Opel Zafira
Isuzu-derived 2.2-litre direct-injection diesel with VP44 injection pump. Fundamentally a solid unit that achieves high mileage with maintenance. The biggest weakness is the injection pump, whose failure becomes very costly.
Zafira diesel top
92 kW diesel in the Zafira A – muscular van diesel.
Engine Weaknesses 8
The VP44 injection pump is the most costly weak point. Failure is heralded by starting difficulties. New pump 1,000–2,200 EUR, workshop up to 2,950 EUR. Older pumps (1 connector) are repairable.
Symptoms: Engine cranks but will not start; power drop, juddering; fault code P1634
The VP44 injection pump on the Y22DTR (PSG16 with integrated control unit) fails from around 150,000 km. Repair costs at Opel dealers up to 2,200 EUR, new parts cheaper at 1,000–1,200 EUR. Vehicles from 1999–2001 particularly affected.
Symptoms: Engine will not restart after stalling, intermittent cutting out, power loss, no throttle response, fault code P0340 (no camshaft sensor present).
The VTG turbocharger on the Y22DTR is prone to sticking vanes from soot deposits, causing sudden power loss and limp mode. Cleaning or replacement required.
Symptoms: Sudden power loss under acceleration, engine enters limp mode, barometric pressure fault code in ECU.
The timing chain on the Y22DTR stretches at higher mileages and produces rattling noises. Engines built before March 2002 are particularly affected. Repair approx. 1,100–2,300 EUR.
Symptoms: Rattling and clattering on cold start, loud chain noise, engine warning light with severe chain stretch.
O-ring seals on the turbocharger outlet hose and faulty boost pressure control valves cause boost pressure loss. Engine enters limp mode. Fault code P0234.
Symptoms: Power loss, limp mode, fault code P0234, whistling noise from engine bay
The boost pressure solenoid (wastegate actuator) on the Y22DTR turbo wears out and loses pressure regulation. Fault code P0234-04. Engine runs lean, turbo does not spool correctly. Replacement of the boost solenoid costs 100–300 EUR.
Symptoms: Noticeably reduced turbo response, power drop especially under load, fault code P0234 (boost pressure solenoid circuit open).
On the Y22DTR in the Vectra C/Signum variant with F35 gearbox, a dual mass flywheel is fitted. It wears from around 150,000 km and should be replaced together with the clutch. Replacement: 700–1,500 EUR.
Symptoms: Vibrations and rattling on start-up and gear changes, rough idle with shaking, clutch slip, deteriorated pull-away.
The water-cooled EGR valve clogs with soot deposits, especially in short-trip use. Cleaning is often sufficient and takes about 5 minutes.
Symptoms: Juddering at low revs, power loss, increased fuel consumption, engine warning light
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.
