I have a Zafira 1.6 2003 model. I could be driving at 70 mph on the motorway and all lights come on the dashboard and engine cuts out. THIS PROBLEM HAS NOW BEEN RESOLVED, 1500 MILES WITHOUT A PROBLEM...!! I took it to guy who used to work for Vauxhalls. He has his own garage now. As I walked into his garage there were five other Vauxhall cars all with same problem. He looked under the bonnet and applied following 3 fixes - unsure which one resolved the problem though:
(1) EGR gasket fitted was NOT the modified one. He changed gasket. The modified has a protruding notch which you can feel.
(2) Cleaned around throttle valve
(3) Reset / updated the car software.
He thinks that it was the last item that fixed the problem.
If anyone wants to get in touch with him please email me and I will give you his contact details:
Tigger01 blueyonder.co.uk
Indy
August 2009