Opel Zafira
Powerful 2.0 L turbo with 240 hp from the OPC. Solid engine, but high loads lead to turbocharger and clutch wear. Regular oil changes critical.
Zafira OPC
141 kW turbo in the Zafira A – the fastest family van of its time.
Engine Weaknesses 4
The turbocharger wears with spirited driving and insufficient run-down time. Bearing lubrication is critical.
Symptoms: Whistling noise, blue smoke, power loss, rising oil consumption.
At high mileage and with spirited use, piston rings wear. Oil consumption above 1 L/1,000 km is possible.
Symptoms: High oil consumption, blue smoke when accelerating, oil-fouled spark plugs.
The high torque of 320 Nm puts heavy strain on the standard clutch. With spirited driving, replacement can be needed from 60,000 km.
Symptoms: Clutch slips under full throttle, bite point rises, burning smell.
Silicone intercooler hoses become brittle and burst under full load. Immediate power loss.
Symptoms: Sudden power loss, hissing sound from engine bay, limp mode.
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.
