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Zafira B MPV 2006
Owners workshop manual
Opel Zafira B MPV 2006 Owners Workshop Manual
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Table Of Contents
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Contents
Table of Contents
Bookmarks
Table of Contents
Contents
Introduction
Your Vauxhall/Opel Zafira Manual
Project Vehicles
Acknowledgements
Safety First
General Hazards
Special Hazards
Roadside Repairs
If Your Car Won't Start and the Starter Motor Doesn't Turn
If Your Car Won't Start Even Though the Starter Motor Turns as Normal
Jump Starting
Wheel Changing
Using the Puncture Repair Kit
Weekly Checks
Identifying Leaks
Towing
Sump Oil
Underbonnet Check Points
1.6 Litre Petrol
1.8 Litre Petrol
2.2 Litre Petrol
1.9 Litre Diesel
Engine Oil Level
Coolant Level
Before You Start
Car Care
Tyre Condition and Pressure
Tyre Tread Wear Patterns
Shoulder Wear
Centre Wear
Brake Fluid Level
Screen Washer Fluid Level
Wiper Blades
Battery
Electrical Systems
Lubricants, Fluids and Tyre Pressures
Routine Maintenance and Servicing - Petrol Models
Degrees of Difficulty
Table of Contents
Servicing Specifications - Petrol Models
Maintenance Schedule - Petrol Models
Component Location - Petrol Models
Underbonnet View of a 1.6 Litre Model
Underbonnet View of a 1.8 Litre Model
Underbonnet View of a 2.2 Litre Model
Front Underbody View
Rear Underbody View
Maintenance Procedures
General Information
Regular Maintenance
Every 10 000 Miles or 6 Months
Removing the Oil Filler Cup
Using an Oil Filler Removal Tool to Slacken the Canister-Type Filter
Engine Oil and Filter Renewal
Every 20 000 Miles or 12 Months
Unscrew the Filter Cup
Withdraw Together with the Element
Separate the Element from the Cap
Power Steering Fluid Level Check
Clutch Hydraulic Fluid Level Check
Brake Pad and Disk Check
Brake Fluid Pipe and Hose Check
Front Suspension and Steering Check
Driveshaft Check
Exhaust System Check
Rear Suspension Check
Bodywork and Underbody Condition Check
Roadwheel Bolt Tightness Check
Electrical Systems Check
Road Test
Every 40 000 Miles or 2 Years
Pollen Filter Renewal
Auxiliary Drivebelt Condition Check
Checking
Every 2 Years, Regardless of Mileage
Handbrake Operation and Adjustment Check
Headlight Beam Alignment Check
Hydraulic Fluid Renewal
Coolant Renewal
Exhaust Emission Check
Cooling System Draining
Cooling System Flushing
Every 40 000 Miles or 4 Years
Air Claner Element Renewal
Spark Plug Renewal
Disconnect Wiring Connector from Inlet Air Temperature Sensor
Every 100 000 Miles or 10 Years
Measuring a Spark Plug Electrode Gap Using a Feeler Blade
Measuring a Spark Plug Electrode Gap Using a Wire Gauge
Routine Maintenance and Servicing - Diesel Models
Coolant Renewal
Driveshaft Check
Handbrake Operation and Adjustment Check
Hinge and Lock Lubrication
Hose and Fluid Leak Check
Pollen Filter Renewal
Power Steering Fluid Level Check
Rear Suspension Check
Servicing Specifications - Diesel Models
Maintenance Schedule - Diesel Models
Component Location - Diesel Models
Underbonnet View of an SOHC Engine Model
Primary Operations
Secondary Operations
Regular Maintenance
Maintenance Procedures - Diesel Models
Engine Oil Drain Plug Location
Unscrew the Filter Cap and Withdraw It Together with the Element
Remove the Two O-Ring Seals
Hose and Fluid Leak Check
Fuel Filter Water Draining
Power Steering Fluid Reservoir Filler Cap
The Fluid Level Should be up to the MAX Mark on the Dipstick
Brake Pad and Disc Check
Check for Wear in the Hub Bearings by Grasping the Wheel
Check the Condition of the Driveshaft Gaiters and the Retaining Clips
Hinge and Lock Lubrication
Bodywork Damage/Corrosion Check
Corrosion Protection Check
Exhaust Mountings
Service Interval Indicator Reset
Fuel Filter Renewal
Instruments and Electrical Equipment
Steering and Suspension
Using Home-Made Tool to Slacken Filter Housing Cover Retaining Ring
Unscrew and Remove the Cover Retaining Ring
Lift the Cover Together with the Filter Element
Recover the 0-Ring Seal
Hanbrake Operation and Adjustment Check
Turn Drivebelt Tensioner Using Spanner on the Pulley Centre Bolt
Lock Tensioner by Inserting a Drill Bit through Hole on Tensioner
Handbrake Cable Adjuster Nut
Remote Control Battery Renewal
Hydraulic Fluid Renewall
Radiator Flushing
Engine Flushing
Air Cleaner Element Renewal
Cooling System Filling
Antifreeze Mixture
Open Bleed Screw in Coolant Pipe above the Exhaust Manifold
Every 50 000 Miles or 6 Years
Every 80 000 Miles or 10 Years
1.6 and 1.8 Litre Petrol Engine In-Car Repair Procedures
Specifications
Compression Test - General Information
Top Dead Centre for no 1 Piston - Locating
How to Use the Chapter
Engine Description
Camshaft Cover - Removal and Refitting
Align the Camshaft Sprocket Timing Marks on 1.6 Litre Engines
Notch on Crankshaft Pulley Rim with Mark at Base of Timing Belt Cover
Locate Rubber Seal into Grooves of Camshaft Cover
Crankstlaft Pulley- Removal and Refitting
Timing Belt Covers - Removal and Refitting
Upper Cover
Lower Cover
Timingt Belt - Removal and Refitting
Centre Cover (1.8 Litre Engines)
Rear Cover
Auxiliary Drivebelt Tensioner Retaining Bolt
Timing Belt Sprockets, Tensioner and Idler Pulley
Camshaft Sprockets
Insert Tool into Slots on End of Camshafts to Lock Camshafts
Camshaft Sprocket Closure Bolts
VVT Oil Control Valves
Camshaft Oil Seals
Valve Clearances
Crankshaft Sprocket
Camshaft and Followers
Using Feeler Blades, Measure Intake Valve Clearances
Camshaft Bearing Cap Numbering Sequence
Camshaft Bearing Cap Numbers
Use a Valve Lapping Tool to Remove the Cam Followers
Apply a Smear of Sealant to the Right-Hand Bearing Caps
Camshaft Bearing Cap Tightening Sequence
Camshaft Bearing Support Retaining Bolts
Cylinder Head
Preparation for Refitting
Refitting
Cylinder Head Bolt Loosening Sequence
Cylinder Head Bolt Tightening Sequence
Sump
Oil Pump
Tighten Cylinder Head Bolts to Specified Stage 1 Torque Setting
Remove Securing Screws and Withdraw Oil Pump Cover from Rear Housing
Unscrew the Oil Pressure Relief Valve Cap
Withdraw the Spring
Check Oil Pump Rotor Endfloat Using a Straight-Edge and Feeler Gauge
Oil Filler Housing
Crankshaft Oil Seals
Flywheel
Right-Hand
Inspection
Renewal
Left-Hand Mounting
Front Mounting/Torque Link
Rear Mounting/Torque Link
Rear Engine Mounting/Torque Link Retaining Bolts and Nut
2.2 Litre Petrol Engine In-Car Repair Procedures
Valve Timing
Operations with Engine in Car
Vauxhall/Opel Camshaft Locking Tool
Camshaft Cover
Crankshaft Pulley/Vibration Damper
Crankshaft Pulley and Timing Chain Cover Timing Marks
Locking Camshaft Sprockets in Position Using Vauxhall/Opel Tool
Timing Chain Cover
Turn Pulley until Flat on Centre Hub Locates with Oil Pump Drive
Fit a New Securing Bolt to the Pulley
Tighten Crankshaft Pulley Whilst Preventing Pulley Rotation
Timing Chain Tensioners
Camshaft Chain Tensioner
Carefully Lever Old Crankshaft Oil Seal out of Cover
Using a Suitable Drift Tap in the New Oil Seal
Timing Chains and Sprockets
Balance Shaft Chain Tensioner
Chain Tensioner and Guide Rails
Turn Inner Piston Screw Clockwise until It Locks in Position
Camshaft Chain and Sprockets
Balance Shaft Chain and Sprockets
Align Silver Link with Triangular Timing Mark on Exhaust Sprocket
Copper-Coloured Link with Diamond Timing Mark on Intake Sprocket
Undo the Retaining Bolts and Remove the Tension Rail and Guide Rails
Using a Drift to Lock the Balance Shaft Sprocket
Refit the Timing Chain Crankshaft Sprocket
Turning the Camshaft Slightly Using an Open-Ended Spanner
Use New Retaining Bolts When Refitting the Sliding Rail
Refit Balance Shaft Crankshaft Sprocket
Refit the Balance Shaft Sprockets Using New Securing Bolts
The Arrow Points Upwards on the Intake Sprocket
Alignment Marks Made on Camshaft Sprockets for Refitting
Use Container Used to Keep Followers and Hydraulic Tappets in Order
Keep Hydraulic Tappets in Labelled Containers with Clean Engine Oil
Lubricate Tappets with Clean Engine Oil before Refitting
Apply Silicone Sealing Compound Thinly to Surface Areas Arrowed
Refitting no 11 Cap to Flywheel/Driveplate End of Intake Camshaft
Refit New Retaining Bolts to the Camshaft Sprockets
Remove Two Coolant Hoses from Front of Cylinder Head
Using a Tap to Clean out the Threads in the Cylinder Block
Check Dowels Are in Position to Locate Cylinder Head Gasket
Ensuring Gasket Is Fitted with Its OBEN/TOP Marking Uppermost
Tightening Cylinder Head down through Its Stages, Using an Angle Gauge
Fit Four New Retaining Bolts to Timing Chain End Cylinder Head
Two of Bolts Are Inside Timing Chain Housing
Undo Two Sump to Transmission Bolts and also Sump-To-Lower Cylinder
Apply Continuous Bead of Silicone Sealer Around Sump
Balance Shaft
Undo Retaining Screws and Remove the Pump Cover Plate
Removing the Inner and Outer Rotors
Using a Feeler Blade to Check Inner-To-Outer Rotor Clearance
Flywheel/Driveplate
Manual Transmission Models
Automatic Transmission Models
Undo the Retaining Bolt
1.9 Litre SOHC Diesel Engine In-Car Repair Procedures
Compression Test
Leakdown Test
Open the Cover on the Fuse/Relay Box
Remove the Fuel Pump Relay
Top Dead Centre for no 1 Piston
Release the Hose Support Clip
Lift off the Plastic Cover over the Top of the Engine
Undo Central Bolt and Remove Auxiliary Drivebelt Tensioner Assembly
Valve Timing
Screw Fastening Stud of Special Tool into Oil Pump Housing
Position Ring of Tool Attached to Fastening Stud/Crankshaft Sprocket
Undo Retaining Bolt to Release Vacuum Lines from Camshaft Cover
Timing Belt
Move Leak-Off Hose Assembly Rearward, then Lift Camshaft Cover
Fit the Seal to the Camshaft Cover Groove
Crankshaft Pulley/Vibration Damper Retaining Bolts
Camshaft Sprocket
Using Screwdriver Resting on Pivot Bolt, Move Adjusting Lever
Tensioner Pointer Is Aligned with the Mark on the Backplate
High-Pressure Fuel Pump Sprocket
Tensioner Assembly
Remove the Bolt and Washer
Slide Sprocket off End of the Crankshaft
Camshaft Oil Seal
Idler Pulley
Slacken/Remove Retaining and Remove Timing Belt Tensioner Assembly
The Slot on Tensioner Backplate Must Locate over Peg on Engine Bracket
Thickness of each Shim Should be Stamped on One of Its Surfaces
Camshaft Bearing Cap Retaining Bolts
Carefully Release Oil Pipe from Its Location in the Cylinder Head
Undo Support Bracket Bolts, Release Retaining Clips
Cylinder Head Gasket Thickness Identification Hole
Using Dial Test Indicator to Measure Piston Protrusion
Place New Gasket in Position with Words ALTO/TOP Uppermost
Intermediate Shaft Bearing Housing Support Bracket Retaining Bolts
Air Conditioning Compressor Mounting Bracket Retaining Bolts
Removing Oil Baffle Plate from Inside the Sump
Renew Pick-Up/Strainer Sealing Ring Prior to Refitting
Apply Continuous Bead of Silicone Sealing Compound to Sump Flange
Oil Filter Housing
Oil Pump Housing Retaining Bolts
Undo Retaining Screws and Lift off Oil Pump Cover
Oil Pump Inner and Outer Rotor Identification Dots
Oil Filter Housing Retaining Bolts
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Table of Contents
Download this manual
Vauxhall/Opel Zafira
Owners Workshop Manual
Models
covered
Zatira·B
MPV
modOIS
Petrol:
1.6 Utre
(1598cc), 1.8 litre (1796cc)
&
2.2
lltre
(2198cc)
Turbo-diesel:
1.9
lltre (1910cc)
Does
NOT cove, 2.0 litre
turbo
petrol
engine, 1.71/tre
d/ese/
engine or dual
fuel
models
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This manual is also suitable for:
Zafira b mpv 2005
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