2006 Vauxhall Zafira high emissions

Car: Vauxhall Zafira
Year: 2006
Variant: 1.6 xep
Categories: Running Rough, Starting & Power Loss

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2006 zafira 1.6 xep engine failed mot/nct test , on high emissions of 9.07 co vol percent @ low idle 800rpm hc 159 ppm
High idle also failed @2900rpm 3.02 co vol percent hc80 ppm lambada @ .93 , I scanned with code reader , no faults , no emission light on , put emission cleaner in tank and ran it on motorway hard driving for half an hour , no mis fires thru rev range , slight gradual reduction in power at higher gears 4 th and 5 th 5000 to 6000 rpm , I carried out another co test later in week driving at high engine range once engine was warmed up , following week a misfire developed , read code and indicated no 1 engine misfire , replaced coil rail and plugs ,I cleared codes and misfire went , the coil was shorting to cylinder head , i remeasured emissions and showed 10.0 co vol , I checked air filter and inlet for blockages , I have also checked vacuum pipes and intake for leaks , catalytic converter has been inspected , no blockages or missing core , this vehicle has 70,000 miles done since new 1 owner , always serviced , the main dealer also scanned ecu , no codes found , and has not come across this problem before , recommended checking timing marks and changing timing belt , did this on friday , no change , marks were exact , checked values of map , ect , air temp sensor , , and erg valve and feed back values ,
all advice welcome , regards , ken
Posted: Nov 9, 2012 (11 years ago)
Sounds like your having the type of nightmare I have every day with problem cars.Any way all I can suggest is back to basics ,are the compressions okay,or is there a particular cylinder down in compression from the rest.it may not misfire but just not be working efficiently are plugs all okay,is fuel pressure okay ? Engine oil level okay? Certainly looks like your air fuel ratio is all wrong when your getting such high co readings .Other thing are lambda probe voltages fluctuating switching correctly and heating elements operating okay.Hope this helps ,If you are able to get a break out box and monitor e.c.u. Signals then that would be a quicker way of seeing what's happening or not happening.
Posted Nov 10, 2012 (11 years ago)
Nice Question,comprehensive.
In an ideal world I'd like to see the live data,air flow mesured and predicted to be specific,the AFM could well be functioning enough to not flag a code but not well enough to actually read the flow,Tech II or OP Com would be able to read either,even the cheap ebay clones.
MY only other suspect is a possible injector pintle leaking,a slight dribble would give your gas readings,difficlut to test but again,with TECH II I'd be looking at both long and short term fuel trim readings,if your code reader can give these it'd be a help or it's injectors out and bench tested,if you have someone local.
Posted Nov 10, 2012 (11 years ago)
Thanks for support and info on last 2 posts , I proceeded to do fuel pressure check on fuel rail , in limits 3.8 bar in limits , then I did a pressure check upstream of catalytic converter , max 2 bar @2000 rpm , read zero , no blockage , next I checked precat O2/lambda sensor values and input/out put voltages and resistances, all in limits , I then did same with post cat 02/lambda sensor and found signal voltage coming sensor were fluctuating 5v to .2v , limit should be .6 v steady , so I preceded to take out sensor and found it was sooted over , I scotchbrited it and ran wd40 thru slots , put it back in and ran it again this time the values came down after a few minutes to a steady .7v , checked emissions and were fine , fingers crossed will check in a weeks time and hope emissions stay in limits ,
Posted Nov 10, 2012 (11 years ago)
Is there diagnostic equipment available without having to do difficult voltage and resistance checks , as I have use of I pad or laptop, what's best value program or equipment for these tasks , thanks in advance ken
Posted Nov 11, 2012 (11 years ago)
Glad to hear you have a result and well done at your persistence ,that's what finds faults and sorts cars combined with knowledge. Launch do a good tool that covers a wide range of vehicles and can read scrolling values ,but it,s quite expensive.But as so many things work on duty cycle now adays it makes it harder to look at these without the correct tool.
Posted Nov 11, 2012 (11 years ago)
I'd say the cheapest option would be the chinese clones of TECH II or OPCOM on ebay and while these are limited to Vaux/opel they are dealer level software and cover a hell of a lot,just load them into the laptopamabob,fine if all you want to do is Vaux,get's a little bit silly when you want a big coverage,you'd need software for each manufacturer,and as this would mean a lot of cash,probably as much as a Launch or Snapon mid range would cost £2500>.
I'd say the bare minimum would be the AUTEL 700 series,doesn't cover every function but would have pointed you to the non fluctuation of the o2 sensor and the short and long term fuel shift readings.
'Course non of this means squat without training and understanding of the systems which you seem to have,unlike all the mooks that by code readers to switch off the mil because everybody knows garages are rip of bast#####,right?
Posted Nov 11, 2012 (11 years ago)

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