Is the 1.9-litre CDTi 120 engine, as used in the Zafira as well as many Saabs and Fiats, really a "disaster zone"?

I refer to the answer you gave stating that that the 1.9 CDTi 120 in the Zafira can be a "disaster zone". Since I assume that this is the base engine that powers Vauxhall/Opel, Saab and many Fiat vehicles, and was jointly designed and developed by GM and Fiat, it is a very "far reaching" comment, unless it is to do with the Zafira installation. I am interested as I have the 150 HP version in a Saab.

Asked on 17 March 2012 by TW, via email

Answered by Honest John
May I refer you to the entry for the SAAB 9-3 that has this same engine: www.honestjohn.co.uk/carbycar/saab/9-3-2002/?secti...d, and if you are unable to simply click on links, here is the specific content:

"1.9 diesel autos vulnerable to failure of heat exchanger in radiator admitting coolant to the ATF and wrecking the transmission. On cars just out of warranty GM Saab will usually contribute 40 per cent. Alternators of 1.9 diesels fail regularly. Saab dealers may quote £600 to replace but this has sometimes been reduced to £300 when the customer complained. 1.9 diesels can be delightful to drive, but give a lot of problems: Failed inlet manifold swirl flaps (and the flaps can beak and be ingested by the engine). Failed EGRs. Choked DPFs. Failed timing belts, often because the waterpump seized. Belt, tensioner, pulleys and waterpump need replacing every 40,000 miles. Failed oil pumps. Failed dual mass flywheels. Failed turbos."
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