The technical team at HELLA have identified a common fault relating to engine power on certain Opel engines.

The team has received an increase in queries about insufficient engine power relating to certain Opel Astra, Zafira and Meriva models. These are popular in Ireland, as are the same models in imported Vauxhall versions. The problem is often related to the exhaust gas recirculation (EGR) system.

HELLA’s technical experts have found that the engine warning light tends to come on in Opel/Vauxhall models fitted with the engine code Z16XEP. After further investigation, the following diagnosis and repair procedures have been revealed to help technicians resolve the problem.

If, when undergoing a diagnostic test, the insufficient engine power symptom occurs in line with the following list of fault codes, a clogged or blocked EGR channel is the probable cause.

Fault codes:

    P0171 – Mixture too lean

    P0300 – Misfire on multiple cylinders identified

    P0301 / P0302 / P0303 / P0304 – Misfire identified on cylinders 1/2/3/4

    P1300 – Fuel tank empty

In order to eliminate a defect with the EGR valve, technicians should run a check on the periphery of the EGR system. If no errors are found there, technicians should do the following:

    Read out error memory and delete all existing fault codes

    Dismantle intake manifold as per manufacturer's specifications

    Clean the EGR channels in the intake manifold with the appropriate tools

    Fit intake manifold as per manufacturer's specifications

    Read out error memory and, if necessary, delete all existing fault codes

Finally, a test drive should be carried out and the error memory read once again.