Rear light cluster circuit board
usually 60,000–200,000 km · Wear part
Signs: Bulb failure warnings, lights flicker
Fix: Replace the lamp / board
€40–150
Common faults, service intervals and costs
Opel Zafira B
2005–2014
3
engines covered
19
known faults
147,830
roadworthiness tests in the statistics
9
official recalls
Enter your VIN and mileage and get a plan built for your exact engine and gearbox.
The Opel Zafira B was built from 2005 to 2014.
For this generation we cover 3 engines and 19 known faults, each with the mileage range where it usually appears.
The most expensive known risk is 6T40 / 6T45 3-5-R wave plate: it usually appears at 80,000–200,000 km and costs €1,200–2,500 to fix.
In UK roadworthiness tests in 2024, at 150–200 thousand km this model most often failed on: lights, wipers and visibility (24.6 %), suspension (17.4 %), brakes (11.7 %). It fails more often than an average car of the same age and mileage on: exhaust, emissions and leaks. It fails less often than average on: steering.
Engines
| Engine | Fuel | Timing drive | Oil |
|---|---|---|---|
| 1.6 / 1.8 16v Ecotec (Opel Family 1: Z16XER / Z18XER) | Petrol | Belt · 120,000 km / every 96 mo | 5W-30 · dexos2 · ~4.5 L · every 15,000 km |
| 1.9 JTD / MultiJet / CDTI / TiD (Fiat 1.9 8v / 16v) | Diesel | Belt · 120,000 km | 5W-40 / 10W-40 · Fiat 9.55535-N2 / GM-LL-B-025 · ~4.5 L · every 15,000 km |
| 1.7 CDTI / DTI / VCDi (Isuzu) | Diesel | Belt · 150,000 km / every 96 mo | 5W-30 · dexos2 / GM-LL-B-025 · ~5.4 L · every 15,000 km |
Faults typical of this model
CIM steering column module
usually 80,000–200,000 km · Medium risk
Signs: Indicators / wipers / horn stop working
Fix: Repair or replace CIM
€150–450
Front wishbone bushes
usually 80,000–160,000 km · Wear part
Signs: Knocks, pulls under braking
Fix: Replace bushes / arms
€150–350
Heater blower resistor overheating (recall)
at any mileage · High risk
Signs: Fan only on max; melted connector — fire risk
Fix: Check the recall was done (free)
free / recall
M32 6-speed manual gearbox bearings (6-speed only)
usually 100,000–220,000 km · High risk
Signs: Whine or growl in 5th / 6th gear and off throttle, gear lever vibrates or jumps out of gear
Fix: Replace the bearings (and the output shaft if worn) and fill the gearbox to the corrected oil level
€700–1,800
Faults by engine
1.6 / 1.8 16v Ecotec (Opel Family 1: Z16XER / Z18XER)
Camshaft phaser (variator) failure
usually 80,000–160,000 km · Medium risk
Signs: Rattle / diesel-like noise, P0016–P0017 codes
Fix: Replace phasers and solenoids
€400–900
Ignition module (cassette)
usually 80,000–160,000 km · Medium risk
Signs: Misfire; oil from the cam cover gasket in plug wells
Fix: Replace module and cam cover gasket
€150–400
Thermostat housing / coolant leaks
usually 80,000–160,000 km · Medium risk
Signs: Coolant loss, overheating
Fix: Replace housing
€150–350
Oil cooler housing seal (oil in coolant)
usually 100,000–200,000 km · Medium risk
Signs: Oil in the expansion tank
Fix: Replace oil cooler seals
€200–500
1.9 JTD / MultiJet / CDTI / TiD (Fiat 1.9 8v / 16v)
Swirl flaps / intake manifold (16v)
usually 100,000–180,000 km · High risk
Signs: Flaps can break and fall into the engine; engine light
Fix: Replace manifold or fit blanking kit
€250–700
EGR valve clogging
usually 100,000–180,000 km · Medium risk
Signs: Power loss, limp mode
Fix: Clean or replace EGR
€200–500
Turbo actuator / VGT sticking
usually 120,000–200,000 km · Medium risk
Signs: Overboost or underboost, limp mode
Fix: Clean or replace turbo actuator
€250–900
1.7 CDTI / DTI / VCDi (Isuzu)
Injectors (Denso) / high-pressure pump
usually 150,000–250,000 km · Medium risk
Signs: Smoke, knocking, hard start
Fix: Test and replace
€600–1,500
EGR valve / cooler
usually 100,000–200,000 km · Medium risk
Signs: Limp mode
Fix: Clean or replace
€200–700
Turbo oil seals
usually 150,000–250,000 km · Wear part
Signs: Smoke, oil use
Fix: Service the turbo
€400–900
Gearboxes
Manual
Clutch wear
usually 120,000–200,000 km · Medium risk
Signs: Slipping, high bite point
Fix: Replace clutch kit
€500–900
Easytronic (automated)
Easytronic clutch actuator / gear selector
usually 60,000–160,000 km · High risk
Signs: Won't select a gear, 'F' on the display, clutch not disengaging
Fix: Repair actuator, clutch re-learn
€400–1,200
Automatic (Aisin AF40 / GM 6T40 / 6T45)
6T40 / 6T45 3-5-R wave plate
usually 80,000–200,000 km · High risk
model years 2008–2017 only
Signs: Loss of 3rd, 5th and reverse
Fix: Replace the wave plate (gearbox rebuild)
€1,200–2,500
AF40 valve body / harsh shifts
usually 100,000–200,000 km · Medium risk
Signs: Harsh or flared shifts
Fix: Fluid change; valve body repair
€300–1,200
Scheduled service
Intervals and typical prices for the 1.6 / 1.8 16v Ecotec (Opel Family 1: Z16XER / Z18XER) engine. Other engines differ in oil, timing drive and some filters; the app gives the exact plan.
| Item | Interval | Typical price |
|---|---|---|
| Engine oil + oil filterEngine | every 15,000 km or every 12 months | €70–150 |
| Cabin (pollen) filterClimate | every 15,000 km or every 12 months | €15–40 |
| Brake fluidBrakes | every 24 months | €50–95 |
| A/C service (regas + desiccant)Climate | every 24 months | €70–150 |
| Air filterEngine | every 30,000 km or every 24 months | €15–45 |
| Spark plugsIgnition | every 60,000 km or every 48 months | €50–160 |
| Auxiliary (serpentine) beltEngine | every 120,000 km | €70–180 |
| Timing belt kit + water pumpEngine | every 120,000 km or every 96 months | €450–900 |
| Coolant replacementCooling | every 150,000 km or every 96 months | €70–150 |
| Manual gearbox oilTransmission | every 150,000 km | €60–130 |
| Front brake padsBrakes | usually at 30,000–60,000 km | €60–150 |
| Front brake discs + padsBrakes | usually at 60,000–120,000 km | €150–320 |
| Rear brake padsBrakes | usually at 50,000–90,000 km | €50–130 |
| Tyres (set of 4)Wheels | usually at 40,000–60,000 km | €320–700 |
| Wiper bladesBody | checked at service | €20–50 |
| 12V batteryElectrical | checked at service | €100–220 |
Roadworthiness tests by mileage
Share of tests in the United Kingdom (DVSA MOT, 2024) that this model failed because of each system. Bold red means more often and green less often than an average car of the same age and mileage. Sample: 147,830 tests.
| thousand km | 0–50 | 50–100 | 100–150 | 150–200 | 200–250 | 250+ |
|---|---|---|---|---|---|---|
| Brakes | 3.2 % | 5.2 % | 8.5 % | 11.7 % | 14.1 % | 14.2 % |
| Suspension | 4.2 % | 7.2 % | 11.9 % | 17.4 % | 20.6 % | 20.9 % |
| Steering | 0.3 % | 0.6 % | 1.4 % | 2.4 % | 3.3 % | 4.1 % |
| Tyres and wheels | 2.8 % | 6.1 % | 8.9 % | 10.6 % | 11.8 % | 11.4 % |
| Lights, wipers and visibility | 6.4 % | 12.7 % | 18.9 % | 24.6 % | 27.9 % | 27.8 % |
| Body and corrosion | 1.3 % | 2.4 % | 4.4 % | 6.3 % | 7.4 % | 7.9 % |
| Exhaust, emissions and leaks | 2.3 % | 3.9 % | 7.4 % | 10.5 % | 11.9 % | 11.7 % |
Official recalls
Recalls the manufacturer published in the United Kingdom for this model (9). The same recalls usually apply across Europe. Ask an authorised dealer to check by VIN whether your car is affected and whether the work has been done.
- Airbag Vauxhall cross carline Driver’s Airbag - Takata01/12/2025 · R/2025/511
- Wheels / tyres The fixed roof luggage carrier rails may become loose27/08/2019 · R/2019/286
- Wheels / tyres Movement of wiring harness connector to fan speed resistor may lead to connector plug terminals becoming heat damaged25/04/2019 · R/2019/082
- Electronics / software Software issue with hill start assist feature25/02/2019 · R/2019/059
- Fire risk Potential melting and fires within the blower motor regulator25/10/2018 · R/2018/214
- Fire risk Risk of fire28/05/2016 · R/2016/104
- Fire risk Risk of fire14/12/2015 · R/2015/245
- Steering Steering may fail19/05/2010 · R/2010/032
The other recalls (1) are listed in the app.
Sources and notes
Faults, intervals and prices are indicative and collected from public sources and owner experience; always rely on the service book and a qualified workshop. Test statistics: DVSA – Anonymised MOT tests and results, Open Government Licence v3.0. Owner complaints: NHTSA ODI (public domain). Recalls: DVSA Vehicle Safety Branch Recalls Database, OGL v3.0. Brand and model names are trademarks of their owners and are used only to describe the vehicles.
Updated 07/10/2026