Vauxhall GM 1.9 CDTi DTH Problems
Picture below is of a DTH engine in a 2007 Vauxhall Zafira. In the foreground is the new intake manifold, EGR valve and turbo cold side pipe. It is clear to see the intake flaps and actuator bar that controls them.
Picture below shows how much you have to remove to get the manifold off. Cambelt, and diesel pump. This type of engine is near impossible to time up with out the proper plate and locking pin. Note the new water pump. Only a fool would do all this without fitting a new pump.
Job is easier on a Vectra than a Zafira. Remember to loctite the engine mount bolts up! Like VW TDi Golfs they can move and wear the cam belt.
We have seen allot of these DTH engines with broken cam belts, due to the bottom rubber crankshaft pulley breaking up after 70.000miles and the alternator drive belt coming off and gong under the bottom cam belt cover and jamming the cam belt up till it breaks. Common cause for crankshaft pulley failure is a seized free wheel pulley on the alternator.
Fiat engine made in India with a never ending list of faults...
Single cam 8v 19DT (1.9CDTi) engines strip the keyway out of the bottom cambelt pulley! P0340 codes! Pulley is only £29 from your dealership! Ignore the fault for too long and it will slip round enough to bend the valves. Beware eight valve engien has a lefthand thread crank bolt!
We now offer an upgrade click on the link 1.9 CDTi Vauxhall, Saab, Alfa Romeo, Fiat > Intake manifold fix
(date information written)
Page updated 28-05-18