The original Vauxhall Zafira appeared at the end of the 1990s it was pretty revolutionary, because it offered the flexibility of seven seats in a comparatively compact footprint. And it drove like a hatchback – not a ‘van with windows’. It was a massive hit, which is why Vauxhall refined the recipe over two further generations, resulting in the more modern-looked and even more flexible Zafira Tourer (also known as the Zafira C) we focus on here.
As with any car, there are good bits and less good bits, and as a Haynes reader you’ll be far more concerned with the knowing about the parts that are likely to go wrong, and how you’re going to fix them.
Well, here’s our breakdown (pardon the pun) of the Vauxhall Zafira Tourer’s common problems.
What recalls has the Vauxhall Zafira Tourer been subject to?
The Vauxhall Zafira C is on a par with most rivals in the number of times it has been recalled over its life.
More than 42,000 early cars were recalled because the hill-hold system was incorrectly programmed, causing it to stay on longer than it should have. Then 20,447 examples were recalled because their roof bars were found to work their way loose over time.
A small number of Zafira Tourers were recalled in 2017 because the “third row seat retaining bolts and second row seat belt shoulder anchor retaining bolts may not be tightened to the correct specification”.
After that, 537 examples were recalled because the threaded portion of their track rod ends were not the right specification, and could fail.
Front side airbags forced another small recall – these needed to be replaced.
What common problems does the Vauxhall Zafira C (2011-2019) have?
The Vauxhall Zafira C fitted with a diesel engine, is known to suffer a problem in which fuel leaks from its tank when full – both disconcerting and expensive. Fortunately the fix isn’t too difficult.
And given that the weather in the UK and Europe can be… changeable, it would be a little inconvenient if your Zafira Tourer's windscreen wipers were to play up. Unfortunately, they do.
Some owners have reported a fault that causes a smell of exhaust fumes in the cabin. This is both unpleasant and dangerous, so you need to fix it pronto.
A vibration from the rear end of the Zafira C is also reasonably common, and concerns the vibration damper on the rear brake calipers.
The rear brakes are also the source of another common issue – when the brakes seize on to the brake disc. Not ideal.
Does the Vauxhall Zafira Tourer have fuel-leak problems?
If you’ve just filled up your diesel Zafira Tourer, and notice a smell of fuel, it’s right that you’re concerned. If that odour of fuel is accompanied by a puddle of fuel underneath your car, then it’s doubly bad, because fuel is expensive, and so you want it all to remain where you put it, and not on the road.
The issue lies with the fuel pump that sits inside the fuel tank itself. This pump will need to be replaced, and if your vehicle has a floor access panel beneath the rear seats, this is where you access the top of the tank. However, some vehicles won’t have this panel, and will require the tank to be removed first. The Haynes Zafira Autofix gives instructions on how to carry out both methods, but make sure you follow all the safety instructions along the way.
Why are your Zafira C windscreen wipers not working?
This is the sort of fault that pops to the forefront of your attention precisely because you only become aware of it at the moment you need the piece of equipment to work as you expect. In short, you tend to only notice that your wipers are knackered when you try to turn them on as the wet stuff falls from the sky.
The first thing to do is to disconnect the wiper motors, after which you start the engine and run it for a couple of minutes. Then you must switch off the engine, then reconnect the wiper motors. If they remain faulty, then you’ll need to replace both wiper motors. If only one is faulty, you can replace just the one with the issue.
Where is that exhaust smell coming from in your Zafira Tourer?
There you are, driving along quite the thing in your Vauxhall Zafira Tourer when suddenly your nose detect something amiss. What’s that smell? Doesn’t smell nice, that’s for sure, and it’s getting stronger. Smells like exhaust fumes, which is not good. It’s something you need to fix ASAP.
The issue can be either a damaged EGR pipe or a leak between the turbocharger and the front exhaust pipe.
Either will be reasonably easy to trace. You should check for exhaust gas leaks at the diesel particulate filter-turbocharger union, check the front exhaust pipe for damage and leaks, check the turbocharger for leaks, looks for damage or wear on the exhaust front pipe/manifold, and do the same for the exhaust pipe to the turbocharger. The Haynes Zafira Autofix offers technical drawings and advice on turbocharger procedures, so will help you along the way as you get to the bottom of the issue.
Is your Vauxhall Zafira Tourer vibrating under braking?
You’re happy when your Vauxhall Zafira C just hums along. But rumbling? That’s unusual, and is a description usually reserved for vehicles with big V8 engine under the bonnet. A Zafira Tourer doesn’t rumble – until it does.
The noise emanates from the rear end, and is most noticeable when slowing down from speed or when you’re braking after reversing.
The issue lies with the rear brake calipers, and more specifically the fact that the vibration damper has failed. So, you’ll need to invest in a new component (part number: 13437038 [damper] and 13581864 [retaining bolt]), then follow the instructions in your Haynes Zafira Autofix on how to jack up the rear end safely, after which it’s simply a case of undoing one bolt and removing the old vibration damper, before attaching the new one with the new bolt, and tightening it to the correct torque of 28 Nm. Hey presto – no more rumbles.
Are your Vauxhall Zafira Tourer rear brakes hot and smelly?
Getting out of your Vauxhall Zafira Tourer and noticing the smell of hot brakes is not ideal. But it can happen to the rear brakes on the Vauxhall MPV, because corrosion can build up between the brakes pads and calipers, causing them to stick.
The solution is to fire up your Haynes Zafira Autofix and follow the procedure to remove and replace the rear brake pads. You’ll need to clean up the calipers and the guide pins along the way, including lubricating the guide pins, but once you’ve done everything the brakes should operate perfectly.
