thinking fuel pump but if the engine runs with this vacumn lead disconnected its got to be related to one of the egr solenoids / air actuaters sticking? has anyone come across this before some help would be appreciated thanks :mmmm



 
Hi,
I have had a similar problem of non-starting in the past connected to this vacuum valve. The spindle that it operates within the aluminium casting was sticking and causing the butterfly flap within to stick in the closed position preventing air passing. I took the casting off and cleaned out all the carbon build up with gunk and a stiff brush and lubricated the spindle with copious amounts of wd40, then 3 in 1 oil. It has been fine since.

http://s813.photobucket.com/albums/zz58/enforcer777/

Above link - photo may help
 
Has anyone found a cure for there non starting without glowplugs ?

I have a vectra c 2.0dti 03 reg and mine starts first time when glowplugs are used or if i take temp sensor off and force glowplugs on it starts first time.

But if left for an hour after a short run my car will just crank and crank then finally starts with a big cloud of smoke that smells of diesel.

Now glowplugs are fine replaced relay and leakoff pipes and t-pieces,cleaned out EGR and maf sensor.

Cant see it being injector seals or air in system because if it was no amount of glowplug would make it start if there's air in system it would need to ex spell this first before it would start.

No fault codes or EML and only happens when slightly warm if i start from hot its fine and same when its been left over night and glowplugs come on its fine but if we have a very mild morning i get the same problem.
 
i had the same problem during the summer but took it to a diesel specialist and they did the injector seals and has started first time since even on mild days and cold days i have left mine for 5 days and started it fired up first then died and turned the key again and no problems
 
I have a 53 Zafira 2.0 DTi which started playing up over xmas and the last time it started was on 5th January 2011. My local garage has had it for 3 months and have finally decided they can't fix it after fitting a secondhand fuel pump and even moving the ECU from the original pump. They had it at a Vauxhall garage and say they have been unable to get it coded so it works. It has done 115k but is in good condition, I am reluctant to let it go to the scrappy any advice?

I am in West Wiltshire so if you know anyone down this way who may be able to help please let me know. Thanks

Bob
 
update I now have the car back and it seems that it is immobilised, the radio is reading the word "safe" when switched on and the immobiliser light, car with a spanner is flashing on the dash. Any help would be welcome
 
For getting rid of safe on the radio. Turn radio off. Turn on ignition. Then press AS on the radio and while keeping it pressed turn on the radio, it should ask for a code after a few seconds with the amount of attempts allowed (10 if it's the first time you've done it). Then input the code from the manual.
 
Hi,

Any luck with fixing this fault as we have the same 2.0 Dti Turbo Zafira and yeap same non starting issue - so far £650 and still a pain to start. Its covered 147,000 miled and qwe had the injector seals replaced 3 years ago due to the same type of fault.

Over the last 7 weeks we have had the following done:-

Glow plugs changed (initial breakdown diagnosed by AA as Glow plugs at fault),
New battery a week later (died within 2 minutes),
Leak off pipes and "T" parts replaced - EGR valve cleaned up as very dirty (done by myself-much smoother to drive after)
Hometune then carried out an oil change, oil filter and diesel filter also replaced,
Ran for a week again no problem - Then Glow plug control system and relay replaced following another non starting session,
Ran for a week again no problem - Then Air Mass Flow meter replaced.

Our local Vauxhall garage seem to love us as its more money every week for them but with it being Christmas we just dont have the money to keep throwing at it. Just feels like they are changing things to justify giving it back to us.

One thing I have noticed which seemed od at the time when it wont start the REV and SPEEDO fall back below the zero mark but normally they stay on zero when cranking it over- is that an indication that the crank sensor is faulty as on some other posts the rev counter dropping to ZERO is an indication of that fault.

At NO TIME does the engine management light come on !!
 
Hi,

Any luck with fixing this fault as we have the same 2.0 Dti Turbo Zafira and yeap same non starting issue - so far £650 and still a pain to start. Its covered 147,000 miled and qwe had the injector seals replaced 3 years ago due to the same type of fault.

Over the last 7 weeks we have had the following done:-

Glow plugs changed (initial breakdown diagnosed by AA as Glow plugs at fault),
New battery a week later (died within 2 minutes),
Leak off pipes and "T" parts replaced - EGR valve cleaned up as very dirty (done by myself-much smoother to drive after)
Hometune then carried out an oil change, oil filter and diesel filter also replaced,
Ran for a week again no problem - Then Glow plug control system and relay replaced following another non starting session,
Ran for a week again no problem - Then Air Mass Flow meter replaced.

Our local Vauxhall garage seem to love us as its more money every week for them but with it being Christmas we just dont have the money to keep throwing at it. Just feels like they are changing things to justify giving it back to us.

One thing I have noticed which seemed od at the time when it wont start the REV and SPEEDO fall back below the zero mark but normally they stay on zero when cranking it over- is that an indication that the crank sensor is faulty as on some other posts the rev counter dropping to ZERO is an indication of that fault.

At NO TIME does the engine management light come on !!
that sounds like cranksensor
 
Hi I have the 03 zafira dti and it won't start, had all the usual work done and it turns out it needs a new pump. Any one know of some on in the north east who can replace pump and re program it to the cars immobiliser with a tech 2 machine or opcom? If anyone can would u txt or call me on 07411350101 or 01642 490874 please
 
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