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Opel · Known Issues

2019 Opel Zafira Problems: 3 Known Issues

2019 model year · NHTSA recalls, manufacturer TSBs, and owner forum reports · Updated September 2026

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Issue summary

According to Au7o's research across NHTSA recalls, manufacturer TSBs, and owner forum reports, the 2019 Opel Zafira has 3 documented known issues, with 2 rated critical. The most serious are Zafira Tourer 1.6 CDTI EGR Cooler Failure ($550-$1,500 repair) and 1.6 CDTi Timing Chain Tensioner Failure and Chain Stretch (B16DTH/B16DTE/B16DTL) ($1,700-$4,500 repair). Across all issues with published estimates, repair costs range from $200 to $4,500. DIY maintenance guides at au7o.io.

In This Article

  • Zafira Cooling1
  • Zafira Engine1
  • Zafira Emissions1
  • FAQ
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In This Article

  • Cooling1
  • Engine1
  • Emissions1
  • FAQ

All 3 Known Issues

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On the 2013-2019 Opel Zafira 1.6 CDTI (B16DTH "Whisper Diesel"), the B16DTH "Whisper Diesel" 1.6 CDTI in Zafira Tourer (and shared Astra J/K) suffers EGR cooler failure with similar symptoms to the 2.0 CDTI: coolant disappearing, white smoke, and sweet smell. Typical onset 80,000-150,000 km.

This issue also affects: Opel Astra, Opel Insignia, Opel Combo

Common Symptoms

  • coolant loss
  • white smoke
  • sweet smell
  • sluggish performance

How to Fix

EGR cooler assembly replacement €550-€1,100. Check for coolant in oil (head gasket damage from hydrolock attempts). Use only Dex-Cool-compatible coolant (G12++) — mixed coolants accelerate failure.

What you need to fix it

Only diagnosis- and fitment-reviewed repair parts are linked here.

  • Genuine Opel 55509027 EGR cooler assembly for Zafira C 1.6 CDTI

    Confirm VIN/engine; alternate D16/B16 variants require seller/EPC confirmation.

    J&D van den Bosch

As an Amazon Associate, we earn from qualifying purchases; other part links may also earn au7o a commission. Confirm fitment by VIN before buying.

Typical repair cost:$550 - $1,500

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Manually Verified
Medium Confidence

On the 2014-2019 Opel Zafira, the 'whisper diesel' 1.6 CDTi engines fitted to the Zafira Tourer C suffer a well-documented timing chain failure. The original chain tensioner lacks a gasket, so oil drains out of the tensioner when the engine is switched off. This produces a metallic rattle/ticking on cold start (typically 2-5 seconds) as the chain runs slack before oil pressure builds. Over time the chain stretches, the plastic guides wear, and in severe cases the chain can jump timing or snap, causing pistons to contact valves and destroying the engine. Failures are commonly reported well before 100,000 miles. The chain is at the rear of the engine (gearbox side), making it a labour-intensive repair.

This issue also affects: Opel Astra, Opel Combo, Opel Corsa

Common Symptoms

  • Metallic rattle or ticking on cold start
  • Rattle from gearbox end of engine
  • Reduced power and acceleration
  • Engine misfire / rough running
  • Check engine light
  • Poor fuel economy

How to Fix

Replace the timing chain, both sprockets, guides and the uprated/gasketed tensioner as a kit (10-12 hours labour, often requiring engine/gearbox separation). Catch it early at the first cold-start rattle. Frequent oil changes with the correct dexos2 spec oil at 6,000-9,000 mile intervals slow chain wear. If the chain has already snapped, expect a full engine rebuild or replacement.

What you need to fix it

Only diagnosis- and fitment-reviewed repair parts are linked here.

  • GTAutomotive GTCK207 full 1.6 CDTI timing-chain kit

    Confirm VIN, transmission, OE numbers and sealed tensioner revision.

    GTAutomotive Parts

As an Amazon Associate, we earn from qualifying purchases; other part links may also earn au7o a commission. Confirm fitment by VIN before buying.

Typical repair cost:$1,700 - $4,500

Research This Issue

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Community Reported
High ConfidenceVerifiedReviewed Jun 2026

On the 2015-2019 Opel Zafira, euro 6 diesel Zafira Tourer C models with SCR/AdBlue (1.6 CDTi B16DTH and 2.0 CDTi B20DTH/D20DTH) commonly suffer NOx sensor failure. The upstream/downstream NOx sensors degrade and report implausible values, setting catalyst-efficiency and NOx-sensor codes (e.g. P20EE, P229F, P118B) and putting the car into reduced power / limp mode with an emissions warning and a restart countdown in some cases. German owners (motor-talk.de) report this as a known fault from around 80,000 km. NOx sensors are relatively expensive genuine parts and often fail again if cheap aftermarket units are used.

This issue also affects: Opel Grandland, Opel Movano, Opel Combo

Common Symptoms

  • Engine warning / emissions light
  • Reduced power / limp mode
  • Restart-limit or AdBlue countdown warning
  • Stored NOx/SCR fault codes

How to Fix

Diagnose with a scan tool to identify which NOx sensor (position 1 upstream or position 2 downstream) and confirm the SCR catalyst is functioning. Replace the failed NOx sensor with an OE-quality part and clear codes. Verify AdBlue/DEF quality and dosing, and rule out a genuinely degraded SCR catalyst before condemning the sensor.

What you need to fix it

Only diagnosis- and fitment-reviewed repair parts are linked here.

  • Genuine 55485493 position-1 NOx sensor for Zafira C 1.6 B16DTH

    Zafira C 1.6 B16DTH/B16DTJ, position 1, chassis F1000001-F1999999 or F2000001-F2999999, OE 55485493. Supply VIN; not the D16 branch.

    Vauxcentre
  • Genuine 55485442 position-2 NOx sensor for Zafira C 1.6 B16DTH

    Zafira C 1.6 B16DTH/B16DTJ, position 2, chassis F1000001-F1999999 or F2000001-F2999999, OE 55485442. Supply VIN; not the D16 branch.

    Vauxcentre
  • Genuine 55598161 position-1 NOx sensor for Zafira C 2.0 diesel

    Supply VIN and confirm engine/position.

    Vauxcentre
  • OE 55598169 position-2 NOx sensor for Zafira C 2.0 B20DTH

    Confirm VIN, engine and current supersession; do not infer D20 fitment without EPC confirmation.

    Neo Brothers

As an Amazon Associate, we earn from qualifying purchases; other part links may also earn au7o a commission. Confirm fitment by VIN before buying.

Typical repair cost:$200 - $600

Research This Issue

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Community Reported
High ConfidenceVerifiedReviewed Jun 2026
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Other Opel Models

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Frequently Asked Questions

What are the most common Opel Zafira problems?

According to Au7o's research across NHTSA recalls, manufacturer TSBs, and owner forum reports, the 2019 Opel Zafira has 3 documented issues. The most frequently reported are: Zafira Tourer 1.6 CDTI EGR Cooler Failure, 1.6 CDTi Timing Chain Tensioner Failure and Chain Stretch (B16DTH/B16DTE/B16DTL), NOx Sensor / SCR System Failure on Euro 6 Diesels (Zafira Tourer C). Of these, 2 are rated critical and should be addressed promptly.

Is the Opel Zafira reliable?

The 2019 Opel Zafira has 3 known issues compiled from NHTSA recalls, manufacturer TSBs, and owner forum reports. 2 issues are rated critical: Zafira Tourer 1.6 CDTI EGR Cooler Failure and 1.6 CDTi Timing Chain Tensioner Failure and Chain Stretch (B16DTH/B16DTE/B16DTL). Prospective buyers should inspect for these issues and factor potential repair costs into their purchase decision. Regular maintenance following the manufacturer's schedule helps prevent many common problems.

How much does it cost to fix common Opel Zafira problems?

Repair costs for known Opel Zafira issues range from $200 to $4,500, depending on the specific problem and whether you choose DIY or professional repair. The most critical issue, Zafira Tourer 1.6 CDTI EGR Cooler Failure, typically costs $550-$1,500 to repair. Au7o provides step-by-step DIY maintenance guides that can help reduce repair costs.

What is the 2013-2019 Opel Zafira Zafira Tourer 1.6 CDTI EGR Cooler Failure?

The B16DTH "Whisper Diesel" 1.6 CDTI in Zafira Tourer (and shared Astra J/K) suffers EGR cooler failure with similar symptoms to the 2.0 CDTI: coolant disappearing, white smoke, and sweet smell. Typical onset 80,000-150,000 km. Repairs typically run $550-$1,500. Severity: high.

What is the 2014-2019 Opel Zafira 1.6 CDTi Timing Chain Tensioner Failure and Chain Stretch (B16DTH/B16DTE/B16DTL)?

The 'whisper diesel' 1.6 CDTi engines fitted to the Zafira Tourer C suffer a well-documented timing chain failure. The original chain tensioner lacks a gasket, so oil drains out of the tensioner when the engine is switched off. This produces a metallic rattle/ticking on cold star… Repairs typically run $1,700-$4,500. Severity: high.

Content on this page was compiled with AI assistance using NHTSA complaints, TSBs, owner reports, and public automotive data. While we strive for accuracy, this information may contain errors. Always verify repair procedures and specifications with your vehicle's service manual or a qualified mechanic.

Data compiled from NHTSA recalls, manufacturer TSBs, automotive forums, and AI-assisted research. No aggregated owner-report counts available for this vehicle yet.

What is the 2015-2019 Opel Zafira NOx Sensor / SCR System Failure on Euro 6 Diesels (Zafira Tourer C)?

Euro 6 diesel Zafira Tourer C models with SCR/AdBlue (1.6 CDTi B16DTH and 2.0 CDTi B20DTH/D20DTH) commonly suffer NOx sensor failure. The upstream/downstream NOx sensors degrade and report implausible values, setting catalyst-efficiency and NOx-sensor codes (e.g. P20EE, P229F, P1… Repairs typically run $200-$600. Severity: medium.