Opel · Known Issues

2005-2022 Opel Zafira Problems: 9 Issues Every Owner Should Know

2005-2022 model years · NHTSA recalls, manufacturer TSBs, and owner forum reports · Updated June 2026

According to Au7o's research across NHTSA recalls, manufacturer TSBs, and owner forum reports, the 2005-2022 Opel Zafira has 9 documented known issues, with 6 rated critical. The most serious are Zafira B Fire Risk — HVAC Blower Resistor (2015-2016 Recall) ($0-$0 repair), Zafira Tourer 1.6 CDTI EGR Cooler Failure ($550-$1,500 repair), 1.6 CDTi Timing Chain Tensioner Failure and Chain Stretch (B16DTH/B16DTE/B16DTL) ($1,700-$4,500 repair), Steering Column Intermediate Shaft Loose Press-Fit (Safety Recall R/2010/032) ($0-$0 repair), Electric Power Steering (Delphi EPS) Column Unit Failure ($250-$900 repair) and Front Suspension Control Arm Bolt Corrosion / Breakage (KBA Recall 15411R) ($0-$0 repair). Across all issues, repair costs range from $50 to $4,500. DIY maintenance guides at au7o.io.

All 9 Known Issues

On the 2009-2010 Opel Zafira, zafira B vehicles built between 16 November 2009 and 24 March 2010 were recalled because the steering column intermediate shaft can have a loose press fit on the upper joint yoke. Over time this develops increasing free play and a knocking noise from the steering column; if ignored, it can ultimately lead to loss of steering control. Approximately 8,854 UK cars were affected under DVSA recall R/2010/032 (launched May 2010). This is a separate, later steering recall to the earlier steering-wheel-controls campaign.

Common Symptoms

Knocking noise from steering column
Increased free play in steering
Loose / vague steering feel
Risk of loss of steering control

How to Fix

Have a new intermediate steering shaft fitted under the manufacturer recall (free of charge). Check the recall status by VIN with an Opel/Vauxhall dealer; any car with knocking or play in the column from this build window should be inspected before further driving.

Typical repair cost:$0 - $0

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On the 2005-2014 Opel Zafira, zafira B models fitted with the Delphi/GM electric power steering (EPS) column-mounted unit commonly lose power assistance, often in both directions. The torque/position sensor inside the column-integrated EPS motor unit degrades, and the system stores fault code C1500 (Torque Position Sensor). The fault frequently starts intermittently — assistance cuts out briefly then returns — before becoming permanent, leaving the steering very heavy and hard to turn. This is a recognised failure of the EPS control unit/sensor rather than a hydraulic pump or fluid issue.

Common Symptoms

Loss of power steering assistance
Heavy / hard steering in both directions
Intermittent loss of assist that later becomes permanent
Power steering warning light
Steering fault stored in module

How to Fix

Diagnose via stored code (C1500). The EPS column unit can be remanufactured/repaired (sensor and electronics rebuilt) by specialists at lower cost than a new genuine unit, or replaced with a new column. Reset/relearn the steering angle sensor after fitment. Check connector and wiring integrity first, as poor connections can mimic the fault.

Typical repair cost:$250 - $900

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On the 2013-2019 Opel Zafira 1.6 CDTI (B16DTH "Whisper Diesel"), the B16DTH "Whisper Diesel" 1.6 CDTI in Zafira Tourer (and shared Astra J/K) suffers EGR cooler failure with similar symptoms to the 2.0 CDTI: coolant disappearing, white smoke, and sweet smell. Typical onset 80,000-150,000 km.

This issue also affects: Opel Astra, Opel Insignia, Opel Combo

Common Symptoms

coolant loss
white smoke
sweet smell
sluggish performance

How to Fix

EGR cooler assembly replacement €550-€1,100. Check for coolant in oil (head gasket damage from hydrolock attempts). Use only Dex-Cool-compatible coolant (G12++) — mixed coolants accelerate failure.

Typical repair cost:$550 - $1,500

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Manually Verified

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On the 2005-2014 Opel Zafira, the 1.8 16V petrol engine (Z18XER, later A18XER) in the Zafira B is prone to coolant leaks. The water pump seal fails and weeps coolant from the pump pulley area (sometimes spraying onto the air-con compressor), and the plastic coolant pipes/housings and ageing hoses crack and seep. Owners also report the oil cooler/cooler seal weeping. If unnoticed the car loses coolant and can overheat. Note this engine is timing-BELT driven (not chain), so the belt and tensioner/water pump should be serviced together to avoid belt failure causing valve damage.

Common Symptoms

Coolant leak under car / low coolant level
Coolant spray around water pump pulley
Sweet coolant smell
Engine overheating
Visible weeping from plastic coolant pipes

How to Fix

Pressure-test the cooling system to pinpoint the leak. Replace the water pump (ideally with the timing belt and tensioner as a combined job, ~every 60k miles / belt interval), and renew cracked plastic coolant pipes, the thermostat housing and any perished hoses. Inspect the oil cooler seal. Use the correct long-life coolant.

Typical repair cost:$150 - $600

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On the 2014-2019 Opel Zafira, the 'whisper diesel' 1.6 CDTi engines fitted to the Zafira Tourer C suffer a well-documented timing chain failure. The original chain tensioner lacks a gasket, so oil drains out of the tensioner when the engine is switched off. This produces a metallic rattle/ticking on cold start (typically 2-5 seconds) as the chain runs slack before oil pressure builds. Over time the chain stretches, the plastic guides wear, and in severe cases the chain can jump timing or snap, causing pistons to contact valves and destroying the engine. Failures are commonly reported well before 100,000 miles. The chain is at the rear of the engine (gearbox side), making it a labour-intensive repair.

This issue also affects: Opel Astra, Opel Combo, Opel Corsa

Common Symptoms

Metallic rattle or ticking on cold start
Rattle from gearbox end of engine
Reduced power and acceleration
Engine misfire / rough running
Check engine light
Poor fuel economy

How to Fix

Replace the timing chain, both sprockets, guides and the uprated/gasketed tensioner as a kit (10-12 hours labour, often requiring engine/gearbox separation). Catch it early at the first cold-start rattle. Frequent oil changes with the correct dexos2 spec oil at 6,000-9,000 mile intervals slow chain wear. If the chain has already snapped, expect a full engine rebuild or replacement.

Typical repair cost:$1,700 - $4,500

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On the 2005-2014 Opel Zafira, the 1.9 CDTi engines in the Zafira B use intake-manifold swirl flaps controlled by a plastic actuator linkage. The linkage rod and bushings wear or break, so the flaps no longer move correctly, triggering limp mode and stored fault codes P2279 (intake air system leak) and/or P2075 (intake manifold runner position sensor/switch). German owners (motor-talk.de, zafira-forum.de) report this commonly around 90,000-150,000 km, often alongside EGR and DPF clogging on the same engine. Left unrepaired, a flap can break off and be ingested by the engine.

Common Symptoms

Limp mode / reduced power
Check engine light
Hesitation under acceleration
Rough running
Increased exhaust smoke

How to Fix

Fit a swirl flap linkage repair kit (replacement rod, bushings and clips) — a low-cost fix that restores flap movement; clear codes afterwards. Some owners delete/blank the swirl flaps where legal. Inspect and clean the EGR valve and intake at the same time, as carbon build-up worsens the problem.

Typical repair cost:$50 - $350

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On the 2005-2014 Opel Zafira all, vauxhall/Opel issued a major safety recall in 2015-2016 for Zafira B (Mk2, 2005-2014) after dozens of vehicles caught fire. The blower-motor resistor pre-resistor and associated wiring could overheat and ignite. Many owners reported repeat fires after the initial recall fix; a second improved recall followed.

This issue also affects: Buick Enclave, Lincoln Continental, Lincoln Navigator

Common Symptoms

burning smell from vents
blower fault
cabin fire

How to Fix

Check VIN against Vauxhall/Opel recall database — both R/2015/116 and the follow-up action. If unsure whether your car has had BOTH fixes, request paperwork. Do not run the blower on continuous high if recall status is unknown.

Typical repair cost:$0 - $0

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Manually Verified

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On the 2020-2022 Opel Zafira, later Zafira Tourer/Life models (and related Vivaro vans on the same platform) built between 23 September 2020 and 30 June 2022 were recalled because corrosion of the front suspension control-arm bushing area can cause the control-arm mounting bolt to break. A broken bolt leads to sudden unpredictable handling and potential loss of vehicle control. Around 76,778 vehicles were covered by the German KBA campaign (references 15411R/15414R/15415R).

Common Symptoms

Front-end clunk or knock
Unpredictable handling
Risk of control arm detaching
Recall notice issued

How to Fix

Under the recall, an authorised workshop replaces the screws/bolts and bushings on both sides of the front control arms. Owners should check recall status by VIN and have the work done before further driving if a clunk or handling change is noticed at the front.

Typical repair cost:$0 - $0

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On the 2015-2019 Opel Zafira, euro 6 diesel Zafira Tourer C models with SCR/AdBlue (1.6 CDTi B16DTH and 2.0 CDTi B20DTH/D20DTH) commonly suffer NOx sensor failure. The upstream/downstream NOx sensors degrade and report implausible values, setting catalyst-efficiency and NOx-sensor codes (e.g. P20EE, P229F, P118B) and putting the car into reduced power / limp mode with an emissions warning and a restart countdown in some cases. German owners (motor-talk.de) report this as a known fault from around 80,000 km. NOx sensors are relatively expensive genuine parts and often fail again if cheap aftermarket units are used.

This issue also affects: Opel Grandland, Opel Combo

Common Symptoms

Engine warning / emissions light
Reduced power / limp mode
Restart-limit or AdBlue countdown warning
Stored NOx/SCR fault codes

How to Fix

Diagnose with a scan tool to identify which NOx sensor (position 1 upstream or position 2 downstream) and confirm the SCR catalyst is functioning. Replace the failed NOx sensor with an OE-quality part and clear codes. Verify AdBlue/DEF quality and dosing, and rule out a genuinely degraded SCR catalyst before condemning the sensor.

Typical repair cost:$200 - $600

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Frequently Asked Questions

What are the most common Opel Zafira problems?

According to Au7o's research across NHTSA recalls, manufacturer TSBs, and owner forum reports, the 2005-2022 Opel Zafira has 9 documented issues. The most frequently reported are: Zafira B Fire Risk — HVAC Blower Resistor (2015-2016 Recall), Zafira Tourer 1.6 CDTI EGR Cooler Failure, 1.6 CDTi Timing Chain Tensioner Failure and Chain Stretch (B16DTH/B16DTE/B16DTL). Of these, 6 are rated critical and should be addressed promptly.

Is the Opel Zafira reliable?

The 2005-2022 Opel Zafira has 9 known issues compiled from NHTSA recalls, manufacturer TSBs, and owner forum reports. 6 issues are rated critical: Zafira B Fire Risk — HVAC Blower Resistor (2015-2016 Recall) and Zafira Tourer 1.6 CDTI EGR Cooler Failure and 1.6 CDTi Timing Chain Tensioner Failure and Chain Stretch (B16DTH/B16DTE/B16DTL) and Steering Column Intermediate Shaft Loose Press-Fit (Safety Recall R/2010/032) and Electric Power Steering (Delphi EPS) Column Unit Failure and Front Suspension Control Arm Bolt Corrosion / Breakage (KBA Recall 15411R). Prospective buyers should inspect for these issues and factor potential repair costs into their purchase decision. Regular maintenance following the manufacturer's schedule helps prevent many common problems.

How much does it cost to fix common Opel Zafira problems?

Repair costs for known Opel Zafira issues range from $0 to $4,500, depending on the specific problem and whether you choose DIY or professional repair. The most critical issue, Zafira B Fire Risk — HVAC Blower Resistor (2015-2016 Recall), typically costs $0-$0 to repair. Au7o provides step-by-step DIY maintenance guides that can help reduce repair costs.

What year Opel Zafira is the most reliable?

Reliability varies across model years of the Opel Zafira. Based on documented issues, problems are most commonly reported in earlier model years. Au7o recommends checking the specific known issues for your target year before purchasing, and having a pre-purchase inspection performed by a qualified mechanic. Our known issues database covers the 2005-2022 Opel Zafira with 9 documented issues compiled from NHTSA recalls, manufacturer TSBs, and owner forum reports.

All 9 Known Issues

2009-2010 Opel Zafira: Steering Column Intermediate Shaft Loose Press-Fit (Safety Recall R/2010/032)#

Common Symptoms

How to Fix

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2005-2014 Opel Zafira: Electric Power Steering (Delphi EPS) Column Unit Failure#

Common Symptoms

How to Fix

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2013-2019 Opel Zafira: Zafira Tourer 1.6 CDTI EGR Cooler Failure#

Common Symptoms

How to Fix

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2005-2014 Opel Zafira: 1.8 Petrol (Z18XER/A18XER) Coolant Leaks and Water Pump Failure#

Common Symptoms

How to Fix

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2014-2019 Opel Zafira: 1.6 CDTi Timing Chain Tensioner Failure and Chain Stretch (B16DTH/B16DTE/B16DTL)#

Common Symptoms

How to Fix

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2005-2014 Opel Zafira: 1.9 CDTi Swirl Flap (Drallklappen) Linkage Failure (Z19DTH/Z19DT)#

Common Symptoms

How to Fix

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2005-2014 Opel Zafira: Zafira B Fire Risk — HVAC Blower Resistor (2015-2016 Recall)#

Common Symptoms

How to Fix

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2020-2022 Opel Zafira: Front Suspension Control Arm Bolt Corrosion / Breakage (KBA Recall 15411R)#

Common Symptoms

How to Fix

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2015-2019 Opel Zafira: NOx Sensor / SCR System Failure on Euro 6 Diesels (Zafira Tourer C)#

Common Symptoms

How to Fix

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Frequently Asked Questions

What are the most common Opel Zafira problems?

Is the Opel Zafira reliable?

How much does it cost to fix common Opel Zafira problems?

What year Opel Zafira is the most reliable?

What is the 2005-2014 Opel Zafira Zafira B Fire Risk — HVAC Blower Resistor (2015-2016 Recall)?

What is the 2013-2019 Opel Zafira Zafira Tourer 1.6 CDTI EGR Cooler Failure?

What is the 2014-2019 Opel Zafira 1.6 CDTi Timing Chain Tensioner Failure and Chain Stretch (B16DTH/B16DTE/B16DTL)?

What is the 2009-2010 Opel Zafira Steering Column Intermediate Shaft Loose Press-Fit (Safety Recall R/2010/032)?

What is the 2005-2014 Opel Zafira Electric Power Steering (Delphi EPS) Column Unit Failure?

What is the 2020-2022 Opel Zafira Front Suspension Control Arm Bolt Corrosion / Breakage (KBA Recall 15411R)?

What is the 2015-2019 Opel Zafira NOx Sensor / SCR System Failure on Euro 6 Diesels (Zafira Tourer C)?

What is the 2005-2014 Opel Zafira 1.9 CDTi Swirl Flap (Drallklappen) Linkage Failure (Z19DTH/Z19DT)?

What is the 2005-2014 Opel Zafira 1.8 Petrol (Z18XER/A18XER) Coolant Leaks and Water Pump Failure?