2003 Vauxhall Zafira wont rev over 2500

Car: Vauxhall Zafira
Year: 2003
Variant: 20dti
Categories: Running Rough, Starting & Power Loss
Car drives great then spaner light comes on and wont rev over 2500 revs. Switch ignition off, back to normal until the light comes back on. Also very hard to start if left more than 2 days, no white smoke. No fault codes.
Posted: Feb 12, 2011 (13 years ago)
these engines are prone to problems,check the inlet manifold,egr valve and swirl flaps are not carboned up,if so you need to remove and clean out thoroughly,also common problems with injector seals leaking,check spill pipes arenot leaking and that all vacuum pipes and actuators are not split/damaged or loose,what fault codes are you getting?
Posted Feb 12, 2011 (13 years ago)
Ther isnt any exhaust gas going into the inet, i think that means egr is closed. I cant see any fuel or air leaks. Ther is no fault code. I do think the injector seals my be the starting problem but dont know how to diagnose this.

Thax for your reply.
Posted Feb 13, 2011 (13 years ago)
remove the fuel leak off pipes and check for a black oily residue in fuel,if there is then injector seals are leaking,if you renew the injector seals then check/replace the fuel filter if contaminated
Posted Feb 13, 2011 (13 years ago)
Can I replace the injector seals or do I have to send them away? I have just repaced the fuel filter and it was black. I'm going to try an air flow meter for the other fault.

Thanks again for your help.
Posted Feb 13, 2011 (13 years ago)
Can I replace the injector seals or do I have to send them away? I have just repaced the fuel filter and it was black. I'm going to try an air flow meter for the other fault.

Thanks again for your help.
Posted Feb 13, 2011 (13 years ago)
if you have a little mechanical knowledge then you can replace the injector seals yourself,yiu need to remove camcover and loosen camshaft housing bolts and this will give you enough room to access the injector seals,remember to retorque all bolts when refitting,if you don`t feel confident doing this then get it into a garage,come back to us if you get stuck
Posted Feb 13, 2011 (13 years ago)
I do have some mechanical knowledge. I'm an autoelectrician but i work on heavies so dont have a clue about the wee stuff.

Thanks again for all your help.
Posted Feb 13, 2011 (13 years ago)

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