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Opel Zafira 1.6 CNG Turbo ecoFLEX Cosmo common faults.

2008–2011, MPV, natural gas, 150 HP.

The fault list covers: A16XNT, Z16XNT engine, M32, F40 transmission.

What you save stays on this device only. My saves

3 fault write-ups. All are important. 2 recalls.

If you know the year, pick it. Faults for other years drop out of the list.

Before you buy

Known faults

3 important faults

Easytronic: automated manual gearbox, clutch and shift actuator

expensive

The Opel Easytronic is not a conventional automatic: it is an ordinary manual gearbox in which electric actuators operate the clutch and change gear. There is no torque converter, and the drive breaks for a moment when it shifts.

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The typical faults are: clutch and shift actuator failure, clutch wear, and lost adaptation values. Symptoms: jerking when pulling away, delayed or harsh shifts, an "F" warning, a stuck gear, and no creep.

Removal and refurbishment often come to 2,500 to 3,000 euro. On an old Corsa or Astra that can cost more than the car. A software update and an oil change sometimes help if it only jerks, but an actuator fault means replacing the part.

between 80,000 and 180,000 km2,500–3,000 EUR

What to check

  • Try it cold and warm: pulling away, creep, 1 to 2 and 2 to 3 shifts. Jerking or delay is suspect
  • Watch for the "F" or gearbox warning on the dash
  • Ask for a fault code read with Opel compatible diagnostics (not just generic OBD): actuator codes of the P1607 / P1728 / P1729 kind
3 more steps in the write-up

Astra H: M32 six speed manual, bearing and synchro wear

expensive

In the Astra H diesel range, on the Z17DTH engine, two manual gearboxes were available: the five speed F23 and the six speed M32.

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The known weakness of the M32 is wear of the bearings and the synchro rings: a whine while driving, a stiff shift, especially 3rd to 4th. Replacement or a rebuild is expensive.

between 100,000 and 200,000 km

What to check

  • Count the gears: 6 raises the M32 suspicion on this engine group; 5 means more likely the F23
  • When warm, at 80 to 100 km/h, listen for gearbox whine: a noise that rises with the revs is suspect
  • Try the 3 to 4 and 4 to 5 shifts cold and warm: binding, scratchiness
1 more steps in the write-up

F40 six speed manual gearbox: oil level and synchro wear

expensive

The Opel F40 is the six speed manual designed for GM's stronger turbo and diesel engines (around 400 Nm) (Astra H/J, Insignia, Zafira B/C and others). The typical fault is the oil level.

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Leaks do happen; and if the level drops, the synchro rings wear quickly (a stiff or scratchy shift). At high mileage the input shaft bearing can whine. Rare but documented: gear damage from a sudden shift at high revs.

The oil change is about every 50,000 km, and the fill is about 3.2 litres. The "lifetime" promise does not replace that.

between 120,000 and 250,000 km

What to check

  • Look for oil leaks on the gearbox casing and the shafts: a low level means fast synchro wear
  • Try every gear cold and warm: scratchiness, binding
  • When warm, at open road speed, listen for input shaft whine
2 more steps in the write-up

Checklist

Opel Zafira 1.6 CNG Turbo ecoFLEX Cosmo

First what you would check on any car. Then the faults of this model.

Before you buy

Checklist

The printed sheet starts with what you would check on any car. What you tick stays on this device only.

On every car

Ask the owner

Faults of this model

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Official recall2 recallsShow

The manufacturer fixes these for free at a franchised dealer. Ask with the VIN whether it was done.

Most recent: 4 August 2025

SR/02979/25Safety recallInjuries4 August 2025 · EU Safety Gate

The structure of the airbag can deteriorate. If the airbags deploy, it could result in fragments from the inflator, injuring the vehicle's occupants. The product does not comply with the Regulation on the approval and market surveillance of motor vehicles and their trailers, and of systems, components and separate technical units intended for such vehicles.

Remedy: Type of economic operator taking notified measure(s): Manufacturer Category of measure(s): Recall of the product from end users Date of entry into force: 04/08/2025 Type of economic operator taking notified measure(s): Manufacturer Category of measure(s): Request to stop driving Date of entry into force: 04/08/2025

The authority's notice

A12/01581/24Safety recallInjuries1 December 2023 · EU Safety Gate

The propellant used in the driver airbag inflator can degrade when exposed to very high temperatures and levels of humidity. If activated after an impact, excessive internal pressure may cause the inflator to burst, and metal fragments could pass through the cushion material causing injury to occupants. The product does not comply with the Regulation on the approval and market surveillance of motor vehicles and their trailers, and of systems, components and separate technical units intended for such vehicles.

Remedy: Type of economic operator taking notified measure(s): Manufacturer Category of measure(s): Recall of the product from end users Date of entry into force: 01/12/2023

The authority's notice

Engine and transmission

2 engines · 2 transmissions

A16XNT · 1.6 CNG ecoFlex Turbo

110 kW (150 HP) · unknown

M32 · 6-speed manual, transverse (Opel/GM M32)

manual · 6 speed

Torque limit320 Nm
MakerOpel/GM

We built the code from the model and the gear count. The factory sheet does not state it. More than one engine code is possible. The fault list shows the faults of each. More than one transmission is possible. The gear count does not tell them apart. The code is on the side of the transmission.

Variant data

What is in this version

Factory data

Trim
CNG Turbo ecoFLEX Cosmo
Body
MPV
Fuel
natural gas
Transmission
manual
Engine size
1598 cc
Power
110 kW (150 HP)
Drive
FWD
Production
2008–2011

Factory service interval

The manufacturer specifies this for this version. Of the mileage and the time, the one that comes first is the one that counts.

  • Air filter

    • 60,000 km or 4 years

  • Cabin (pollen) filter

    • 30,000 km or 2 years

  • Brake fluid change

    • first: 3 years, then 2 years(first change at 3 years, then every two years)
All B versions

Information, not an expert opinion

We write the descriptions, and we put the source next to them. A person reviews them before they go out. They are still information, not a technical expert opinion.

  • A fault on the list does not mean the car you are looking at has it.
  • A fault missing from the list does not mean the model is fault-free. Write-ups are made model by model. Not all of them are done.
  • You decide whether to buy. This is no substitute for an inspection. That needs a workshop and a history check.
Details in the terms