Opel Zafira
Powerful 2.0-litre diesel with good long-distance characteristics, but characteristic weak points in the oil supply and emissions system. The oil suction pipe seal is the best-known and sometimes critical issue. With regular maintenance and primarily motorway use a reliable unit – short-trip use should be avoided due to DPF problems.
Zafira diesel standard
121 kW in the Zafira Tourer – decent engine for the van.
Engine Weaknesses 4
The seal on the oil suction pipe to the oil pump hardens over time and draws in false air. This results in low oil pressure which causes the engine to shut down. Affects nearly all A20DTH at higher mileage.
Symptoms: Warning 'Oil pressure low — switch off engine' especially on cold start or after long standstill, engine shutdown by protection system.
The EGR valve and intake manifold carbon up with typical diesel use on frequent short trips. After the emissions scandal software update the problem worsens due to increased EGR rate.
Symptoms: Power loss, misfires at mid rpm, increased fuel consumption, black smoke on acceleration, engine management light.
With frequent short-trip driving the DPF cannot complete full regeneration. The filter permanently clogs and must be cleaned or replaced.
Symptoms: Warning 'Particulate filter full', persistent warning despite motorway driving, increased fuel consumption, power loss.
The KBA ordered a mandatory recall in 2020: the A20DTH contained an illegal defeat device. Software update required. After the update, increased EGR carbon deposits may occur.
Vehicle Weaknesses 16
Tie rod end not sufficiently tightened to the steering knuckle. In the worst case, severely reduced steering control.
Suspension springs cannot cope with the high kerb weight and full 7-person loading. Broken springs lead to MOT failures.
Rear axle rubber bushings wear out and become loose. MOT inspectors flag this as excessive play in suspension arms. Wheel alignment is required after replacement.
Software fault can cause the hill-start assist and electric parking brake to operate incorrectly, potentially leading to uncontrolled rolling.
Suspension springs break after just a few years, especially on the front axle. Frequent MOT failures.
Air conditioning frequently develops leaks and loses refrigerant. Complete loss of cooling performance.
The Radio-Nav900 system powers itself down and restarts at regular intervals. Cause is a temperature problem in the unit.
The 6-speed M32 manual gearbox does not always shift cleanly, especially when cold. Bearings and synchro rings wear at higher mileages.
The heated seats on the driver and passenger side fail — a well-documented issue confirmed in multiple forums.
Brake discs and pads wear above average. Frequent MOT complaints.
Headlights and tail lights malfunction. Frequent MOT complaints even after just three years.
On the Zafira Tourer, seam sealant between roof and pillar tears open, allowing water to enter the A-pillar and interior.
The Zafira Tourer develops rust on lower door edges and rear wheel arches from around 6–8 years old. Sill rust starts at the door seal recess.
On the Zafira Tourer, the plastic coolant expansion tank cracks at pressure points and hose outlets. Slow coolant loss often goes unnoticed.
The Zafira Tourer's centre and rear silencers rust through quickly with frequent short-trip use. Leaks lead to increased noise.
In the Zafira Tourer, headlining fixings (only hook-and-loop tape) come loose and creak with temperature changes. Dashboard trim panels also vibrate.
Reports & Tests
Oil loss from engine and gearbox is the most common reason for failing the MOT. Axle springs fail earlier than usual under the higher vehicle weight. Compared to its predecessor, clear quality improvements in suspension and electronics.
