Opel Zafira
Early 2.0 L common-rail diesel. Solid basic design, but EGR valve and injectors are weak points. Check dual-mass flywheel at high mileage.
Zafira diesel standard
74 kW in the Zafira A – acceptable engine for the van.
Engine Weaknesses 4
Bosch injectors leak at the copper sealing rings or internally. Diesel smell and rough running are the result.
Symptoms: Diesel smell in engine bay, rough cold start, black smoke, knocking.
The dual mass flywheel wears from the diesel-typical torsional vibrations. In extreme cases it locks up the clutch.
Symptoms: Rattling at idle, vibrations when pulling away, shuddering on clutch engagement.
The variable vanes in the turbocharger stick together through soot deposits. Turbo fails to build pressure.
Symptoms: Power loss, turbo no longer spools up, limp mode, boost pressure fault code.
The EGR valve clogs with soot, especially in short-trip use. Engine enters limp mode.
Symptoms: Power loss, black smoke, engine warning light, rough idle.
Vehicle Weaknesses 12
The front subframe rusts through at weld seams and control arm mounts. Engine undershield retains moisture, accelerating corrosion. In advanced stages the vehicle is no longer MOT-worthy.
Ball joints and track rod ends wear prematurely on the Zafira A and are regularly flagged at the MOT. Shock absorbers tend to bottom out under full load and become leaky.
The rear Bosch and Lucas brake calipers of the Zafira A seize in cold and damp conditions. Piston retraction no longer functions; brake discs overheat and fuel consumption rises.
Early Zafira A models suffer from defective ABS sensors that trigger the ABS warning light and deactivate the system. This problem was resolved on later build years. On older vehicles sensors should be checked on purchase.
ABS sensors corrode and fail. ABS and ESP are disabled.
The rear electric window regulators of the Zafira A fail. Common causes are cable breaks in the rubber grommet to the rear door and defective switches or motors. Inexpensive to repair.
The innovative Flex7 seating system of the Zafira A, which folds the rear seats into the floor, sticks with increasing use. Plastic latches break and cables snap.
The innovative Flex7 seating system wears mechanically; seats can no longer be folded or latched.
The blower pre-resistor of the Zafira A fails regularly. The blower can then only be operated at the highest speed; all lower speeds are non-functional.
The steering rack seals of the Zafira A become porous from approx. 100,000 km. Power steering fluid leaks; steering becomes heavy.
On the Zafira A the sunroof and AC drains block regularly. When water backs up, it enters the front footwell.
The plastic expansion tank of the Zafira A develops hairline cracks with age and loses coolant. Gradual loss without visible puddle.
