Vauxhall Zafira intermittantly not starting

does the vehicle crank over?if not then check the obvious things first like battery condition and check the alternator charge rate.also check the starter motor,if it is cranking but not starting then check the injector seals,if you remove the injector spill pipes the fuel should be clear,if you have an oily residue then the injector seals are leaking,this would cause low fuel pressure which results in poor starting

A common problem on that model, is deterioration of the spill pipes, which allows air to get into the fuel system , hence starting probs . ( Also doesn't help if car parked uphill . Here is a good article / walkthrough from the Vauxhall forum which will help you .



)21-6-2007 05:47 AM #1 Dillmiester View Profile View Forum Posts
VxON Barfly Join Date Apr 2007
Location Leicester
DrivesVectra 2 Liter DTI
Posts 135


Heres something I wrote earlier

This guide is relating to “Spill pipes” or Leak off pipes” which when defective cause poor or no starting on Vauxhall DTI engines. This is a very common fault and should be one of the first areas to look at when the DTI refuses to start. It is also the cheapest place to start as new leak off pipe costs around £2.99 from most motor factors
The EGR valve is located in the same area and I recommend having a look at the same time.
Remove the “Ecotec” engine cover.
I recommend cleaning the area with a degreasing agent like “Gunk” note any obvious areas of oil/dirt leakage.
The leak off pipes take excess fuel back from the injectors into the pump, this is required to keep pump pressure and if defective will cause poor starting or even prevent starting. I also believe that this has an effect on fuel economy. These pipes crack over time due to the high temperature they work in and this corrodes the rubber in the pipes causing cracks and leaks.
The spill pipes are the furry braided pipes above each injector inlet, they meet together and connect to the fuel pump.
Most car shops sell diesel "leak off" pipe in a meter length for around £2.99. Vauxhall also sell this for a little more.
There is a plastic rail covering the pipes which should be loosened to enable access. There is also a water pipe in the area which can be disconnected from the header tank and moved out of the way (keep it higher than the header tank).
Make a note of where the old leak off pipes are and draw a quick diagram as you will be making a new one soon.
Use a pair of pliers to slowly pull the old pipes out however they will probably crack leaving parts attached to the metal pipes on the block. I ended up cutting mine out of the holes with a small craft knife and screwdriver. Make sure you get all the old pipe out, check with a torch.
Soak the old pipe in hot water for a while, this will help to remove the three T pieces (you will need them to make up the new pipe work). Clean the T pieces with de carb or similar spray. If any are defective, replace. Cut and fit the new pipe, use some WD40 on the joints to help lubricate as you go.
Job done, don’t forget to attach the long pipe back onto the pump.
Well done! you have just saved yourself a £125 Vauxhall garage bill (and thats if they had the sense to look for the problem in the first place).

EGR
The EGR valve is the round unit that sits in front and below the leak off pipes. The large 3” charge pipe connects below it. The EGR has a small pipe connected to it and runs to a solenoid near the battery.
Remove the EGR with the two screws. You may find it is full of oily coke (mine was very dirty). Give it a good clean (it takes a while). Also take off the charge pipe and give the inlet a clean up and flush. Petrol and de carb can be used to clean these parts and i found an old toothbrush useful for this. The EGR has a small rubber O ring gasket. I was not able to source one of these as Vauxhall do not sell them separately.
The result should be better starting, smoother running and more MPG!
The other common starting problem is the injector seals but lets hope we dont need to go down that road as for me its a garage job at about £250 (not vauxhall price).
Whilst your in the engine bay check all those little vacuum tubes for cracks. A very common problem as even small cracks cause running problems.