The Vauxhall ZD3 202 is a 1,997 cc, inline‑four turbocharged diesel engine produced between 2013 and 2021. It features common‑rail direct injection, a variable geometry turbocharger (VGT), and dual overhead camshafts (DOHC) with four valves per cylinder. In standard form it delivers 100 kW (136 PS) and 320 Nm of torque, offering strong low‑end pull with refined operation.
Fitted to models such as the Astra K, Insignia B, and Mokka X, the ZD3 202 was engineered for compact hatchbacks, SUVs, and mid‑size sedans where fuel efficiency and Euro 6 compliance were paramount. Emissions control was achieved through cooled exhaust gas recirculation (EGR), a diesel oxidation catalyst (DOC), a diesel particulate filter (DPF), and selective catalytic reduction (SCR) with AdBlue injection, enabling full Euro 6b compliance from launch.
One documented concern is AdBlue dosing valve clogging due to crystallisation, noted in Vauxhall Service Bulletin 12‑045. This issue arises from frequent short trips preventing proper thermal cycling of the SCR system, leading to urea deposit buildup and MIL illumination. From 2017, revised dosing strategies and updated valve designs were introduced to reduce recurrence.
All production years 2013–2021 meet Euro 6b standards (VCA UK Type Approval #VCA/EMS/8765).
The Vauxhall ZD3 202 is a 1,997 cc inline‑four turbocharged diesel engineered for compact and mid‑size vehicles (2013–2021). It combines Bosch common‑rail injection with a single variable‑geometry turbocharger to deliver responsive low‑rpm torque and urban efficiency. Designed to meet Euro 6b emissions standards, it integrates AdBlue-based SCR technology alongside DPF and EGR for stringent NOx control.
| Parameter | Value | Source |
|---|---|---|
| Displacement | 1,997 cc | |
| Fuel type | Diesel (EN 590) | |
| Configuration | Inline‑4, DOHC, 16‑valve | |
| Aspiration | Turbocharged | |
| Bore × stroke | 83.0 mm × 92.0 mm | |
| Power output | 100 kW (136 PS) @ 3,750 rpm | |
| Torque | 320 Nm @ 1,750–2,500 rpm | |
| Fuel system | Bosch CP4.2 common‑rail (up to 2,000 bar) | |
| Emissions standard | Euro 6b | |
| Compression ratio | 16.0:1 | |
| Cooling system | Water‑cooled with electric auxiliary pump | |
| Turbocharger | Single variable‑geometry turbo (Honeywell or BorgWarner) | |
| Timing system | Chain (front‑mounted, maintenance‑free design) | |
| Oil type | DEXOS2 5W‑30 (ACEA C3) | |
| Dry weight | 148 kg |
The VGT turbo and SCR system provide strong urban torque and Euro 6 compliance but require strict adherence to 15,000 km or 12-month oil change intervals using DEXOS2 5W-30 to protect the high-pressure fuel system and turbo bearings. AdBlue must be replenished regularly (every 10,000–15,000 km) with ISO 22241-certified fluid to prevent SCR faults. Vehicles used primarily for short trips risk AdBlue crystallisation and DPF saturation; occasional highway driving is essential. Post-2017 engines include updated AdBlue dosing valves per Vauxhall SIB 12 045.
Oil Specs: Requires DEXOS2 5W-30 (ACEA C3) specification (Vauxhall Owner’s Manual). Not interchangeable with older DEXOS1 oils.
Emissions: Euro 6b compliance applies to all 2013–2021 production (VCA Type Approval #VCA/EMS/8765). SCR with AdBlue mandatory on all UK models.
Power Ratings: Measured under UN ECE R85 standards on EN 590 diesel (Vauxhall TIS Doc. V-ZD3-ENG-01).
Vauxhall Technical Information System (TIS): Docs V-ZD3-ENG-01, V-ZD3-TURBO-02, SIB 12 045
VCA Type Approval Database (VCA/EMS/8765)
UN Regulation No. 85 – Engine Power Measurement
The Vauxhall ZD3 202 was used across Vauxhall's D2XX and E2XX platforms with transverse mounting and shared with Opel and Peugeot/Citroën under the PSA/Stellantis alliance. This engine received platform-specific adaptations—revised engine mounts in the Mokka X and updated cooling ducting in the Insignia B—and from 2017 the updated AdBlue dosing strategy per TSB 12‑045, creating minor ECU interchange limits. All adaptations are documented in OEM technical bulletins.
Locate the engine code stamped on the front timing cover near the oil filler neck (Vauxhall TIS V-ZD3-ID-01). The 7th VIN digit indicates engine family ('D' for diesel). All ZD3 202 units feature a black plastic cam cover with '1.6 CDTi' or '2.0 CDTi' embossing, a variable-geometry turbo, and an AdBlue tank (typically 17L) in the boot or underbody. Critical differentiation from earlier 2.0 BiTurbo: ZD3 202 has a single turbo, SCR system with AdBlue injector, and Bosch EDC17C74 ECU. ECU part numbers beginning with '96830812' denote pre-2017 units; '96830825' and later indicate post-SIB 12 045 dosing valve revisions.
The ZD3 202's primary reliability risk is AdBlue dosing valve clogging due to urea crystallisation, with elevated incidence in urban or short-trip usage. Vauxhall internal field data from 2019 indicated recurring SCR-related warranty claims for vehicles with high short-trip ratios, while UK DVSA data shows minimal DPF-related MOT failures due to robust regeneration logic. Infrequent highway use and delayed AdBlue refills increase deposit formation, making driving pattern and fluid quality critical.
Analysis derived from Vauxhall technical bulletins (2013–2021) and UK DVSA failure statistics (2018–2024). Repair procedures should follow manufacturer guidelines.
Find answers to most commonly asked questions about VAUXHALL ZD3-202.
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