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Vauxhall Zafira 1.9 DTi Z19DT 2008 - New DPF problems - Fixed #

Posted by Peter Holland on February 19, 2014, 4:07 pm

Year of Manufacture *: 2008
Engine Size and Code *: Z19DT
( Optional ) Scanner Used: Tech 2
( Optional) Fault Codes: None

This car had a blocked DPF replaced by a local garage who then asked me to reset the DPF counter to stop the glow plug light flashing. This one duly done and all seemed well. 200 miles later, glow plug light is flashing again, no fault codes stored but DPF is shown as being 154% blocked!! Reset counter and check differential pressure feed back which showed no unduly high back pressure issues. So, sent it out again to see what happens.

Another 200 miles later, the light is back on, no fault codes stored but DPF again shows 162%. The car drives fine but maybe a bit smoky.

I have checked the EGR via diagnostics and it appears to be working. MAF with EGR shut - 54 Kg/h, EGR open, MAF drops to 12 Kg/h at idle. A road test under hard acceleration shows a maximum differential pressure reading of 11 KPA @ 1.04 volts.

I don't understand how the ECU calculates the DPF condition but I can only assume that it uses the reading from the pressure sensor which appears to be ok.

I'm not sure where to go from here!

Re: Vauxhall Zafira 1.9 DTi New DPF problems

Posted by Mark Carter on February 19, 2014, 6:29 pm, in reply to "Vauxhall Zafira 1.9 DTi New DPF problems"
Mark Carter

Genuine or pattern ?

Modern cars, Its all wizardry and witchcraft

Re: Vauxhall Zafira 1.9 DTi New DPF problems

Posted by Steve Harvey on February 20, 2014, 7:51 am, in reply to "Re: Vauxhall Zafira 1.9 DTi New DPF problems"
Steve Harvey

Hi Peter,
Are you sure the pressure sensor is reading correctly? Check the flexible pipe from the DPF where it rises to the sensor at the bulkhead/steering rack area.
Regards Steve Harvey

Re: Vauxhall Zafira 1.9 DTi New DPF problems

Posted by kelly clarke on February 20, 2014, 8:34 pm, in reply to "Re: Vauxhall Zafira 1.9 DTi New DPF problems"
Kelly Clarke

I hit exactly the same problem on a Vectra, even though it is a new dpf some Vauxhalls require a regen to be performed on them as soon as it is fitted. Once regenerated problem was resolved.

Kelly

Re: Vauxhall Zafira 1.9 DTi New DPF problems

Posted by Andrew Broomhead on February 20, 2014, 11:15 pm, in reply to "Re: Vauxhall Zafira 1.9 DTi New DPF problems"
Andy Broomhead

Was regen done correctly or just forced? Oils done after Egr is working you say, how did you prove this or did you just read live data? Did you find out why it had clogged up in the first place? Real or micky mouse Dpf?
The only aftermarket ones that will work correctly and run their own passive regen (which will cut down the need for active regen) are Delphi at the moment.
Sparki

Re: Vauxhall Zafira 1.9 DTi New DPF problems

Posted by Peter Holland on February 21, 2014, 1:07 pm, in reply to "Re: Vauxhall Zafira 1.9 DTi New DPF problems"
Peter Holland

I have now replaced the pressure sensor and physically measured the back pressure and there basically isn't any - or very little. So I reset the pressure sensor learnt values, reset the DPF again and road tested. After 16 miles the DPF is up to 8%

I have tried to regen the DPF but I appear to be experiencing some issues with my Tech 2 at the moment as it keeps loosing comms with the car which it did part way through the regen process. I'm very worried about trying it again in case I damage the new DPF!

Re: Vauxhall Zafira 1.9 DTi New DPF problems

Posted by Lee Mackintosh on February 22, 2014, 12:39 pm, in reply to "Re: Vauxhall Zafira 1.9 DTi New DPF problems"
Lee Mackintosh

I'm fairly sure snapon scanners can do the forced regen so maybe worth seeing if you know anyone who can help you.

Re: Vauxhall Zafira 1.9 DTi Z19DT 2008 - New DPF problems #

Posted by Peter Holland on February 26, 2014, 10:26 am, in reply to "Vauxhall Zafira 1.9 DTi Z19DT 2008 - New DPF problems #"
Peter Holland

Having tried but failed to carry out a regen, it won't now let me perform another until it has clocked up another 31 miles apparently!

I have since confirmed that it was fitted with a none genuine DPF which is a little worrying but I still don't know how it calculates the DPF percentage when there is no back pressure to speak of. I have been monitoring exhaust gas temperatures and have noted that there is a difference between sensor 1 and 2 of around 30 degrees, sensor 1 being the highest, but I have no live data to compare these readings.

Re: Vauxhall Zafira 1.9 DTi Z19DT 2008 - Live data required.

Posted by Peter Holland on February 27, 2014, 11:08 am, in reply to "Vauxhall Zafira 1.9 DTi Z19DT 2008 - New DPF problems #"
Peter Holland

Has anyone got one of these Zafiras in at the moment? I'm looking for some live data taken from a Z19DT engine up to temperature, particularly the MAF reading, EGR, DPF pressure, exhaust temp sensor 1 and 2 and DPF percentage etc.

I'm still trying to work out how it calculates DPF percentage as hopefully this information would lead on to diagnosing why the data is telling me that the DPF is filling up so quickly. I've been through Vauxhall TIS but can find no tests for the pressure sensor or exhaust temp' sensors.

I've driven this car for about 70 miles now (my commute to work is over 50 miles a day which can be handy) and have noted that there is still very little back pressure recorded but exhaust temp sensor 1 reads 380 deg.C and and sensor 2 reads 288 deg.C at motorway cruising speed. Not sure if this isn't a little high?

Re: Vauxhall Zafira 1.9 DTi Z19DT 2008 - Live data required.

Posted by Barnaby Donohew on February 27, 2014, 8:17 pm, in reply to "Re: Vauxhall Zafira 1.9 DTi Z19DT 2008 - Live data required."
Barnaby Donohew

I apologise if you've covered some of these things already but I just thought that before going too far with looking at exhaust gas temperatures etc (which seem ok to me - although if I was cuffing it on an A road I'd get them a bit hotter!) are you sure that the dpf is ever going into regen mode when on a run?

Quite a few conditions need to be met before it will do so: e.g. engine running temp >70 deg C for more than a couple of mins; no DTCs (or at least no DPF DTCs in ECU?); dpf loading above a certain threshold (70%+?); constant(ish) & minimum speeds; exhaust temperatures sustained above (and below) certain limits (less than 1000 deg I think?). I don't think this is the case for Vauxhalls but in some cases you need the correct quantity of fuel (probably around 3/4 tank). Try and find the exact criteria for your vehicle if you can. Essentially the info is similar to the sort of lists you encounter when trying to find the criteria to enable obd monitors.

Also check for other basics - has the intake been smoked? Gently ask the owner if the engine has been remapped. Either could cause excess smoke.

With respect to the differential pressure sensor I think these are sometimes used to instigate regen but not always. Sometimes they are used to map the system in some way (don't ask me how!) and/or perform straightforward diagnostic functions.

Finally remember also that static regen is not as good as dynamic regen and that you should make sure it is going in to dynamic regen mode on a run after a static regen. Sometimes a static regen won't get the counters reset below 70% so you have to take it on a dynamic regen run straight after. Also if you are instigating a regen with your scanner (either static or dynamic) then it could chuck itself out of regen mode if any of the above conditions (e.g. temps too high/low or dtcs appear) are no longer valid.

HTH.

Re: Vauxhall Zafira 1.9 DTi Z19DT 2008 - Live data required.

Posted by Peter Holland on February 28, 2014, 2:26 pm, in reply to "Re: Vauxhall Zafira 1.9 DTi Z19DT 2008 - Live data required."
Peter Holland

Thanks for your reply Barnaby, that has given me some more food for thought. I have tried again to carry out a static regen but after 15 minutes of running, Tech 2 remained at 0% complete. I have since learnt that the DPF has to be above 600 deg.c before it will start to regenerate. I didn't let mine go above 530 deg.c for I aborted it. I was concerned that it was taking too long and was worried about causing more damage! I am going to have another play with it this afternoon, paying attention to the MAF readings this time.

Re: Vauxhall Zafira 1.9 DTi Z19DT 2008 - New DPF problems #

Posted by Scott Neal on March 6, 2014, 6:43 am, in reply to "Vauxhall Zafira 1.9 DTi Z19DT 2008 - New DPF problems #"
Edited by board administrator March 6, 2014, 12:37 pm

Hi Peter

We encountered exactly the same problem as you on one of these. The car came in with a blocked dpf to us which we think was due to a sticking egr valve. We renewed the egr valve and ended up fitting an aftermarket dpf supplied by vauxhall due to the genuine one being on back order and had been for some time. We were assured that it would be fine and that they had fitted them before with no issues. We fitted it then took it to vauxhall for a software update, there is a software update regarding the dpf regen. The customer drove the car for a few weeks with no issues then returned to us with the glow plug light flashing. Not sure exactly what was wrong but it was like the car couldn't complete the regen for some reason. We think it was unhappy with the back pressure or temperature readings from the aftermarket dpf. We put it into vauxhall and told them that the aftermarket dpf wasn't going to work.
They fitted a new genuine dpf foc which they sourced from another dealer. Hope this helps.
I'll have a look once I get to work and see if I stored any live data. I'm not sure if I did.

Fixed #

Posted by Peter Holland on March 12, 2014, 3:09 pm, in reply to "Re: Vauxhall Zafira 1.9 DTi Z19DT 2008 - New DPF problems #"
Edited by board administrator March 14, 2014, 2:53 pm

Thanks for that information Scott, I suspect we have the same issue with this car but without any live data to compare to it I have drawn a blank. The customer has opted to go for a DPF removal which involves sending the ECU away for a remap etc. The cost of a genuine DPF was way more than the cost of having it removed......

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