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Vauxhall Zafira common problems (2005-2011)

Vauxhall Zafira

The Vauxhall Zafira Mk2, also known as the Zafira B, is the sort of car bought by people who have lots of backsides to put on seats, so its seven seats are ideal. But of course, if your family is big enough to need seven seats, then the day-to-day cost of living must be starting to sting a bit. And that’s where Haynes can lend a helping hand, because we can help you diagnose the common problems your Zafira is likely to suffer, and show you how to get it back on the road as cheaply as possible.

That’s why a Haynes manual is a prime example of ‘buy now, don’t pay later’, because we can help you avoid a garage’s labour costs by sorting out your car yourself.

Vauxhall Zafira

What recalls has the Vauxhall Zafira been subject to?

The Vauxhall Zafira is well known for having suffered issues with its heater blower resistor, which can fail and cause a fire. In the original recall, the fix wasn’t carried out properly, so the car has had to be recalled a couple of times since, to get it sorted once and for all.

The steering system has been the source of a couple of recalls. First it was recalled because the steering wheel controls were rendered inoperative, then a new intermediate shaft had to be fitted to the steering set-up.

A small number of cars were recalled for incorrectly tightened towing hitch bolts. Then 2015 cars were recalled of potential chafing of the fuel tubes. These required protection to be fitted.

Vauxhall Zafira

What common problems does the Vauxhall Zafira Mk2 have?

The Vauxhall Zafira B suffers a problem in which the engine can suddenly stall when driving, and then will not restart. The car will also not respond to accelerator inputs.

The gearbox is not without issue either, because it can develop a sticky shift between third and fourth, and scraping noises can be a similar issue between fifth and sixth gears. Another issue concerns the starter motor, which can operate inconsistently.

A clogged diesel particulate filter can cause issues, while the fuel gauge can go on the blink. The condenser and intercooler on some models can work loose, too.

Vauxhall Zafira

Does the Vauxhall Zafira have starting problems?

Driving along only to find that your engine has cut out and won’t restart is somewhat less than optimal, but that’s sometimes happen with the Vauxhall Zafira Mk2.

Plug in a fault code reader and it will likely display the code: P0093.

The problem lies with a faulty high-pressure fuel pump regulator, which needs to be replaced.

This is a feature that is covered in great depth in your Haynes Zafira manual, so don’t feel daunted. It’s easy, so crack on.

Vauxhall Zafira

Does the Vauxhall Zafira have gearbox problems?

Owners have reported that the Vauxhall Zafira can suffer and issue that causes a sticky gearshift action between third and fourth gears. They’ve also noted that when driving along between 1800rpm and 2800rpom, there can be a scraping noise from underneath.

The first issue concerns the synchromesh between third and fourth gears, and the second issue is cause by the same fault between fifth and sixth gears.

In both, the solution is to remove the gearbox and take it to an expert for repair. Then refit it yourself. You will save a vast amount of cash on the labour costs involved in the removal and replacement.

And we’ve already done it, so you can just follow the steps in your Haynes Zafira manual and you’ll be good to go.

If you want to service your Vauxhall Zafira's cooling system check out our free video below.

Does the Vauxhall Zafira B have starter-motor problems?

Yes, but technically it isn’t the starter that’s at fault here. Sometimes the starter can suddenly jump into action when the ignition is turned on, or when the engine is already running. Both are not good things.

The problem lies with the engine control unit, which can have a hissy fit when water gets into it.

You’ll need to try out the ECU, then check the wiring loom and connectors to see how the water got into the unit.

Again, we can show you how to remove and replace the ECU, and how to trace the wires with our comprehensive wiring diagrams. They’re all in the relevant chapter of your Haynes Zafira manual.

Vauxhall Zafira

Does the Vauxhall Zafira have fuel-gauge problems?

Not knowing how much fuel your car has left in it, is one of motoring’s great gambles. At some stage you’re going to come a cropper and end up stopped at the side of the road. Vauxhall Zafira owners sometimes face this problem, because the software in the instrument cluster unit can get itself all in a fluster.

The solution is to remove the cluster and take it to an expert for reprogramming. The good news is that removing the cluster is very easy indeed. Just follow our step-by-step guide in your Haynes Zafira manual and it’ll be out before you know it. And then back in again shortly after.

Vauxhall Zafira

Does the Vauxhall Zafira have intercooler problems?

Unfortunately, the condenser and intercooler on the Vauxhall Zafira can become loose over time.

First of all, you need to check your Haynes Zafira manual to ensure that the parts have actually been fitted in the correct order (the intercooler should be attached to the radiator, and the condenser to the intercooler). This is shown in the manual, and if the components on your vehicle are in the wrong order, then we’ll show you how to fit them correctly. When doing so, you’ll need to replace the screw (part no: 11099561) and locking nut (part no: 90424093).

Does the Vauxhall Zafira Mk2 have DPF problems?

On occasion, diesel-powered versions of the Zafira B can raise DPF warnings.

The first step towards repairing this is to plug in a fault code reader to find out what the issue is.

If the issue is ash accumulation, the solution is to raise the vehicle and set it on axle stands, then remove the exhaust gas pressure sensor and inject cleaner into the exhaust.

Then simply refit the sensor and lower the vehicle to the ground.

Vauxhall Zafira