2010 Opel Zafira Problems: 5 Known Issues

On the 2009-2010 Opel Zafira, zafira B vehicles built between 16 November 2009 and 24 March 2010 were recalled because the steering column intermediate shaft can have a loose press fit on the upper joint yoke. Over time this develops increasing free play and a knocking noise from the steering column; if ignored, it can ultimately lead to loss of steering control. Approximately 8,854 UK cars were affected under DVSA recall R/2010/032 (launched May 2010). This is a separate, later steering recall to the earlier steering-wheel-controls campaign.

On the 2005-2014 Opel Zafira, zafira B models use an electro-hydraulic power steering pump (an electric motor and control unit driving a hydraulic pump, made by TRW or ZF) and commonly lose power assistance, often in both directions. Moisture getting past worn seals into the pump housing can damage the control electronics or motor winding, and long periods at full lock overload the motor. The fault frequently starts intermittently — assistance cuts out briefly then returns — before becoming permanent, leaving the steering very heavy and hard to turn. This is a recognised failure of the electric pump motor/control unit rather than the steering rack.

On the 2005-2014 Opel Zafira all, official DVSA bulletin NCA/2015/026 covers right-hand-drive Vauxhall Zafira B model years 2005-2014 and states that an overheated heater-fan resistor can create a fire risk if the failed thermal fuse is manipulated or bypassed. Vauxhall then issued a second safety recall, 16-C-050, for Zafira B vehicles with manual air conditioning or without air conditioning, including vehicles already repaired under 15-C-097, because the resistor could degrade under specific circumstances and lead to fire.

On the 2005-2014 Opel Zafira, the 1.8 16V petrol engine (Z18XER, later A18XER) in the Zafira B is prone to coolant leaks. The water pump seal fails and weeps coolant from the pump pulley area (sometimes spraying onto the air-con compressor), and the plastic coolant pipes/housings and ageing hoses crack and seep. Owners also report the oil cooler/cooler seal weeping. If unnoticed the car loses coolant and can overheat. Note this engine is timing-BELT driven (not chain), so the belt and tensioner/water pump should be serviced together to avoid belt failure causing valve damage.

On the 2005-2014 Opel Zafira 1.9 CDTi Z19DTH, the 16-valve 1.9 CDTi engine (Z19DTH) in the Zafira B uses intake-manifold swirl flaps controlled by a plastic actuator linkage. The linkage rod and bushings wear or break, so the flaps no longer move correctly, triggering limp mode and stored fault codes P2279 (intake air system leak) and/or P2075 (intake manifold runner position sensor/switch). German owners (motor-talk.de, zafira-forum.de) report this commonly around 90,000-150,000 km, often alongside EGR and DPF clogging on the same engine. Left unrepaired, a flap can break off and be ingested by the engine.