2004 Vauxhall Zafira Elegance 2.0 DTi turbo diesel

Summary:

You put up with a lot when it is a company car

Faults:

In first year gear box stuck. It was repaired under warranty. Then had problems with the EMS light coming on and the car slowing down. This was usually sorted by stopping the car and restarting it. Later had problems with clutch slipping. Had to have new one fitted. Then car completely conked out. Problem was due to some sensor in the engine.

Recently we have had difficulty in starting the car.

The EMS light has also stayed on for a while before going out. Last outing it started with difficulty. Stopped the car to go shopping. It would not re start. RAC recovered it to a garage. Gave EMS codes to the garage. Garage said that codes were not giving correct diagnosis, and there is probably a problem with the EMS. Vauxhall quoted me for a new one, £2600 in all. When I said this was a little excessive, seeing as otherwise, after everything else being replaced/fixed, the car worked very well - he said - now listen to me darlin... I might add we have just bought a Volkswagen as our main car, not a Vauxhall. I just regret that we didn't ditch the Zafira on part exchange. If only I had read this web site earlier.

General Comments:

Good concept, pity the car is a bag of -----

Would you buy another car from this manufacturer? No

Review Date: 23rd February, 2011

14th Jun 2026, 16:37

Early Zafira's were terrible. We had two in the family - a 2003 model which was the worst, but a more recent 2014 model was much better.

I would say all are better than the similar French MPV offerings of the time (Espace, Picasso, etc) but only just.

For anything else, a Ford Galaxy a less safe bet than the VW Sharan despite being basically the same car.

With these vehicles, you toss a coin for reliability. You need to get lucky.

In reply to 14th Jun 2026, 16:37

14th Jun 2026, 20:33

Opel/Vauxhalls from this period were generally poor, not only the Zafira, most parts are shared with other models from that era. Often it was the ECU itself that was defective. It would then throw random error codes, confusing many mechanics. There could be problems with the wiring harness too, also complicated to figure out. Many of these got wrecked early on due to electronic problems that most mechanics were not able to figure out.

2004 Vauxhall Zafira Energy 2.0 DTi turbo diesel

Summary:

Vauxhall should be honest about EGR faults and be more helpful

Faults:

EGR system problems. Fault would show on motorway journeys, normally going up inclines and throttling back. Engine management light would flash on, loss of power and then OK. This would happen several times, then go into limp home mode.

Put onto diagnostic system, no fault shown. Several faults found by inspection. EGR butterfly valve sticking, inside EGR blocked up with carbon. Cleaned, refitted, all working.

The solenoid controlling the inlet manifold valve sticking. This was also blocked up with carbon. To view, remove the gray plastic cover plate and move the valve. Chances are it's sticking and feels gritty in its movement. Cleaned this with WD40 and all works well.

Also the inlet manifold is totally blocked with carbon build up. Unfortunately quite a big job as the fuel pipes are in the way. A couple of times the turbo did not kick in, showed a lack of power. This was because the vacuum tube to it came off. The whole vacuum system suffers from this.

General Comments:

Love the Zafira for carting the kids around and all their junk.

Found it very good for towing small trailers.

Would you buy another car from this manufacturer? Don't Know

Review Date: 12th June, 2010

13th Jun 2010, 08:03

While reading your review, I was wondering if you had a diesel. Sure enough you do. What I wonder is when will all manufacturers realize that diesels and EGR valves just don't mix well. They all cause some kind of problem; most typically a blocked or restricted intake to coking of turbos. I've owned VW's and now a Ford truck, and the single biggest headaches for all were the EGR systems.

14th Jun 2010, 08:34

The exhaust gas recirculation units on diesels are designed to feed back in exhaust gas to reduce emissions, but it mixes with oily vapour and creates thick black cruddy sludge which causes problems. On my old diesel, I just blanked off the unit with little effect. My mpg didn't alter after blanking the unit off, but it did take a tad longer to warm up in cold weather. I cleaned out my manifold and scraped it clean, and because it was only oily vapour going in, it remained clean.