Opel Zafira
Solid naturally aspirated engine with good refinement, but known weaknesses in the timing chain drive. Examples before engine number 11065400 (March 2002) have an inadequately lubricated primary chain. Piston rings with insufficient tangential tension lead to elevated oil consumption.
Zafira top engine
108 kW in the Zafira A – well powered for the van.
Engine Weaknesses 7
The guide rail retaining bolt in the cylinder head can come loose or break, causing chain slap. In the worst case, a cylinder head replacement is needed. Engines before no. 11065400 (up to March 2002) are particularly affected.
Symptoms: Rattling or clattering noises in the timing chain area, especially on cold start; in advanced stages misfires and engine warning light
The secondary chain for the balance shafts can fail together with the chain tensioner. A break leads to severe engine vibrations and secondary damage. A complete chain replacement always includes both chain sets.
Symptoms: Strong irregular vibrations, metallic clattering from engine bay; sudden severe power loss when chain breaks
Engines in the serial number range 11300883–11378500 were produced with piston rings whose tangential preload was outside specification. The rings lose radial force prematurely; oil consumption up to 0.5–1 L/1,000 km.
Symptoms: Blue smoke from exhaust at higher revs; strong airflow from the oil dipstick with the engine running indicates piston rings
The ignition control module on the Z22SE is sensitive to heat and can fail when it gets hot. The engine then will not start or runs rough. Replacing the module resolves the problem permanently.
Symptoms: Engine will not start or starts with a delay, intermittent misfires at operating temperature
The plastic coolant expansion tank on the Z22SE tends to crack at higher mileages. Excessive coolant loss can lead to overheating. Regular visual inspection recommended.
Symptoms: Dropping coolant level, visible cracks or moisture on reservoir, temperature rise
The thermostat tends to stick or open with a delay at higher mileages, causing fluctuating operating temperatures. On the motorway in particular, temperature swings of 10–15 °C are visible.
Symptoms: Temperature gauge fluctuating between 80 °C and 100 °C; engine does not reach normal operating temperature at high speed
The Z22SE has no conventional camshaft sensor; its function is taken over by the ignition module. Faulty connectors or a worn ignition module trigger fault code P0340. Checking the cable connections is often sufficient.
Symptoms: Rough idle, misfires, engine warning light with fault code P0340; engine hard to start or briefly will not start
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.
