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

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 ignor… Repairs typically run $0-$0. Severity: high.

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

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 Po… Repairs typically run $250-$900. Severity: high.

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

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 t… Repairs typically run $0-$0. Severity: high.

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

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 star… Repairs typically run $1,700-$4,500. Severity: high.

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

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. Repairs typically run $550-$1,500. Severity: high.

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

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 se… Repairs typically run $150-$600. Severity: medium.

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

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 P207… Repairs typically run $50-$350. Severity: medium.

Opel · Known Issues

2005-2022 Opel Zafira Problems: 9 Known Issues

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

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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), 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), Front Suspension Control Arm Bolt Corrosion / Breakage (KBA Recall 15411R) ($0-$0 repair), 1.6 CDTi Timing Chain Tensioner Failure and Chain Stretch (B16DTH/B16DTE/B16DTL) ($1,700-$4,500 repair) and Zafira Tourer 1.6 CDTI EGR Cooler Failure ($550-$1,500 repair). Across all issues with published estimates, repair costs range from $50 to $4,500. DIY maintenance guides at au7o.io.

All 9 Known Issues

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 Movano, 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.

What you need to fix it

Only diagnosis- and fitment-reviewed repair parts are linked here.

Genuine 55485493 position-1 NOx sensor for Zafira C 1.6 B16DTH
Zafira C 1.6 B16DTH/B16DTJ, position 1, chassis F1000001-F1999999 or F2000001-F2999999, OE 55485493. Supply VIN; not the D16 branch.
Vauxcentre
Genuine 55485442 position-2 NOx sensor for Zafira C 1.6 B16DTH
Zafira C 1.6 B16DTH/B16DTJ, position 2, chassis F1000001-F1999999 or F2000001-F2999999, OE 55485442. Supply VIN; not the D16 branch.
Vauxcentre
Genuine 55598161 position-1 NOx sensor for Zafira C 2.0 diesel
Supply VIN and confirm engine/position.
Vauxcentre
OE 55598169 position-2 NOx sensor for Zafira C 2.0 B20DTH
Confirm VIN, engine and current supersession; do not infer D20 fitment without EPC confirmation.
Neo Brothers

As an Amazon Associate, we earn from qualifying purchases; other part links may also earn au7o a commission. Confirm fitment by VIN before buying.

Typical repair cost:$200 - $600

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High ConfidenceVerifiedReviewed Jun 2026

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), Steering Column Intermediate Shaft Loose Press-Fit (Safety Recall R/2010/032), Electric Power Steering (Delphi EPS) Column Unit Failure. 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 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) and 1.6 CDTi Timing Chain Tensioner Failure and Chain Stretch (B16DTH/B16DTE/B16DTL) and Zafira Tourer 1.6 CDTI EGR Cooler Failure. 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. 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

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

Electric Power Steering (Delphi EPS) Column Unit Failure#

1.6 CDTi Timing Chain Tensioner Failure and Chain Stretch (B16DTH/B16DTE/B16DTL)#

1.9 CDTi Swirl Flap (Drallklappen) Linkage Failure (Z19DTH/Z19DT)#

Zafira Tourer 1.6 CDTI EGR Cooler Failure#

1.8 Petrol (Z18XER/A18XER) Coolant Leaks and Water Pump Failure#

Zafira B Fire Risk — HVAC Blower Resistor (2015-2016 Recall)#

Front Suspension Control Arm Bolt Corrosion / Breakage (KBA Recall 15411R)#

NOx Sensor / SCR System Failure on Euro 6 Diesels (Zafira Tourer C)#

Other Opel Models