Zafira-B ; Panoramic ; Z22YH ; Auto

[Inevitability]

A quick update on where I am with diagnosing the issue ...
User evocarlos over on the z22se forum was kind enough to share his experience with the symptoms of a bad pump on a Z22YH.
Sadly, its a lot like what I experience on mine.
I am still waiting to run have the tools to run a proper diagnostic on my car and confirm this (using the method that has been posted on many threads, which is to compare Fuel Pressure demand with Fuel Pressure measured).
But with the amount of experience that evocarlos has , it's as good as confirmed anyway.
A little bit of a bummer that it's the pump and not the regulator, but it's good that I am narrowing it down... that only gets me closer to fixing it nad being able to get it running.

One small piece of good news is that , even with the bent aircon radiator, I let the car idle for a while and switched on the aircon... it delivers cold air and nothing leaks.
Still have to try and straighten that AC radiator gently and hope nothing breaks.

[Inevitability]

Dear Diary...

I posted a thread here ... this is what I saw from the fuel pressure feedback. To me it looks like the pressure sensor is dead. Which doesn't mean that pump or regulator are ok... so that's still looking likely... but if the sensor is dead and need replacement, I might as well start with that and see what happens next.

[Inevitability]

Stripped the pump about a month ago and forgot to post here...
zafira_z22yh_pump_stripped.jpg

[Inevitability]

turns out it was the notorious "cracked diaphragm" ...

zafira_z22yh_pump_diaphragm.jpg

[Inevitability]

great news is that i managed to fix the pump!
Ordered the parts from eBay, took a couple of weeks to get to me, then had some delays getting to it.
Also, I couldn't get that metal ball out to open up the hole to fill the pump with oil... tried a few different things that would only have damaged the pump, so i gave up on that.
Then I saw a video on YouTube where the guy submerged the whole pump in oil and assembled it under oil.
Bl00dy brilliant! So I did the same and it worked!
Was a bit "fiddly" cos the oil I had wasn't very transparent and I had to do some of the assembly by touch rather than being able to see it clearly through the oil ...but in the end it worked, and the car idles fine now, and it's out of limp mode, and drives fine (from a fuel delivery point of view).


Next up ... now that I can drive the car around, there are some rattles and knocks (suspension parts probably, but possibly mountings), and a slight whining noise from the auto transmission.


Need to get that transmission noise diagnosed first.
Gonna check the transmission fluid level to see if it's as simple as the fluid being low.
Next I might try changing out the fluid, if its not too difficult and if i can find the gasket and filter for reasonable prices locally.
If none of that works, I'll need to take it to a mechanic to get it looked at, and if it turns out to be a serious issue, I'll have to weigh up the cost of trying to get it fixed vs looking for another transmission.

[northpole]

Need to get that transmission noise diagnosed first.
Gonna check the transmission fluid level to see if it's as simple as the fluid being low.
Next I might try changing out the fluid, if its not too difficult and if i can find the gasket and filter for reasonable prices locally.
If none of that works, I'll need to take it to a mechanic to get it looked at, and if it turns out to be a serious issue, I'll have to weigh up the cost of trying to get it fixed vs looking for another transmission.

You don't need a gasket or anything... it is just a drain- and fill plug tou need to remove... always remove the fill plug first. Than the drain plug it helps with draining the old oil. And if you got the 5 speed f23 gearbox it probably is old oil.

[Inevitability]

Great info ... thanks!
I have the AF20 transmission.

[northpole]

Great info ... thanks!
I have the AF20 transmission.

https://workshop-manuals.com/vauxhal...af_20/_af_22)/

That should help

[Inevitability]

Thanks to the link from @northpole, I got the transmission fluid drained.
Also drained the engine oil.
Had a rough time of it, which is documented here , but both drain plugs are off now.

Next up:
- get replacement drain plugs ,
- get some fluid for the transmission
- get some oil and a new oil filter for the engine
- drive it around to see if it's made any difference to that slight whining sound that was coming from the transmission

[Tugaville]

great news is that i managed to fix the pump!
Ordered the parts from eBay, took a couple of weeks to get to me, then had some delays getting to it.
Also, I couldn't get that metal ball out to open up the hole to fill the pump with oil... tried a few different things that would only have damaged the pump, so i gave up on that.
Then I saw a video on YouTube where the guy submerged the whole pump in oil and assembled it under oil.
Bl00dy brilliant! So I did the same and it worked!
Was a bit "fiddly" cos the oil I had wasn't very transparent and I had to do some of the assembly by touch rather than being able to see it clearly through the oil ...but in the end it worked, and the car idles fine now, and it's out of limp mode, and drives fine (from a fuel delivery point of view).


Next up ... now that I can drive the car around, there are some rattles and knocks (suspension parts probably, but possibly mountings), and a slight whining noise from the auto transmission.


Need to get that transmission noise diagnosed first.
Gonna check the transmission fluid level to see if it's as simple as the fluid being low.
Next I might try changing out the fluid, if its not too difficult and if i can find the gasket and filter for reasonable prices locally.
If none of that works, I'll need to take it to a mechanic to get it looked at, and if it turns out to be a serious issue, I'll have to weigh up the cost of trying to get it fixed vs looking for another transmission.

Hi There,

Glad you sorted the fuel pump, I too need to do this to my pump.
I have a question regarding the way you repaired the pump by submerging it , instead of the drill and fill option, how did you remove the excess atf oil from inside the pump just before closing it ?
Or did you just filled it to the maximum and closed it.
I've seen a few on youtube, is there a particular one you recommend?
Thank you