Opel Zafira B MPV 2006 Instruction manual

Vauxhall/Opel Zafira
Owners Workshop Manu al
Models covered
Zat ira·B MPV modOIS
Petrol: 1.6 Utre (1598cc), 1.8 litre (1796cc) & 2.2 ll tre (2198cc)
Turbo-diesel: 1.9
lltre (1910cc)
Does NOTcove, 2.0 litre turbo petrolengine, 1.71/tre d/ese/ engine or dual fuelmodels

Contents
LIVING WITH YOURVAUXHALL/OPEL ZAFIRA
Introdu ct ion to the Va ux hall/Opel Zafira
Safetyfirst!
Roadside repairs
Ifyour car won't start
J um p starting
Wheel changing
Usingthe puncturerepair kit
Identifyi
ng leaks
Towing
Weekly checks
Introduction
Underbonnet
check points
Engineoil level
Coola
nt level
Ty recon dition a nd pressure
Brake and cl ut chfluid level
Screen washer flu
id level
Wiper blades
Battery
El ec t ri cal sys tems
Lubricants and fluids
Tyre pressures
MAINTENANCE
Routine maintenance and servicing
Petrol models
Servicing specifications
Ma intenance schedule
Ma intenance procedu res
Diesel mode ls
Se rvici ng specifications
Ma intenance schedule
Ma intenanceprocedures
Pa
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A•6
Page
18•1
Page
18•2
Page 18 •3
Page
18•5

REPAIRS AND OVERHAU
Engine and associated systems
1.6 and 1.8 litre petrol engine in-car repair procedures
2.2 litre petrol engine in-car repair procedures
1.9 litre SOHC diesel engine in-car repair procedures
1.9 litre DOHC diesel engine in-car repair procedures
Engine removal and overhaul procedures
Cooling, heating and air conditioning systems
Fuel and exhaust systems -petrol engines
Fuel and exhaust systems -diesel engines
Emissions control systems
Starting and charging systems
Ignition system -petrol engines
Transmission
Clutch transmission
Automatic transmission
Easytronic transmission
Driveshafts
Brakes and suspension
Braking system
Suspension and steering
Body equipment
Bodywork and fittings
Body electrical system
Wiring diagrams
REFERENCE
Dimensions and weights
Fuel economy
Buying spare parts
Vehicle identification
General repair procedures
Jacking and vehicle support
Disconnecting the battery
Tools and working facilities
MOTtest checks
Fault finding
Glossary
of technical terms
Index
ontents
Page 2A•1
Page 28•1
Page 2C•1
Page 2D•1
Page 2E•1
Page 3•1
Page 4A•1
Page
48•1
Page 4C•1
Page 5A•1
Page 58•1
Page 6•1
Page 7A•1
Page 78•1
Page 7C•1
8•1
Page 9•1
Page 11•1
Page REF•1
REF•2
Page REF•6
Page REF•7
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REF•25
Page REF•29

o·4 Introduction
The Vauxhall/Opel Zafira-8 model was
introduced in the UK in the Spring
of 2005
as a replacement
for the previous Zafira,
the 'A' model. The Zafira is available with
only one body style, that of a 5-door Multi
Personnel Vehicle
(MPV), and with 1.6, i .8
and 2.2 litre petrol engines, and 1.9 litre
diesel engines. 2.0 litre turbo petrol engines
are also available, but are not covered in
this manual.
All the petrol engines are DOHC
16-valve units, whereas the diesel engines
are available in either SOHC 8-valve,
or
DOHC 16-valve form.
According
to engine type, the manual
gearbox
is ofthe 5- or6-speed all synchromesh
type, with a 4-
or 6-speed electronically-
controlled automatic transmission optionally
available
on certain models.
All models have front-wheel-drive with
fully-independent front suspension, and semi-
independent rear suspension with a torsion
beam
and trailing arms.
A wide range
of standard and optional
equipment is available within the Zafira range
to suit most tastes, including electro/hydraulic
power steering, air conditioning, remote
central locking, electric windows, electric
sunroof, anti-lock braking system, electronic
alarm system and supplemental restraint
systems.
For the home mechanic, the Zafira is a
relatively straightforward vehicle to maintain,
and most of the items requiring frequent
attention
are easily accessible.
Your Vauxhall/Opel Zafira
manual
The aim ofthis manual is to help you getthe
best value from your vehicle. It can do so in
several ways. It can help you decidewhat work
must be done
(even should you choose to get
it done by a garage), provide information on
routine maintenance and servicing, and give
a logical course of action and diagnosis when
random faults occur. However, it is hoped
that you will use the manual by tackling the
work yourself.
On simpler jobs, it may even
be quicker than booking the car into a garage
and going there twice, to leave
and collect it.
Perhaps most important, a lot of money can
be saved by avoiding the costs a garage must
charge
to cover its labour and overheads.
The manual has drawings and descriptionsto
show the function
of the various components,
so that their layout can be understood. Then
the tasks
are described and photographed in a
clear step-by-step sequence.
References
to the 'left' or 'right' are in the
sense of a person
in the driver's seat, facing
forward.
Project vehicles
The main vehicle used in the preparation
of this manual, and which appears
in many of
the photographic sequences, was a Vauxhall
Zafira 'Life' with a 1.6 litre petrol engine.
Additional work was carried out on a Zafira
'Design' with a 1.9 litre SOHC diesel engine.
Acknowledgements
Thanks are also due to Draper Tools
Limited, who provided some of the workshop
tools, and
to all those people at Sparkford
who helped
in the production of this manual.
We
take great pride in the accuracy
of information given in this manual, but
vehicle manufacturers make alterations
and design changes during the production
run of a particular vehicle of which they do
not inform us. No liability can be accepted
by the authors or publishers for loss,
damage or injury caused by any errors in,
or omissions from, the information given.

Working on your car can be dangerous.
This page shows just some
of the potential
risks and hazards, with the aim
of creating a
safety-conscious attitude.
General hazards
Scalding
• Don't remove the radiator or expansion
tank cap while the engine
is hot.
• Engine oil, automatic transmission fluid or
power steering fluid may also
be dangerously
hot ifthe engine has recently been running.
Burning
• Beware of burns from the exhaust system
and from any part
of the engine. Brake discs
and drums can also be extremely hot
immediately after use.
Crushing
• When working under or near -3
a raised vehicle, n ~
always ~..,£......"(], }t.,_ @©
supplement the /1@ - ~~ -~
jack with axle 'ill!J.~f~f§[~~~~
st~nds, or use /I'~
dnve-on -\)
ramps.
~((,~ILJ...-~
Never
venture
under a car which
is only supported by a jack.
• Take care if loosening or tightening high-
torque nuts when the vehicle is on stands.
Initial loosening and final tightening should be
done with the wheels on the ground.
Fire
• Fuel is highly flammable; fuel vapour is
explosive.
• Don't let fuel spill onto a hot engine.
•
Do not smoke or allow naked lights
{including pilot lights) anywhere near a
vehicle being worked on. Also beware
of
creating sparks
(electrically
or by use of tools).
• Fuel vapour is heavierthan air, so
don't
work on the fuel system with the vehicle over
an inspection pit.
• Another cause
of fire is an electrical
overload
or short-circuit. Take care when
repairing
or modifying the vehicle wiring.
• Keep a fire extinguisher handy, of a type
suitable for use on fuel and electrical fires.
Electric shock 1..
1 1 ?
,,
• Ignition HT
voltage can be
dangerous,
especially
to f-'" ,.r
people with heart f
problems or a ,..r
pacemaker. Don't
./
work on or near the ) ~
ignition system with J 1 1 < ) "\,._'
the engine running or J \ , ,
the ignition switched on.
• Mains voltage is also dangerous. Make
sure that any mains-operated equipment is
correctly earthed. Mains power points should
be protected by a residual current device
(RCD) circuit breaker.
Fume or gas intoxication
• Exhaust fumes are
poisonous; they often
contain carbon
monoxide, which is
rapidly fatal
if inhaled.
Never run the
engine in a
confined space
such as a garage
with the doors shut.
• Fuel vapour
is also
poisonous,
as are the vapours from some
cleaning solvents and paint thinners.
Poisonous or irritant substances
• Avoid skin contact with battery acid and
with any fuel, fluid
or lubricant, especially
antifreeze, brake hydraulic fluid and Diesel
fuel. Don't syphon them by mouth. If such a
substance is swallowed
or gets into the eyes,
seek medical advice.
• Prolonged contact with used engine oil can
cause skin cancer. Wear gloves
or use a
barrier cream
if necessary. Change out of oil-
soaked clothes and
do not keep oily rags in
your pocket.
• Air conditioning refrigerant forms a
poisonous gas
if exposed to a naked flame
(including a cigarette). It can also cause skin
burns on contact.
Asbestos
• Asbestos dust can cause cancer if inhaled
or swallowed. Asbestos may be found in
gaskets and
in brake and clutch linings.
When dealing with such components it is
safest
to assume that they contain asbestos.
Safety First! o·s
Special hazards
Hydrofluoric acid
• This extremely corrosive acid is formed
when certain types
of synthetic rubber, found
in some 0-rings, oil seals, fuel hoses etc, are
exposed
to temperatures above 400°C. The
rubber changes into a charred
or sticky
substance containing the acid. Once formed,
the
acid remains dangerous for years. If it
gets onto the skin, it maybe necessary to
amputate the limb concerned.
• When dealing with a vehicle which has
suffered a fire,
or with components salvaged
from such a vehicle, wear protective gloves
and discard them after use.
The battery
• Batteries contain sulphuric acid, which
attacks clothing, eyes and skin. Take care
when topping-up or carrying the battery.
• The hydrogen gas given
off by the battery
is highly explosive. Never cause a spark
or
allow a naked light nearby. Be careful when
connecting and disconnecting battery
chargers
or jump leads.
Air bags
• Air bags can cause injury ifthey go off
accidentally. Take care when removing the
steering wheel and/orfacia. Special storage
instructions may apply.
Diesel injection equipment
• Diesel injection pumps supply fuel at very
high pressure. Take care when working on
the fuel injectors and fuel pipes.
Warning: Neverexpose the hands,
face
or any other part of the body
to injector spray; the fuel can
penetrate the skin with potentially fatal
results.

o•6 Roadside repairs
The following pages are intended to help in dealing with common roadside emergencies and breakdowns. You will find more
detailed fault finding information at the back
of the manual, and repair information in the main chapters.
car won't start and
.............. _ motor doesn't
[::] If it's a model with automatic transmission, make sure the selector
is in P or N.
O Open the bonnet and make sure that the batteryterminals are
clean and tight.
O Switch on the headlights and try to start the engine. If the
headlights
go very dim when you're trying to start, the battery is
probably flat. Get out
of trouble by jump starting (see next page)
using a friend's
car.
If your car won't start even
though the starter motor
turns as normal
O Is there fuel in the tank?
O Is there moisture on electrical components under the bonnet?
Switch off the ignition, then wipe
off any obvious dampness with
a dry cloth. Spray a water-repellent aerosol product (WD-40
or
equivalent} on ignition and fuel system electrical connectors like
those shown in the photos.
3 Check all multiplugs and wiring
connectors for security.
4Check that all fuses are still in good
condition and none have blown.
Check that electrical connections are secure (with the ignition switched off) and spray them with
a water-dispersant spray like WD-40 if you suspect a problem due
to damp.

When jump-starting a car using a booster
battery, observe the following precautions:
II' Before connecting the booster battery,
make sure that the ignition
is switched
off.
Caution: Remove the keyin case the
central locking engages when the
jump leads are connected.
II' Ensure that all electrical equipment
(lights, heater, wipers, etc)
is switched off.
II' Take note of any special precautions
printed on the battery case.
II' Make sure that the booster battery is the
same voltage as the discharged one in
the vehicle.
v If the battery is being jump-started from
the battery in another vehicle, the
two
vehicles MUST NOTTOUCH each other.
e/ Make sure that the transmission is in
neutral (or PARK, in the case of automatic
transmission).
Connect the other end
of the red lead to
the positive(+) terminal ofthe booster
battery. r
Roadside repairs o•?
Connect the other end of the black jump
lead
to a bolt or bracket on the engine
block, well away from the battery, on the
vehicle
to be started.
Make sure
that the jump leads will not
come intocontactwith thefan, drjve-belts
or other moving parts of the engine.
Start the engine using the booster
battery and run it
at idle speed. Switch
on the lights, rear window demister and
heater blower motor, then disconnect
the jump leads in the reverse order
of
connection. Turn off the lights etc.

o·s Roadside repairs
Wheel changing
Note: MostZafira models are equipped with a puncture repair kit and do not have a spare wheel and jack. If your car has a puncture repair kit,
refer to the information containedon the nextpage.
A\. Warning: Do not change a wheel in a situation where you risk being hit by other traffic. On busyroads, try to stopin a Jay-by or
.£ll.. a gateway. Be wary of passing traffic while changing the wheel- it is easy to become distracted by the job in hand.
Preparation
[] When a puncture occurs, stop as soon as
it is safe to do so.
D Park on firm level ground, if possible, and
well out
of the way of other traffic.
D Use hazard warning lights if necessary.
Changing the wheel
1Lift the
floor covering and open the
storage compartment by lifting and
turning the retaining ring. Release the
strap and lift out the tool bag.
4
On models with steel wheels, use the
special tool to pull the wheel trim from the
wheel.
On models with alloy wheels, use
the screwdriver provided inserted at the wheel
bolt holes to prise off the trim. Slacken each
wheel bolt by half a turn.
D Ifyou have one, use a warning triangle to
alert other drivers
of your presence.
D Apply the handbrake and engage first or
reverse gear gear (or Park on models with
automatic transmission).
2The spare wheel is located under the rear of the car. Unscrew the spare wheel cradle
retaining bolt in the luggage compartment
floor using the wheel brace.
5Locate the jack head below the jacking
point nearest the wheel to be changed;
the jacking point is indicated by
an arrow
in the sill. Turn the handle until the base of the
jacktouches the ground ensuring that the jack
is vertical. Raise the vehicle until the wheel is
clear of the ground. Ifthe tyre is flat make sure
that the vehicle is raised sufficiently to allow
the spare wheel to be fitted.
7Lower the vehicle
to the ground, then
finallytighten the wheel bolts in a diagonal
sequence. Refit the wheel trim. Note that
the wheel bolts should be tightened to the
specified torque at the earliest opportunity.
[] Chock the wheel diagonally opposite the
one being removed - a couple of large
stones will do for this.
D Ifthe ground is soft, use a flat piece of
wood to spread the load underthe jack.
3From under the car, unhook the catch and
lower the spare wheel cradle. Detach the
safety cable and lower the cradle to the
ground. Lift out the spare wheel.
6Remove the bolts and lift the wheel from
the vehicle. Place it beneath the sill
as a
precaution against the jack failing. Fit the
spare wheel and tighten the bolts moderately
with the wheel brace.
Finally ...
D Remove the wheel chocks.
f.J Place the damaged wheel or tyre in the
spare wheel cradle, then raise and secure
the cradle.
~ Stow the jackand tools in the storage
compartment and refit the cover.
D Check the tyre pressure on the wheel
just fitted. If it is low, drive slowly to the
nearest garage and inflate the tyre to the
right pressure.
D Have the punctured wheel repaired at the
earliest opportunity.

Roadside repairs o•9
Using the puncture repair kit
/:... Warning: Do not attempt to repaira punctured tyre in a situation where you risk being hit by other traffic. On busy roads, try to
L..!l., stop in a lay-by or a gateway. Be wary of passing traffic while using the kit - it is easy to becomedistracted by the job in hand.
+. Warning: Repair of a tyre using the puncture repair kit must be regardedas a 'get you home' emergencyrepaironly. A new tyre
~ must be fitted as soon aspossible.
Preparation
O When a puncture occurs, stop as soon as
it is safe to do so.
D Park on firm level ground, if possible, and
well out of the way of other traffic.
Repairing the puncture
1Open the storage compartment cover
located at the right-hand side
of the
luggage
compartment. Take out the
sealant bottle and bracket together with the
air hose.
4Take the long air hose into the car and
screw it onto the connection on the
electric pump.
Important notes
D Use hazard warning lights if necessary.
D If you have one, use a warning triangle to
alert other drivers
of your presence.
2Detach
the air hose from the bracket
and screw it onto the sealant bottle
connection. Slide the sealant bottle onto
the bracket making sure it is fully located and
will not fall
over.
5Open the cover
on the front of the electric
pump, pull out the wiring plug and insert
it into the adjacent accessory socket.
To avoid discharging the battery when the
electric pump is running, it is advisable
to
start the engine.
D If the correct tyre pressure is not obtained within 10 minutes, it is likely that the tyre is too
badly damaged to be repaired with the kit.
D If it is necessary to release the pressure in the tyre, press the '-' button on the electric
pump.
l] The maximum speed sticker attached to the sealant bottle should be placed in the driver's
field
of view. Do not exceed the permitted maximum speed until an undamaged wheel and
tyre have been fitted.
O On completion, disconnect the sealant bottle, tyre repair kit and long air hose, and connect
the end of the short air hose to the free connection on the sealant bottle. This will prevent
any remaining sealant from leaking out.
D Continue driving immediately so that the sealant is evenly distributed around the inside of
the tyre.
[] After driving approximately 6 miles (but no more than 1Ominutes) stop and check the tyre
pressure by connecting the long air hose directly to the tyre valve. As long as the pressure
indicated on the gauge is more than 1 .3 bar (19 psi) it may be adjusted using the electric
pump. If the pressure has fallen below 1.3 bar (19 psi) the repair has not been successful
and the car should not be driven. It will therefore be necessary to seek roadside assistance.
O Apply the handbrake and engage first or
reverse gear gear (or Park
on models with
automatic transmission).
3Unscr~wJhe dust cap from the punctured
tyre, and screw the sealant bottle short air
hose onto the tyre valve.
6Press the '+' button on the electric pump
to start the pump. The pump will initially
pump the sealant into the tyre which will
take approximately 30 seconds, and then start
to inflate the tyre. During the initial 30 second
period the pressure gauge
on the pump will
indicate up to 6 bar (87 psi) and then drop.
The correct tyre pressure
(see end of Weekly
checks) should be obtained within 10 minutes.
The electric pump can then be switched off by
pressing the'+' button again.
Finally ..•
D Stowthe puncture repair kit in the storage
compartment and refit the storage
compartment cover.
O Do not exceed 50 mph until a new tyre
has been fitted.
O Obtain a new sealant bottle as soon as
possible, or another puncture will leave
you stranded.

0·10 Weekly checks
Identifying leaks
Puddles on the garage floor or drive, or
obvious wetness under the bonnet or
underneath the car, suggest a leak that needs
investigating. It
can sometimes be difficult to
decide where the leak is coming from,
especially if the engine bay is very dirty
already. Leaking oil orfluid
can also be blown
rearwards by the passage ofair under the car,
giving a false impression of where the
problem lies.
Sump oil
Engine oil may leak from the drain plug...
Antifreeze
Leaking antifreeze often leaves a crystalline
deposit like this.
Towing
When all else fails, you may find yourself
having to get a
tow home - or of course
you may be helping somebody else.
Long-distance recovery should only be
done by a garage
or breakdown service. For
shorter distances,
DIY towing using another
car
is easy enough, but observe the following
points:
DUse a proper tow-rope they are not
expensive. The vehicle being towed must
display
an ON TOW sign in its rear window.
DAlways turn the ignition key to the 'on'
position when the vehicle is being towed,
so that the steering lock is released, and the
direction indicator and brake lights work.
Warning:
Most automotive oils
and fluids arepoisonous. Wash
them
off skin, and change out
of contaminatedclothing,
without delay.
Oil from filter
...or from the base of the oil filter.
Brake fluid
A leak occurring at a wheel is almost
certainly brake fluid.
D Only attach the tow-rope to the towing eyes
provided.
DTo fit the towing eye, remove the circular
cover from the front or rear bumper, as
required, then screw
in the towing eye anti-
clockwise
as far as it will go using the handle
of the wheel brace to turn the eye. Note that
the towing eye has a left-hand thread.
DA towing eye is provided with the tool kit in
the luggage compartment.
D Before being towed,
release the handbrake
and select neutral
on the transmission. On
models with automatic transmission, special
precautions apply. If
in doubt, do not tow, or
transmission damage may result.
'the smell of a. fluid leahtng
from the car may provld~.a
clue to .what's Ieakin{l, So1m1
t '----" fluids are distinct.lvefy coloured.
It may help to clean ·tne· car carefully
and to park it oversome ~ean paper
overnight as an aid to locating the
source of thefttatt •.
Remember that some leaks may only
isnmnjng.
Gearbox oil
Gearbox oil can leak from the seals at the
inboard ends ofthe driveshafts.
Power steering fluid
Power steering fluid may leak from the pipe
connectors
on the steering rack.
D Note that greater-than-usual pedal pressure
will be required to operate the brakes, since
the vacuum servo unit is only operational with
the engine running.
D Greater-than-usual steering effort will also
be required.
[]The driver of the car being towed must
keep the tow-rope taut at all times
to avoid
snatching.
D Make sure that both drivers know the route
before setting off.
LJ Only drive at moderate speeds and keep the
distance towed to a minimum. Drive smoothly
and allow plenty of time for slowing down at
junctions.

Introduction
There are some very simple checks which
need only take a few minutes to carry out, but
which could save you a lot of inconvenience
and expense.
These Weekly checks require no great skill or
special tools, and the small amount of time
they take
to perform could prove to be very
well spent, for example:
OKeeping an eye on tyre condition and
pressures, will
not only help to stop them
wearing out prematurely, but could also save
your life.
O Many breakdowns are caused by electrical
problems. Battery-related faults
are particularly
common, and a quickcheck
on aregular basis
will often prevent the majority ofthese.
Underbonnet check points
Weekly checks 0•11
O If your car develops a brake fluid leak, the
first time you might know about it is when your
brakes don'twork properly. Checking the level
regularly will give advance warning ofthis kind
of problem.
O If the
oil or coolant levels run low, the cost
of repairing any engine damage will be far
greater than fixing the leak, for example.
.,.. 1.6 litre petrol
1 Engine oillevel dipstick
2 Engine oilfiller cap
3 Coolantreservoir
(expansion tank)
4 Washer fluid reservoir
5 Battery
.,.. 1.8 litre petrol
1 Engine oil level dipstick
2 Engine oilfiller cap
3 Coolant reservoir
(expansion tank)
4 Washer fluid reservoir
5 Battery

0•12 Weekly checks
.... 2.2 litre petrol
1 Engine oillevel dipstick
2 Engine oil filler cap
3 Coolant reservoir
(expansion tank)
4 Washer fluid reservoir
5 Battery
.... 1.9 litre diesel
1 Engine oil level dipstick
2 Engine oil filler cap
3 Coolant reservoir
(expansion tank)
4 Washer fluid reservoir
5 Battery

Engine oil level
Before you start
v Make sure that the car is on level ground.
v The oil level must be checked with the
engine at normal operating temperature,
however, wait at least 5 minutes after the
engine has been switched off.
The correct oil
Modern engines place great demands on their
oil. It is very important that the correct oil for
your car is used
(see Lubricants andfluids).
Car care
• If you have to add oil frequently, you should
check whether you
have any oil leaks. Remove
the engine undershield
and place some clean
paper under the car overnight, and check for
stains
in the morning. Ifthere are no leaks, then
the engine may
be burning oil, or the oil may
only
be leaking when the engine is running.
e Always maintain the level between the
upper and lower dipstick marks (see photo 3).
If the level is too low, severe engine damage
may occur. Oil seal failure may result if the
engine is overfilled by adding too much oil.
Coolant level
A Warning: Do
not attempt to
remove the expansion tank
pressure cap when the engine is
hot, as there
is a very great risk
of scalding. Do not /eave open
containers
of coolant about, as it
is poisonous.
1The
coolant level varies with the
temperature of the engine. When the
engine is cold, the coolant level should
be slightly above the KALT/COLD mark on the
side of the tank. When the engine is hot, the
level will rise.
1The dipstick is brightly coloured for easy
identification (see Underbonnet check
points for exact location). Withdraw the
dipstick.
3Note the level
on the end of the dipstick,
which should be between the
upper
(MAX) mark and lower (MIN) mark.
Approximately 1.0 litre of oil will raise the level
from the lower mark to the upper mark.
Car care
• Adding coolant should not be necessary
on a regular basis. If frequent topping-up is
required, it is likely there
is a leak. Check the
radiator,
all hoses and joint faces for signs of
staining or wetness,
and rectify as necessary.
2
If topping-up is necessary, wait until
the engine is cold. Slowly unscrew
the expansion tank cap,
to release any
pressure present
in the cooling system, and
remove it.
Weekly checks 0•13
2Using a clean rag or paper towel remove
all oil from the dipstick. Insert the clean
dipstick into the tube
as far as it will go,
then withdraw it again.
4Oil is
added through the filler cap.
Unscrew the cap and
top-up the level.
A funnel may help
to reduce spillage.
Add the oil slowly, checking the level
on the
dipstick frequently. Avoid overfilling
(see Car
care).
e It is important that antifreeze is used in the
cooling system
all year round, not just during
the winter months. Don't
top-up with water
alone,
as the antifreeze will become diluted.
3Add a mixture of water and antifreeze
to
the expansion tank until the coolant is up
to the KALT/COLD level mark. Refit the
cap and tighten it securely.

0•14 Weekly checks
Tyre condition and pressure
It is very important that tyres are in good
condition, and atthe correct pressure -having
atyre failure at any speed
is highly dangerous.
Tyre wear
is influenced by driving style -harsh
braking and acceleration,
or fast cornering,
will all produce more rapid tyre wear. As a
general rule, the front tyres wear out faster
than the rears. Interchanging the tyres from
front to rear ("rotating" the tyres) may result in
more even wear. However, if this is
completely effective, you may have the
expense of replacing all four tyres at once!
Remove
any nails or stones embedded in the
tread before they penetrate the tyre to cause
deflation. If removal of a nail does
reveal that
1 Tread Depth - visual check
The original tyres have tread wear safety
bands
(B), which will appear when the tread
depth reaches approximately
1.6 mm. The
band positions are indicated by a triangular
mark
on the tyre sidewall (A).
the tyre has been punctured, refit the nail so
that its point of penetration is marked. Then
immediately change the wheel, and have the
tyre repaired by a tyre dealer.
Regularly check the tyres for damage
in the
form of cuts or bulges, especially in the
sidewalls. Periodically remove the wheels,
and clean any dirt
or mud from the inside and
outside surfaces. Examine the wheel rims for
signs of rusting, corrosion
or other damage.
Light alloy wheels are easily damaged by
"kerbing" whilst parking; steel wheels may
also become dented or buckled. A new wheel
is very often the only way to overcome severe
damage.
2 Tread Depth - manual check
Alternatively, tread wear can be
monitored with a simple, inexpensive device
known
as a tread depth indicator gauge.
Tyre tread wear patterns
Shoulder Wear
Underinflation (wear on both sides)
Under-inflation will cause overheating ofthe
tyre, because the tyre will flex too much, and
the tread will not sit correctly
on the road
surface. This will cause a loss of grip and
excessive wear, not to mention the danger of
sudden tyre failure due to heat build-up.
Check andadjustpressures
Incorrectwheel camber (wear on one side)
Repair or renew suspension parts
Hard cornering
Reduce speed!
Centre Wear
Overinflation
Over-inflation will cause rapid wear
of the
centre part of the tyre tread, coupled with
reduced grip, harsher ride, and the danger of
shock damage occurring
in the tyre casing.
Check and adjustpressures
If you sometimes have to inflate your car's
tyres to the higher pressures specified for
maximum load or sustained high speed, don't
forget to reduce the pressures to normal
afterwards.
New tyres should be balanced when they are
fitted, but it may become necessary
to re-
balance them
as they wear, or if the balance
weights fitted to the wheel rim should fall off.
Unbalanced tyres will wear more quickly, as
will the steering and suspension components.
Wheel imbalance is normally signified by
vibration, particularly at a certain speed
(typically around 50 mph). If this vibration is
felt only through the steering, then it is likely
that just the front wheels need balancing. If,
however, the vibration is felt through the
whole car, the rear wheels could be
out of
balance. Wheel balancing should be carried
out by a tyre dealer or garage.
3 Tyre Pressure Check
Check the tyre pressures regularly with
the tyres cold. Do not adjust the tyre
pressures immediately after the vehicle has
been used,
or an inaccurate setting will result.
Uneven Wear
Front tyres may wear unevenly as a result of
wheel misalignment.
Most tyre dealers and
garages can check and adjust the wheel
alignment (or "tracking") for a modest charge.
Incorrect camber or castor
Repair or renew suspension parts
Malfunctioning suspension
Repair or renew suspension parts
Unbalanced wheel
Balance tyres
Incorrect toe setting
Adjust front wheel alignment
Note: The feathered edge of the tread which
typifies toe wear is bestchecked
by feel.

Weekly checks 0°1s
Brake (and clutch) fluid level
Note: Models with the Easytronic transmission have a clutch fluid reservoir mounted on the transmission (see Chapter 1 A).
Warning:
• Brake fluid can harm your eyes
and damage painted surfaces,
so use extreme caution when
handling and pouring it.
• Do
not use fluid that has been
standing open for some time, as
it absorbs moisture from the air,
which can causea dangerous loss
of braking effectiveness.
1The MAX and MIN marks are indicated
on the side ofthe reservoir. The fluid level
must be kept between the marks at all
times.
Safetyfirst!
e Ifthe reservoir requires repeated topping-up
this is
an indication of a fluid leak somewhere
in the system, which should be investigated
immediately.
CID If a leak is suspected, the car should not
be driven until the braking system has been
checked. Never take any risks where brakes
are concerned
2
If topping-up is necessary, first wipe
clean the area around the filler cap
to
prevent dirt entering the hydraulic system.
Unscrew the reservoir cap.
Screen washer fluid level
CID Screenwash additives not only keep the
windscreen clean during bad weather, they
also prevent the washer system freezing in
cold weather -which
is when you are likely to
need it most. Don't top-up using plain water,
as the screenwash will become diluted, and
will freeze
in cold weather.
Caution:On no account use engine coolant
antifreeze in the screen washer system -
this
may damage the paintwork.
1The reservoir
for the windscreen, rear
window and headlight (where applicable)
washer systems is located
on the front
left-hand side of the engine compartment. If
topping-up
is necessary, open the filler cap.
3Using a funnel and clear plastic tube,
carefully add fluid, taking care not
to
spill it onto the surrounding components.
Use only the specified fluid; mixing different
types can cause damage to the system. After
topping-up to the correct level, securely refit
the cap
and wipe off any spilt fluid.
2 When topping-up the reservoir a screen
wash additive should be added in the
quantities recommended on the bottle.

0•16 Weekly checks
Wiper blades
1Check the condition of the wiper blades;
if they
are cracked or show any signs of
deterioration, or ifthe glass swept area is 2
To remove a windscreen wiper blade, pull
the arm fully away from the screen until it
locks. Swivel the blade through
90°, then
press the two catches on the wiper blade and
remove the blade. Don't forget
to check the
tailgate wiper blade
as well which is removed
in a similar way.
smeared, renew them. Wiper blades should
be renewed annually.
Battery
Caution: Before carrying out any work on
the vehicle battery, read the precautions
given in 'Safety first!' at the start of this
manual. If the battery is to be disconnected,
refer to 'Disconnecting the battery' in the
Reference Chapter, before proceeding.
ti' Make sure that the battery tray is in
good condition, and that the clamp is tight.
Corrosion
on the tray, retaining clamp and the
1The
battery is located at the front,
left-hand side ofthe engine compartment.
Where fitted, open the insulation jacket
around the battery, then check the tightness
of battery clamps to ensure good electrical
connections.
You should not be able to move
them. Also check each cable for cracks
and
frayed conductors.
battery itself can be removed with a solution
of water and baking soda. Thoroughly rinse
all cleaned areas with water. Any metal parts
damaged by corrosion should be covered with
a zinc-based primer, then painted.
ti' Periodically (approximately every three
months), check the charge condition of the
battery
as described in Chapter 5A.
ti' If the battery is flat, and you need to jump
start your vehicle,
see Roadside Repairs.
2If corrosion (white, fluffy deposits) is
evident, remove the cables from the
battery terminals, clean them with a small
wire brush, then refit them. Automotive stores
sell a tool for cleaning the battery post
...
3 ... as well as the battery cable clamps.

Electrical systems
v Check all external lights and the horn. Refer
to the appropriate Sections of Chapter
12 for
details if any of the circuits are found
to be
inoperative. ··
v Visually check all accessible wiring
connectors, harnesses and retaining clips for
security,
and for signs of chafing or damage.
!. ·· .._ It yo~ need to check your
l.
_bral<e llght$Jill'ld indica
·
unaided, baek fJP .. to ii. flitd:11
·1.-_,_...,..,.1 garagedoor,u,d_Qperate;the
ilghtl:.· • t•'he. tefte.cted. .'.ilJh .. . ·. J_ .. ;_11_0~.UI. ·• $ho .. ..w if
theyareworking properlf:.
1If a single indicator light, stop-light
or
headlight has failed, it is likely that a bulb
has blown and will need to be renewed.
Refer
to Chapter 12 for details. If both
stop-lights have failed, it is possible that the
switch
has failed (see Chapter 9).
3Additional fuses and relays are located in
the fuse/relay box on the left-hand side
of the engine compartment. Refer to the
wiring diagrams at the end of Chapter 12
for details
of the fuse locations and circuits
protected.
Weekly checks 0~11
2Ifmorethan one indicatorlight orheadlight
has failed, it
is likely that either a fuse has
blown or that there is a fault
in the circuit
(see Chapter 12). The main fuses are located
behind the trim panel on the left-hand side of
the luggage compartment.
Turn the catches
and open the cover for access to the fuses.
4
To renew a blown fuse, remove it, where
applicable, using the plastic tool provided.
Fit anew fuse ofthe same rating, available
from car accessory shops. It
is important that
you find the reason that the fuse blew
(see
Electrical fault finding in Chapter 12).

0·1a Lubricants, fluids and tyre pressures
Lubricants and fluids
Engine............................................ Multigrade engine oil, viscosity SAE OW/30, OW/40, 5W/30
or 5W/40 to specification ACEAA3, ACEA 83, ACEA A3/B3,
ACEA A3/B3/B4 or higher
Manual and Easytronic transmissions . . . . . . . . . . . . . . . . . . Vauxhall/Opel gear oil
(09 120 541)
Automatic transmission:
AF22 transmission . . . . . . . . . . . . ................. .
AF40 transmission . . . . . . . . . . . . . . . . . . . . .......... .
Power steering reservoir
............................ .
Cooling system
.................................... .
Brake/clutch fluid reservoir
........................... .
Tyre pressures (cold)
Vauxhall/Opel automatic transmission fluid (91 117 946)
Vauxhall/Opel automatic transmission fluid (93 165147)
Vauxhall/Opel steering fluid (90 544 116)
Vauxhall/Opel silicate-free coolant (09194 431/19 40 650)
Hydraulic fluid to DOT 4
Note: Pressures apply to original-equipment tyres, and may vary if any other make or type of tyre is fitted; check with the tyre manufacturer or
supplierfor correctpressures if necessary.
Normal load (up to 3 passengers)
1.6and 1.8 litre petrol models
195/65 R 15, 205/55 R 16 and 225/ 45 R 17 tyres ................ .
225/40 R 18 tyres
......................................... .
2.2 litre petrol models
205/55 R 16 and 225/45 R 17 tyres ........................... .
225/40 R i 8 tyres
......................................... .
1.9 litre diesel
models
195/60 R 16 tyres . . . . . . . . . . . . ............................ .
205/55 R 16 and 225/45 R 17 tyres
........................... .
225/40 R 18 tyres
......................................... .
Fully laden
1.6 and 1.8 litre petrol models
195/65 R 15, 205/55 R 16 and 225/45 R 17 tyres ................ .
225/40 R 18 tyres
........................................ .
2.2 litre
petrol models
205/55 R 16 and 225/45 R 17 tyres ........................... .
225/40 R 18 tyres. . . . . . . . . . . .
............................ .
1.9 litre diesel
models
195/60 R 16 tyres ......................................... .
205/55 R 16 and 225/45 R 17 tyres
........................... .
225/ 40 R 18 tyres. . . ..................................... .
Space-saver temporary spare tyre
All models ............................................... .
Front
2.0 bar (29 psi)
2.2 bar (32 psi)
2.2 bar (32 psi)
2.4 bar (35 psi)
2.6 bar (38 psi)
2.4 bar (35 psi)
2.5 bar (36 psi)
2.1 bar (30 psi)
2.3 bar (33 psi)
2.4 bar (35 psi)
2.5 bar (36 psi)
2.8 bar
(41 psi)
2.6 bar (38 psi)
2.7 bar (39 psi)
4.2 bar
(61 psi)
Rear
2.0 bar (29 psi)
2.2 bar (32 psi)
2.0 bar (29 psi)
2.2 bar (32 psi)
2.4 bar (35 psi)
2.2 bar (32 psi)
2.3 bar (33 psi)
2.6 bar (38 psi)
2.8 bar
(41 psi)
2.9 bar
(42 psi)
3.0 bar (44 psi)
3.2 bar (46 psi)
3.1 bar (45 psi)
3.1 bar (45 psi)
4.2 bar
(61 psi)

1
pet ine maintenance and servicing
I models
Section number
Air cleaner element renewal . . ............................. 27
Automatic transmission fluid renewal.
........................ 30
Auxiliary drivebelt condition check. . . .
...................... 20
Bodywork and underbody condition check
.................... 13
Brake fluid pipe and hose check . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Brake pad and disc check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Clutch hydraulic fluid level check Easytronic models . . . . . . . . . . 6
Coolant renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Driveshaft check. . . . . . . . . . . . . . . .
........................ 1O
Electrical systems check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Engine oil and filter renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Exhaust emission check
................................... 26
Exhaust system check
.................................... 11
Front suspension and steering check . . . . . . . . . . . . . . . . . . . . . . . 9
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Handbrake operation and adjustment check
................... 21
Section number
Headlight beam alignment check. . . . . . . . . . ................. 22
Hinge and lock lubrication . . . . . . . . . . ...................... 15
Hose and fluid leak check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Hydraulic fluid renewal. . . . . . . . . . .
........................ 24
Pollen filter renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Power steering fluid level check. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Rear suspension check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Regular maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Remote control battery renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Road test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Roadwheel bolt tightness check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Service interval indicator reset
.............................. 18
Spark plug renewal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Timing belt, tensioner and idler pulley renewal -1.6 and
1.8 litre engines
....................................... 29
Valve clearance check and adjustment-1.6 litre and 1.8 litre engines . 31
Easy, suitable for
novice with little
experience
~ IFairly easy, suitable ~ IFairly difficult, ~ IDifficult, suitable ~ IVery difficult, ~
~ for beginner with ~ suitablefor competent~ for experienced DIY ~ suitable for expert ~
"°' some experience ~ DIY mechanic ~ mechanic ~ DIY or professional ~

1A•2 Servicing specifications -petrol models
lubricants and fluids ................................. .
Capacities
Engine oil (including oil filter)
1.6 and i
.8 litre engines .................................... .
2.2 litre engines
.......................................... .
Difference between MIN and MAX dipstick marks
................ .
Cooling system
i .6 and 1.8 litre engines:
Without air conditioning . . . .
............................. .
With air conditioning
.................................... .
2.2 litre engines:
With manual transmission . . . . . . . . . . . . . . . . . . . . . .
......... .
With automatic transmission . . . .
......................... .
Transmission
Manual transmission:
Fi 7+ transmission .
M32 transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.......... .
Automatic transmission (at fluid change):
AF22 transmission
...................................... .
AF40 transmission . . . . . . . . . . . . . . . .
.................... .
Easytronic transmission . . . . .
.............................. .
Washerfluid
reservoir
Without headlight washers. . . . . . . . . . . . . . . . . . . . . . . . . ........ .
With headlight washers
.....................•...............
Fuel tank ................... .
Cooling system
Antifreeze mixture;
50% antifreeze
.....
Ignition system
Spark plugs:*
i .6 litre engines ........................................ .
i .8 litre engines ........................................ .
2.2 litre engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
......... .
* Seekmanufacturer's latest recomendations
Brakes
Brake pad friction material minimum thickness .................. .
Torque wrench settings
Oil filter housing cap-to-filter housing (paper element filter):
1.6 litre engines . . . . . . . . . . . . .
......................... .
1.8 and 2.2 litre engines . . . . . . . . . . . . . . . . . . . . . .
........... .
Roadwheel bolts
........................................ .
Spark plugs . . . . . . . . . . . . . . . . . . . . . . . . .
................... .
Sump drain plug:
1.6 and 1.8 litre engines . . . . . . . . . . . . . . . . . . . . .
..... .
2.2 litre engines
........................................ .
Refer
to Weekly checks on page 0• 18
4.5 litres
5.0 litres
1.0 litre
6.1 litres
6.3 litres
7.1 litres
7.6 litres
i .6 litres
2.4 litres
4.0 litres (approximately)
3.0 litres (approximately)
i .6 litres
2.3 litres
4.2 litres
56 litres
Protection down
to -40°C
Type
Bosch FGR 8 KQEO
Bosch
FOR 8 LEU2
Beru
14 FGR-8DQU7
2.0mm
Nm
12
25
110
25
15
25
Electrode gap
1.3 to 1.4 mm
1.0mm
0.8mm
lbfft
9
18
81
18
11
18