Used car guide

2004 Vauxhall Zafira: common problems and what to check

What gets flagged at MOT on 2004 Vauxhall Zafiras, from 2,953 tests in 2025, plus known faults and what to look at before you buy one.

2,953MOT tests in 2025
53%pass first time (all 2004 cars: 58%)
5,400typical miles a year
2.1×the usual rate for rigid brake pipes

What stands out

Parts flagged at MOT more often on 2004 Vauxhall Zafiras than on all cars registered in 2004.

  • Rigid brake pipes2.1× usual
    Vauxhall Zafira
    35.8% All 2004 cars
    17.1%

    Failed outright at MOT: 6.6%, against 2.7% of all 2004 cars. The rest were advisories or minor defects.

    Rough price £100–£400 our estimate

    At the viewing: Ask to see underneath, or check the MOT advisories: corroded brake or fuel pipes get worse every year and fail the MOT when they do.

  • Engine oil leaks1.7× usual
    Vauxhall Zafira
    27.5% All 2004 cars
    15.8%

    Failed outright at MOT: 0.8%, against 0.4% of all 2004 cars. The rest were advisories or minor defects.

    Rough price £80–£600 our estimate

    At the viewing: Look under the engine and where the car is usually parked for fresh oil. Ask whether the leak has been looked at.

  • Exhaust system2× usual
    Vauxhall Zafira
    19.5% All 2004 cars
    9.7%

    Failed outright at MOT: 5.2%, against 2.5% of all 2004 cars. The rest were advisories or minor defects.

    Rough price £100–£500 (pipe or section) ClickMechanic

    At the viewing: Listen for blowing or rattling from underneath at idle, and look for black soot around joints.

  • Coil springs1.8× usual
    Vauxhall Zafira
    19.2% All 2004 cars
    10.9%

    Failed outright at MOT: 5.1%, against 2.4% of all 2004 cars. The rest were advisories or minor defects.

    Rough price £175–£400 (pair, one axle) ClickMechanic

    At the viewing: Look behind each wheel for a snapped spring coil, and listen for a clunk or twang when turning the wheel lock to lock with the car stopped.

  • Shock absorbers2.1× usual
    Vauxhall Zafira
    14.5% All 2004 cars
    7%

    Failed outright at MOT: 4.1%, against 1.7% of all 2004 cars. The rest were advisories or minor defects.

    Rough price £200–£300 (pair, average rear to front) ClickMechanic

    At the viewing: Push down hard on each corner. It should bounce once and settle. Look for oil on the shock absorber body.

Better than most

Suspension arm bushes and joints: 2.8% here, against 9.5% of all 2004 cars. Rust around suspension or steering mountings: 2.5% here, against 6.6% of all 2004 cars.

By area

The share of 2004 Vauxhall Zafira MOT tests where testers flagged each area, as a fail or an advisory. Rough prices are typical independent-garage costs.

  • Brakes
    54% of testsRough price £150–£350

    At the viewing: Look for a lip on the disc edges and feel for judder or pulling when braking firmly from about 40mph.

  • Suspension
    50% of testsRough price £120–£400

    At the viewing: Listen for knocks over speed bumps, and look behind each front wheel for a snapped coil spring.

  • Tyres
    35% of testsRough price £70–£150

    At the viewing: Check the tread on all four tyres, including the inside edges, and look for cracks or bulges.

  • Lights and electrics
    35% of testsRough price £10–£80

    At the viewing: Ask a friend to check every light, including brake lights and indicators, while you operate them.

  • Oil and fluid leaks
    29% of testsRough price £80–£600

    At the viewing: Look under the engine and on the ground where the car is usually parked for fresh oil or fluid.

  • Exhaust and emissions
    23% of testsRough price £100–£1,200

    At the viewing: Look for black soot in the tailpipe, listen for blowing from the exhaust and check for engine or DPF warning lights.

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Other years

YearMOT testsMost flagged
20184,825Tyres 36%
201711,881Tyres 35%
201611,618Tyres 36%
201514,008Tyres 36%
201426,240Tyres 38%
201325,656Tyres 38%
201214,427Tyres 39%
201110,750Suspension 43%
201013,524Suspension 50%
20097,516Suspension 52%
200810,205Suspension 54%
20078,564Suspension 54%
20065,432Suspension 54%
20053,875Brakes 55%
20031,734Brakes 52%
20021,053Brakes 52%
2001520Brakes 56%

Where this comes from: the DVSA's anonymised results for every MOT test in Great Britain in 2025, counting tests of 2004 Vauxhall Zafiras registered in 2004. "Flagged" includes advisories, so it isn't the same as a fail rate. How we score