Common Faults

Here is a list of some common faults

Chain Problems

* The Number 1 common fault with these cars is the problem with the timing chain. The 2001-2005 Zafira is fitted with Z22SE Engine. This engine is chain driven engine and the chain is fed buy a oil jet that is only 1mm in diameter. The Chain on the Z22SE is tensioned with a hydrolic tensioner. Now the problem here is that once the car gets over 100,000k on the clock the oil becomes dirty easy causing the jets to block and the tensioner to becomes siezed this in turn causes the chain to jump, fly off or even break . This is a major problem with the Zafira as it causes major damage to the vehicle with costs from $4500 to $7000 to repair.
The problem is that common with the Zafira that in europe all the cars had to be returned to have upgraded parts fitted HERE IN AUSTRALIA THE PROBLEM HAS BEEN IGNORED 
"see below for more information regarding the recall"

Engine Oil Consumption
* Problem number 2 Some Engines have a genuine oil consumption problem  infact approximately 1/3rd of all zafira's have a oil serious burning problem. - Apparently the bores were machined with too high a gloss from new causing the rings never to bead in properly resulting in engine oil consumption.  On top of this the pistons were designed when sythetic oils were first on the market. The piston heads on the Z22SE were designed in a way to only comepensate for fully synthetic oils with the theory that it will never soot up (we all know thats not true)
However there is also a major design flaw that also causes this problem. The Zafira's Z22SE engine is fitted with a dip stick that only measures the last 1 liter of the 4.8liter engine oil capacity. What this means is that if you or your mechanic check the oil and see the oil on the dipstick only half full then you make the assumption that the car needs approx 2 liters of oil to fill it again. THIS IS WRONG if the oil is half on the dipstick then the car only needs 500ml of oil MAXIMUM.
With this design flaw of the Z22SE we find vehicles all the time with 2 liters too much oil in them and what this does is clogs the oil rings on the piston causing the vehicle to have a ongoing oil consumption problem that can only be fixed buy re ringing the pistons "and expensive fix"

However if you do have a zafira and its burning lots of oil and you would like it fixed we can help. We have now been upgrading our pistons on our zafira builds and have found a solution to stop oil burn forever.


Running out of oil
Problem number 3 One of the other faults found with this vehilce is that the engine OIL LIGHT does not activate. The engine oil light on the Zafira's dash works however the light will not activate even if you have no oil in the car at all. This is a problem with ALL ZAFIRAS. The problem is with the sensor switch in the cars block "it just does not work at all" on every single Zafira.
Now the problem with this is that in today's world most people don't check there cars fluid levels every week anymore, we tend to just drive them until there is a problem or its due for a service. Now if you combine this problem on the Zafira with problem number 2 you will come to the conclusion that a lot of people have let there Zafira run OUT OF OIL
This problem is the mos common reason why people sell there Zafira or trade them in. We find Zafira's online and in caryards every week that have been run out of oil and quickly bodged up to cover the issue only to pass on some very expensive repairs to someone else. Basically the car engine ver shortly will need a full rebuild "first fault will start with a ticking coming from the big end bearings"

Running out of water
Problem number 4 is the water pump. The water pumps on the Z22SE have a tendency to have a slow leak. Now on most cars this is not such a big job HOWEVER. On the Zafira the water pump is hidden behind the motor under the exhaust manifold it is also driven by the cars internal balance chain. The water pump failing on a Zafira is the worst job of all to repair. Infact it is that big of a job most mechanics will not do the work as it is nearly a 2 day job and costs around $2000 to fix.
Because the water pump is behind the exhaust manifold this problem can be very hard to find as the leakage usually evaporates and never hits the ground making it hard to diagnose.

Having an issue with your water pump? Give me a call we can help get you back up and running for low costs (Nigel aka Zippy Zafira  0401541610) 

Engine Light Issues

* Exhaust System Warning Light coming on due to issues with EGR-Valve and/or Oxygen Sensor.

* rev-counter fluctuates arratically, no doubt due to EGR-Valve and/or Oxygen Sensor Problems.

Holden Recall Notice (to fix timing chain issue)

Category: Service Techline Reference: Issue 10 - Nov

Timing Chain Serviceability - TT & TS with Z22SE Engine

TL314-0210

PROBLEM DESCRIPTION

A number of revisions have been carried out to Z22SE timing chain/drive components to improve quality and durability.

These revised components have been fitted to engines from:  
(PLEASE NOTE this is for the oil jets ONLY, ALL Z22SE Engines in Australia still came out with a faulty designed tensioner and will fail if not changed)

Engine No.: Z22SETA099999

("TA" in number = built at Tonewanda plant)

Engine No.: Z22SE11099999

("11" in number = built at Kaiserslautern plant)

SERVICE RECOMMENDATION

When servicing timing chain/drive system, use the following kit:

Part No.: Description: Qty:

12577164 Timing Chain Service Kit 1

FOR REFERENCE ONLY – Kit 12577164 consists of the following parts:

Part No.: Description: Qty:

24461834 Timing Chain, Camshaft Drive 1

12577163 Oil Nozzle (full flow) 1

24448509 Tensioner Asm. ("V" Groove on end) 1

24449448 Guide – Chain, Moveable (Tens. Side). 1

90537337 Guide – Upper (Cam to Cam) 1

13104978 Guide – Chain, Fixed 1

24424758 Crankshaft Sprocket 1

90537632 Cam Sprocket (Inlet & Exhaust) 2

90537451 Bolt – Camshaft Sprocket 2

PARTS WARNING:

The following (superseded design) timing chain components must NOT be used in repairs: (funny enough when you buy the parts even today from holden they still give you these recalled parts)
13104980 Kit – Timing Chain
90537338 Chain – Timing
90537802 Tensioner Asm – Timing Chain
90537842 Guide – Timing Chain
90537476 Jet Asm. (Oil Nozzle)

Parts Managers Note:

The above parts should be returned to HSPO for credit via the CRRM system.

EUROPEAN RECALL PROOF

Field Remedy: 1532

Subject: Engine - Broken Timing Chain

Models: Engines: Option:

Astra-G 2000...2005,VX220 2000...2002,Speedster 2000...2002,Zafira 2000...2005,Vectra-B 2000...2005,Vectra-C 2002 Z22SE,Z22SE,Z22SE,Z22SE,Z22SE,Z22SE

Complaint: Engine damaged by broken timing chain.

Cause: Missing or insufficient lubrication of the timing chain.

Production: Modified tensioner and lubrication nozzle have been introduced in production

Remedy:

In case of customer complaint please use for the necessary repair the

timing chain kit (Part/Cat.-No. 12577385/ 5636400). This kit contains

the modified timing chain and tensioner.

Spare-Parts: Qty: Part-No.: Catalog-No.:

Set-Drive Parts 1 12 577 385 56 36 400

FunctionalGroup: J - Engine

Complaint Group: 01 - Broken or Cracked

Zippy Zafira
0401541610