UK Car

UK car repair questions? Ask a mechanic for answers ASAP

Connect one-on-one with {0} who will answer your question

Misfire..speed above 30/40 now, egr, coil pack plugs, filter..removing…

Customer Question
vauxhall zafira misfire 3 constant...
vauxhall zafira misfire 3 constant engine light on restricting speed above 30/40 now, egr, coil pack plugs, filter, etc all changed recently to no joy . someone suggested removing valve, what harm does this do, problem been there for over couple months now driving us nuts. car has done over 100,000 miles and is 52 plate but would still expect it to drive better please help
Submitted: 12 years ago.Category: UK Car
Show More
Show Less
Ask Your Own UK Car Question
Answered in 1 hour by:
3/29/2010
UK Auto Mechanic: Bill_Crosby, UK Car Mechanic replied 12 years ago
Bill_Crosby
Bill_Crosby, UK Car Mechanic
Category: UK Car
Satisfied Customers: 3,307
Experience: City & Guilds Vauxhall Master Technician & Auto Electrician Since 1993
Verified

Good evening, I hope I can help you.

 

You need to remove the egr valve and fit a blanking gasket in its place. You then need to get your vauxhall dealer to reprogram the ecu and take away any reference to the egr valve and stop any fault codes being generated.

 

This will cost about £80 at most vauxhall dealerships.

 

Bill.

Ask Your Own UK Car Question
Customer reply replied 12 years ago

Sorry but have looked into that and for 2 reasons it cant be done - 1, the misfire fault needs to be the cylinder next to egr valve and ours is misfire 3 (no 4 is next to egr), also 2, the garage is unwilling to reprogramme the ecu as it is illegal (according to them) to remove egr due to emissions.

 

Someone has since suggested the o2 sensor being dipped in acid to clean it as they had same problem, but we have never heard of this, can you please advise on this?

 

Thanks

UK Auto Mechanic: Bill_Crosby, UK Car Mechanic replied 12 years ago

Vauxhall have a software upgrade to solve this problem so being told its illegal is ****.

 

Also as for the misfire having to be on a particular cylinder is also ****.

 

If your local dealer wont do the software upgrade for you then phone around to the next nearest to see if they will.

 

Also search on google for 'vauxhall egr' to see what the bulletin boards say and what cures problem.

 

You will find I am correct.

 

I have been a vauxhall master tech for almost 20 yrs.

 

Bill

Excerpt from vauxhall service bulletin.

 

Cause: The Euro 4 emission standard will be met even without EGR-valve. This is because of a modified ECU calibration.
Production: On Speedster the EGR valve will remain until end of production. On the Vectra-C, Astra-G and Zafira the EGR-valve will be omit during MY 2004 (running change). The following modifications will be introduced: 1. Engine wiring harness adapted 2. Cover plate for the exhaust gas recirculation duct 3. Omission of exhaust gas recirculation pipe 4. Intake manifold without connection for exhaust gas recirculation pipe 5. New engine control unit calibration 6. Modified bracket for upper engine cover

Remedy:
In case of customer complaint where an EGR valve is detected as faulty
during diagnosis, it should not be renewed but removed.
1. Close exhaust gas recirculation port with a cover plate (Part-/Cat.-No.:
24575592 / 58 50 526) by using gasket (Part-/Cat.-No.: 12570863 / 08 51 761).
The groove on the plate has to show in direction of radiator and and the
plate labeling upwards.
2. Fix the superfluous wiring harness connector with a cable strap
(connector port in direction to front wall).
3. Program ECU with SPS as of TIS-CD 50 (select without EGR).
For torque values and labour time please refer to Service Instruction
"Demounting and mounting EGR valve".

 

Field Remedy: 1897
Subject: Z16XE engine - EGR malfunction
Models: Engines: Option:
Astra-G 2002...2004,Meriva 2003...2004,Vectra-C 2002...2004,Zafira 2002...2004 Z16XE,Z16XE,Z16XE,Z16XE MT,MTA
Complaint: Telltale on, driveabilty complaints, jerking, trouble code P0400 set
Cause: Deposits in EGR between pintle and guide
Production: As of engine number 20BY2510 (10 October 2003) a stepped pintle EGR valve with several design improvements has been introduced.

Remedy:
This remedy is valid for the following models only:

Engine Model Transmission Modelyear until Engine-BP
Z16XE Astra-G MT 2002 - 2004 20CK1163
Z16XE Meriva-A MT & MTA 2003 - 2004 20CF5854
Z16XE Vectra-C MT 2002 - 2004 20CR2606
Z16XE Zafira-A MT 2002 - 2004 20CF5860
Please refer to QI 1899, TSB 1900, QI 1953 or Special Policy Program 05-P-25 for other models with family 1 engine.
In case of customer complaint replace EGR gasket and reprogram engine ECU with software as of TIS 2000 CD 64 or later:

1. Replace EGR gasket by the new version (Part No. 55 560 700,
with flag) before reprogramming the ECU.
- see working procedure „Exhaust Gas Recirculation Valve,
Remove and Install”, Group „L“ of the corresponding
Service Instruction.
Note: The new version of the gasket (1-bore version) can be identified by a ‘flag’ at the outer side of the gasket.

2. Reprogram engine ECU with modified software (Software Version
available as of TIS 2000, CD 64) to deactivated the EGR
valve function.
Spare-Parts: Part-No.: Catalogue-No.:
Gasket 55 560 700 91 06 319
Labour Times: TC: Hours:
U3 189 71 Replace Gasket and 92 0,3
reprogram engine ECU
The costs for this repair will be covered for vehicles not older than 6 years and a mileage lower than 100.000 km.

The regular warranty procedure should be used for claiming Set-up-time.

FunctionalGroup: J - Engine,L - Fuel- and Exhaust System
Complaint Group: 13 - No/Poor Function,19 - Poor Engine Driveability,20 - Poor Performance
Trouble Code: P0400

 

Field Remedy: 1899
Subject: Family 1 engine - EGR malfunction
Models: Engines: Option:
Astra-G 2001...2004,Corsa-C 2001...2005,Zafira 2001...2004,Vectra-B 2001...,Vectra-C 2002...2003 Z14XE| Z16XE| Z16YNG,Z14XE| Z18XE,Z16YNG,Z16XE,Z18XE All
Complaint: Telltale on, driveabilty complaints, jerking, trouble code P0400 set
Cause: Deposits in EGR between pintle and guide
Production: As of following engine numbers a stepped pintle EGR valve with several design improvements has been introduced: Z14XE (Astra G, only MT) 20CK1163 Z16YNG (Astra-G, Zafira-A) 02PV1729 Z18XE (Corsa-C) 20AS5625 Z18XE (Vectra-C) 20AN8145

Remedy:
This remedy is valid for the following models only:

Engine Model Transmission Modelyear until Engine-BP
Z14XE Astra-G AT 2001 - 2004 all
Z14XE Astra-G MT 2001 - 2004 20CK1163
Z14XE Corsa-C MT 2001 - 2003 all
Z14XE Corsa-C AT 2001 - 2005 no BP available
Z16XE Astra-G AT 2001 - 2004 no BP available
Z16XE Vectra-B MT & AT 2001 all
Z16YNG Astra-G MT 2003 - 2004 02PV1729
Z16YNG Zafira-A MT 2001 - 2004 02PV1729
Y16YNG Zafira-A MT 2001 - 2004 02PV1729
Z18XE Corsa-C MT 2001 - 2003 20AS5625
Z18XE Vectra-C MT 2002 - 2003 20AN8145
Please refer to TSB 1897, TSB 1900, QI 1953 or Special Policy Program 05-P-25 for other models with family 1 engine.
In case of customer complaint replace EGR valve by modified version with stepped pintle guide,

- see working procedure „Exhaust Gas Recirculation Valve, Remove and
Install”, Group „L“ of the corresponding Service Instruction.
FunctionalGroup: J - Engine,L - Fuel- and Exhaust System
Complaint Group: 13 - No/Poor Function,19 - Poor Engine Driveability,20 - Poor Performance
Trouble Code: P0400

 

Bill.



Edited by Bill_Crosby on 3/31/2010 at 10:41 PM EST
Ask Your Own UK Car Question
Customer reply replied 12 years ago
Many thanks for that, however, after having tried Vauxhall head office and our local one, no-one is willing to do this, saying that egr fault would show, rather than misfire, they are adamant it is ecu. Our local Vauxhall dealer wants to start again at the beginning (even after our local garage has spent months on it) and charge us plenty in the process, but we have already spent enough. Head office were even less helpful, saying no recall on our model means no further help, great eh? I understand exactly what you are saying I just wish someone could fix it, do you have any contacts up here in Livingston (or near Edinburgh) who could help. Our code was 300 and something a misfire for cylinder 3, not the egr valve.
UK Auto Mechanic: Bill_Crosby, UK Car Mechanic replied 12 years ago

I used to work at curtis motors in dunfermline and I think that steve curtis cars in dalgety bay will do this for you if you ask for it specifically.

 

Misfire code P0303 would have been the one recorded for cyl 3. This could be caused by a faulty coil pack, spark plug or injector.

 

You have already replaced the coil, so you could try replacing the plugs and moving the injector to another cylinder to see if the misfire cures or moves cylinder but I would still look to block the egr and have it reprogrammed..

 

Bill.

Ask Your Own UK Car Question
Customer reply replied 12 years ago

You are right the coil pack was replaced, but so was plugs (vauxhall ones as well), and our garage did move the injector to no 4 hoping the fault would move, but it never did, typical!! In last couple of days light has been going off when foot not on accelerator (strange) but when it is being pressed and trying to build up speed it comes back on. Do you still think its the egr valve? If so, I could always call that firm but it is quite a bit away, and with the car struggling over distance I would worry it wouldnt make it.

 

 

Customer reply replied 12 years ago

Incidentally, to the above info our car has gone through a ridiculous amount of petrol recently meaning we get between 20 and 30 miles for every tenner that goes into it, something not right with that. I have noticed on forums for other people they talk about the mass air flow sensor having something to do with petrol, is this a possible link to our problem do you think? Or would the code be completely different. The only worry is that it means more money for the part and replacment is not sure to fix the problem. Hope you can shed more light on this with the additional info.

Many thanks

Customer reply replied 12 years ago
Not sure why you havent replied to last query, or if you have been away could you please let me know what you think about the above question. THanks
Was this answer helpful?

How JustAnswer works

step-image
Describe your issueThe assistant will guide you
step-image
Chat 1:1 with an uk auto mechanicLicensed Experts are available 24/7
step-image
100% satisfaction guaranteeGet all the answers you need
Ask Bill_Crosby Your Own Question
Bill_Crosby
Bill_Crosby
Bill_Crosby, UK Car Mechanic
Category: UK Car
Satisfied Customers: 3,307
3,307 Satisfied Customers
Experience: City & Guilds Vauxhall Master Technician & Auto Electrician Since 1993

Bill_Crosby is online now

Related UK Car Questions
I have a 2008 zafira 1.9cdti have recently installed a new
Hi there I have a 2008 zafira 1.9cdti have recently installed a new egr valve now have a car with spanner on dashboard the car runs perfect but code points to a misfire on cylinder 4,if I remove fault… read more
Gavin Perry
Gavin Perry
Car mechanic
City and guilds level 3
309 satisfied customers
Exhaust/ emission light on and fault code 0352 - 'coil 2 incorrec
Exhaust/ emission light on and fault code 0352 - 'coil 2 incorrect or high voltage' showing on 04 Astra 1.6 Z16XEP petrol engine. I've replaced spark plugs and engine running fine but light is still o… read more
Nathan B
Nathan B
Garage Owner
Vocational, Technical or Trade Scho
131 satisfied customers
vauxhall vectra 2.2 sri 16v 150 bhp (51-plate) misfires..Main dealer
My Vauxhall Vectra 2.2 SRi 16V 150 bhp (51-plate) misfires (or some other timing-type problem). Timing / firing appears all over the place, and fuel seems unburnt. Main dealer maintains cyl. 2 was not… read more
Matt
Matt
Mechanical Engineer
Bachelor's Degree
5,004 satisfied customers
Vauhall Zafira Club: I have a vauxhall zafira, 56 plate, unleaded
I have a vauxhall zafira, 56 plate, unleaded entry model out here in France. If left for some time it is difficult to start. Engine turns over, but takes ages to catch and start up. Any ideas… read more
Robert
Robert
Mechanic/Roadside assist/Garage Owner
Vocational, Technical or Trade Scho
3,029 satisfied customers
vauxhall zafira B Hi there, had a lot of problems with a vauxhall
Hi there, had a lot of problems with a vauxhall zafira 1.9 cdti 150 (z19DTH) 2008 with DPF Recently fitted a replacement engine due to the old one having injector problems, all was going well till the… read more
Mike
Mike
Proprieter / Diagnostic Technician
High School or GED
19,815 satisfied customers
hello mike its dianne with the vauxhall zafira .the..petrol
hello mike its dianne with the vauxhall zafira .the problem as reacured.ive been told to try and change the petrol pump .what do you think.thank you .dianne.… read more
Mike
Mike
Proprieter / Diagnostic Technician
High School or GED
19,815 satisfied customers
Vauxhall zafira comfort Dti We have a Vauxhall Zafira 2 Litre
We have a Vauxhall Zafira 2 Litre Diesel Dti 2002 (52 Plate). We had a New EGR valve fitted 5 yrs ago when it had done 54,000 miles. 48,000 miles on it has gone again! Could this be a design fault? Sh… read more
Engineering Pro
Engineering Pro
Automotive Development Engineer
Bachelor's Degree
1,366 satisfied customers
Zafira missing no power,cant climb hills.missing on start
zafira missing no power,can't climb hills.missing on start up have to ref it to try and clear it… read more
vauxdoc
vauxdoc
Vocational, Technical or Trade Scho
1,117 satisfied customers
Vauxhall..im driving down the road as normal around 60 mph..pulling
i have a 2000 vauxhall zafira and when im driving down the road as normal around 60 mph all of a sudden engine management light comes on and loose power this happens regulary when pulling out of jucti… read more
Bob
Bob
Diagnostic Mechanic
Vocational, Technical or Trade Scho
2,037 satisfied customers
club: ticking..drove..5th..never have the engine management light come
i have a 55 plate zafira club diesel.Everytime i drive the car in 6th gear when i take it out of 6th and drive normally the engine smokes.I can drive it home and then have to leave the engine ticking … read more
vauxdoc
vauxdoc
Vocational, Technical or Trade Scho
1,117 satisfied customers
Specially: servicing..it has started misfiring and shudders..low gear
I have a Vauxhall Astra 1.6 Manual 99 and i had done a full servicing just couple of month ago. However recently it has started misfiring and shudders a lot specially in low gear. My instinct is the s… read more
vauxdoc
vauxdoc
Vocational, Technical or Trade Scho
1,117 satisfied customers
cuts..i come off at a slip road the revs drop and it stalls
my 53 plate zafira cuts out after about 40 miles of constant driving. its ok on motorways, but when i come off at a slip road the revs drop and it stalls. it restarts ok every time… read more
vauxdoc
vauxdoc
Vocational, Technical or Trade Scho
1,117 satisfied customers
plate..my engine management is on and if i go above 30mph..lose power
i have a zafira 16.its on a 06 plate.my problem is that my engine management is on and if i go above 30mph it starts flashing and i lose power.what problems could there be?… read more
vauxdoc
vauxdoc
Vocational, Technical or Trade Scho
1,117 satisfied customers
150,000 miles..engine management light..stalls..throttle
I have a 2003 1.8 Zafira elegance which has done 150,000 miles. The engine management light is on now all the time when the car is being used. From time to time, perhaps a dozen times in the last year… read more
Bill_Crosby
Bill_Crosby
UK Car Mechanic
City & Guilds
3,307 satisfied customers
Coil pack..it goes out but the diagnostics show misfire in cylinder 4
Our vauxhall astra 1.4 '54' plate had a misfire about 6-8 weeks ago the coil pack was changed it now comes up with an occasional misfire and the engine management light comes on. after the engine is s… read more
Mike
Mike
Proprieter / Diagnostic Technician
High School or GED
19,815 satisfied customers
Miss-fire..cylinder..plugs, coil pack and fuel injectors around
hi i have a miss-fire on a 52 plate astra duel fuel. it has a miss-fire code cylinder 1 and some times brings up multiple miss-fire code? change plugs, coil pack and fuel injectors around. compression… read more
vauxdoc
vauxdoc
Vocational, Technical or Trade Scho
1,117 satisfied customers
.have changed timing belt,coil pack,fuel filter and plugs.initially
4th plug wet when checking plugs.have changed timing belt,coil pack,fuel filter and plugs.initially thought it was cvoil pack then plugs then filter then finally belt as it showed wear when welooked a… read more
Bill_Crosby
Bill_Crosby
UK Car Mechanic
City & Guilds
3,307 satisfied customers
i have recently bought a vauxhall zafira gsi,04 plate with
i have recently bought a vauxhall zafira gsi,04 plate with full service history,it has 5900 miles and twice ive noticed some smoke(more than u would expect)when its warm,but it clears if u put the foo… read more
vauxdoc
vauxdoc
Vocational, Technical or Trade Scho
1,117 satisfied customers
Disclaimer: Information in questions, answers, and other posts on this site ("Posts") comes from individual users, not JustAnswer; JustAnswer is not responsible for Posts. Posts are for general information, are not intended to substitute for informed professional advice (medical, legal, veterinary, financial, etc.), or to establish a professional-client relationship. The site and services are provided "as is" with no warranty or representations by JustAnswer regarding the qualifications of Experts. To see what credentials have been verified by a third-party service, please click on the "Verified" symbol in some Experts' profiles. JustAnswer is not intended or designed for EMERGENCY questions which should be directed immediately by telephone or in-person to qualified professionals.

JustAnswer in the News:

Ask-a-doc Web sites: If you've got a quick question, you can try to get an answer from sites that say they have various specialists on hand to give quick answers... Justanswer.com.
JustAnswer.com...has seen a spike since October in legal questions from readers about layoffs, unemployment and severance.
Web sites like justanswer.com/legal
...leave nothing to chance.
Traffic on JustAnswer rose 14 percent...and had nearly 400,000 page views in 30 days...inquiries related to stress, high blood pressure, drinking and heart pain jumped 33 percent.
Tory Johnson, GMA Workplace Contributor, discusses work-from-home jobs, such as JustAnswer in which verified Experts answer people’s questions.
I will tell you that...the things you have to go through to be an Expert are quite rigorous.

What Customers are Saying:

Wonderful service, prompt, efficient, and accurate. Couldn't have asked for more. I cannot thank you enough for your help.

Mary C.Freshfield, Liverpool, UK

This expert is wonderful. They truly know what they are talking about, and they actually care about you. They really helped put my nerves at ease. Thank you so much!!!!

AlexLos Angeles, CA

Thank you for all your help. It is nice to know that this service is here for people like myself, who need answers fast and are not sure who to consult.

GPHesperia, CA

I couldn't be more satisfied! This is the site I will always come to when I need a second opinion.

JustinKernersville, NC

Just let me say that this encounter has been entirely professional and most helpful. I liked that I could ask additional questions and get answered in a very short turn around.

EstherWoodstock, NY

Thank you so much for taking your time and knowledge to support my concerns. Not only did you answer my questions, you even took it a step further with replying with more pertinent information I needed to know.

RobinElkton, Maryland

He answered my question promptly and gave me accurate, detailed information. If all of your experts are half as good, you have a great thing going here.

DianeDallas, TX

< Previous | Next >

Meet the Experts:

Marty

Marty

European Car Expert

470 satisfied customers

ASE & Bosch Certified Master Tech. Over 30 years experience.

Greg

Greg

Shop Owner

1,562 satisfied customers

17 years Shop Owner /Technician. 27 years experience,

Richard

Richard

UK Car Mechanic

677 satisfied customers

12 years as a technician at a Ford and Jaguar dealer Ford and Jaguar factory certified

Matt

Matt

Mechanical Engineer

5,004 satisfied customers

BEng hons Mech engineering, in auto industry 22 years

Trevor

Trevor

UK Car Mechanic

853 satisfied customers

NVQ 3, Modern Apprenticeship, MOT Tester, 15+ years experience diagnostic technician

Rob

Rob

UK Car Mechanic

823 satisfied customers

city and guilds level 1 2and 3. mot tester , 28 years experience set up training college in afghanistan

martin jones

martin jones

UK Car Mechanic

647 satisfied customers

25 years as a mechanic and mot tester, owned own business for 10 years city and guilds trained

< Previous | Next >

Disclaimer: Information in questions, answers, and other posts on this site ("Posts") comes from individual users, not JustAnswer; JustAnswer is not responsible for Posts. Posts are for general information, are not intended to substitute for informed professional advice (medical, legal, veterinary, financial, etc.), or to establish a professional-client relationship. The site and services are provided "as is" with no warranty or representations by JustAnswer regarding the qualifications of Experts. To see what credentials have been verified by a third-party service, please click on the "Verified" symbol in some Experts' profiles. JustAnswer is not intended or designed for EMERGENCY questions which should be directed immediately by telephone or in-person to qualified professionals.

Show MoreShow Less

Ask Your Question

x