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Manual Details
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Coverage
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Coverage Areas:
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All Models, Engines, Trims, and Transmission Types within the 2005-2011 Zafira B range.
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Manual Completeness:
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Stated as COMPLETE and INTACT, with no missing or corrupt parts or pages, ensuring all necessary information for repair and maintenance is present.
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Format
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Manual Type:
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Factory Service Repair Workshop Manual
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Language:
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English
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Format:
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Digital (ISO image for installation on compatible operating systems)
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Software Installation Notes:
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Installation may take a long time; users are cautioned not to force quit to prevent corrupted installations.
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Software Requirements
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Compatible Operating Systems:
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Windows 2000 Pro SP3 & SP4 (32-bit) and Windows XP Pro SP2 (32-bit). Explicitly states NOT working on 64-bit OS or Windows 8, 10.
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Minimum Hardware Requirements:
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Pentium 166 MHz CPU, 48 MB RAM, 3 GB Free Hard Disk Space for Windows 2000; Pentium II 300 MHz CPU, 64 MB RAM, 3 GB Free Hard Disk Space for Windows XP.
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Installation
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Installation Process:
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Requires extraction of a compressed archive to an ISO file, burning the ISO to a DVD in IMAGE MODE, or mounting it to a virtual drive, then running AUTORUN.EXE. Offers SERVER/STANDALONE installation choice; STANDALONE is recommended.
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Software User Credentials:
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User Name: TIS, Password: (BLANK/NONE!)
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Manual Coverage
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Systems
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Systems Covered:
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Gearbox & Clutch, Electric Starter, Crankshaft/Transmission/Balancer, Wheels & Tyres, Electrical System, Braking System, Suspension, Engine Lubrication and Cooling, Ignition System, Transmission System, Lubrication System, Rear Wheel System, Cylinder Head/Valves, Cooling System, Engine Removal and Installation, Battery/Charging System, Chassis, Lights/Meters/Switches, Frame/Body Panels/Exhaust System, Alternator/Starter Clutch, Fenders and Exhaust Pipe, Front Wheel and Steering System, Engine Fuel System, Crankcase/Piston/Cylinder, Engine Combustion System, Fuel Injection System, Body & Fixtures.
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Electrical System Detail:
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Comprehensive coverage including the Battery/Charging System, Starter Clutch, Alternator, ignition system, and various lighting, meter, and switch circuits, supported by wiring diagrams.
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Chassis And Body Detail:
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Includes sections on Chassis, Frame/Body Panels/Exhaust System, Fenders and Exhaust Pipe, Front Wheel and Steering System, and Body & Fixtures, covering structural, suspension, steering, and bodywork repairs.
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Wheel And Tyre Maintenance:
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Details on wheel alignment, tire pressure monitoring, wheel bearing replacement, and brake component servicing related to the wheels and tires.
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Procedures
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Procedures Included:
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Periodic checks & Adjustments, Troubleshooting, Maintenance, Step-by-step repair instructions, Complete disassembly procedures, Installation requirements for the manual software.
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Troubleshooting Methodology:
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Provides detailed troubleshooting procedures for diagnosing and resolving various vehicle issues, likely utilizing symptom-based approaches and component testing.
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Engine And Transmission Removal:
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Provides detailed step-by-step instructions for the complete removal and installation of the engine and transmission assemblies, including necessary lifting equipment and supporting procedures.
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Depth
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Technical Depth:
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Comprehensive, covering everything from basic maintenance to complete rebuilds, with exploded diagrams and detailed instructions suitable for both DIY enthusiasts and professional mechanics.
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Technical Depth
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Diagnostic Capabilities:
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The manual facilitates advanced diagnostics through detailed wiring diagrams, component testing procedures, and troubleshooting trees for various systems.
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Engine Specifications
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Primary Engine
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Engine Variants Covered:
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The manual covers all engine variants for the Opel Zafira B (2005-2011), which typically included a range of petrol and diesel engines such as 1.6L, 1.8L, 2.0L, and 2.2L petrol engines, and 1.9L CDTI diesel engines. Specific displacements, horsepower, and torque figures would be detailed within the manual's technical specifications sections.
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Fuel System
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Fuel System Coverage:
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Detailed coverage of Engine Fuel System, Fuel Injection System, Engine Combustion System, including components, operation, diagnostics, and repair procedures.
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Fuel Injection Types:
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Covers various fuel injection systems, likely including Multi-Point Fuel Injection (MPI) for petrol engines and Common Rail Direct Injection (CRDi) for diesel engines, detailing their components and operation.
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Performance
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Power And Torque Details:
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The manual contains comprehensive 'Technical Information & Specifications' which would include detailed power and torque figures for all covered engine variants.
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Cooling System
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Cooling System Components:
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Covers radiator, water pump, thermostat, coolant passages, fan operation, and associated sensors and control modules.
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Transmission
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Standard
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Transmission Types Covered:
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Covers both manual and automatic transmission systems found in the Opel Zafira B (2005-2011), including detailed information on Gearbox & Clutch, Transmission System, and Crankshaft/Transmission/Balancer assembly.
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Gear Ratios:
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Specific gear ratios for all transmission options would be detailed within the manual's 'Transmission System' and 'Technical Information & Specifications' sections.
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Features
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Gearbox Clutch Information:
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Detailed procedures for the Gearbox & Clutch, including removal, installation, adjustment, and repair of clutch components and gearbox internals.
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Dimensions
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Weights
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Curb Weight Range:
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Approximately 1500-1700 kg, depending on engine and specification. Exact figures will be available in the manual's 'Technical Information & Specifications' section.
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Gross Vehicle Weight Rating Gvw:
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Typically around 2200-2350 kg. Precise GVWR for different configurations will be specified in the manual.
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Towing Capacity:
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Towing capacity varies by engine and configuration, typically ranging from 1000 kg to 1500 kg. Exact figures would be in the manual or owner's documentation.
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Exterior
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Wheelbase:
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Approximately 2703 mm. Specific dimensions for length, width, and height are detailed in the manual.
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Interior
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Seating Capacity:
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Designed as a 7-seater MPV with the 'Flex7' system, allowing for flexible seating configurations. Interior dimensions are not explicitly listed but implied by the MPV design.
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Cargo
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Cargo Volume Variability:
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The Zafira B is known for its versatile cargo space due to the Flex7 seating system, allowing for multiple configurations from maximum passenger capacity to maximum cargo hauling. Specific volumes for each configuration would be detailed in owner's information, with repair implications in this manual.
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Safety Features
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Ratings
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Euro Ncap Ratings:
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The Opel Zafira B typically achieved 5-star Euro NCAP ratings for adult occupant protection and 4-star for child occupant protection during its production run. Specific safety features and their operation are covered in the manual.
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Active Features
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Active Safety Systems:
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Coverage includes information on the Braking System (ABS, EBD, Brake Assist), Electronic Stability Program (ESP), Traction Control, and relevant sensor systems.
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Lighting Systems Maintenance:
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Covers the repair and adjustment of all exterior and interior lights, including headlights, taillights, brake lights, turn signals, and cabin lighting, along with meter illumination and switches.
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Passive Features
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Passive Safety Features:
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Information on airbags (front, side, curtain), seatbelt pretensioners, and body structure integrity is implicitly covered within the Chassis and Body sections.
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Technology Features
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Infotainment
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Infotainment Systems Coverage:
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While not explicitly detailed as 'infotainment,' the 'Lights/Meters/Switches' and 'Electrical System' sections would cover the operation, diagnostics, and repair of the vehicle's audio, navigation (if equipped), and instrument cluster components.
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Display And Controls:
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The manual will cover the repair and diagnostics of the central information display, radio controls, climate control panel, and steering wheel buttons.
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Driver Assistance
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Driver Assistance Features Covered:
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Information related to ESP, Traction Control, cruise control (if fitted), and parking assist systems (if equipped) would be found within the relevant system sections like Braking System, Suspension, and Electrical System.
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Parking Assist Systems:
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If equipped with parking sensors, the manual will detail their operation, wiring, and troubleshooting procedures within the electrical or chassis sections.
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Cruise Control System:
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Information on the operation, diagnosis, and repair of the cruise control system, including stalk controls, speed sensors, and ECU integration, would be present in the electrical or specific vehicle systems sections.
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Connectivity
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Connectivity Features Coverage:
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Coverage of phone integration (e.g., Bluetooth hands-free) or USB ports (if fitted) would be part of the 'Electrical System' and 'Lights/Meters/Switches' sections.
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Maintenance
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Service Intervals
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General Maintenance Schedule:
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The manual includes 'Periodic checks & Adjustments' and 'Maintenance' sections which would detail recommended service intervals for oil changes, filter replacements, fluid checks, and other preventative maintenance tasks. These are typically based on mileage or time, whichever comes first.
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Fluid Specifications
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Engine Oil Specification:
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Likely covers various GM dexos specifications (e.g., dexos2) or equivalent SAE viscosity grades such as 5W-30 or 0W-30, depending on the engine and climate. Specific recommendations are detailed in the manual.
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Coolant Specification:
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Typically specifies a silicate-free OAT (Organic Acid Technology) coolant, often green or orange in color, conforming to GM 6277M or similar standards. Capacity and type are detailed in the manual.
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Transmission Fluid Specification:
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For manual transmissions, gear oil specifications (e.g., API GL-4) would be provided. For automatic transmissions, specific ATF (Automatic Transmission Fluid) types like GM DEXRON-VI or equivalent would be listed.
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Brake Fluid Specification:
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Typically requires DOT 4 brake fluid. Specific viscosity and boiling point requirements are detailed in the manual.
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Power Steering Fluid Specification:
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Likely requires a specific type of hydraulic fluid compatible with Opel/GM power steering systems, often a low-viscosity ATF or a dedicated power steering fluid. Specifications are in the manual.
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Air Conditioning Refrigerant:
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Uses R134a refrigerant. The manual would detail refrigerant capacity and handling procedures.
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Known Issues
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Common Problems Covered:
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The 'Troubleshooting' section implies coverage of common issues, which for this model could include topics like EGR valve problems in diesel engines, suspension wear, electrical gremlins, or clutch issues. The manual provides diagnostic procedures to address these.
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Common Engine Issues:
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For diesel variants, the diesel particulate filter (DPF) regeneration issues and injector problems are common. Petrol engines may experience ignition coil failures. The manual provides diagnostic steps for these.
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Common Suspension Issues:
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The manual's suspension section would cover common wear items like shock absorbers, suspension arms, bushings, and potentially issues related to the electronic suspension system if equipped.
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Vehicle History
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Model Evolution
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Model Lineage:
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The Zafira B succeeded the first-generation Zafira A. It built upon the flexible seating 'Flex7' system and offered a more modern design and improved technology. The Zafira B was later succeeded by the Zafira Tourer.
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Facelifts And Updates:
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The Zafira B received a significant facelift in 2008, which updated styling, interior trim, and powertrain options. The manual is specific to the 2005-2011 period, encompassing both pre- and post-facelift models.
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Production
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Production Period:
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2005-2011
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Brand Heritage
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Opel Design Philosophy:
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Opel vehicles, including the Zafira B, often embody a balance of practicality, comfort, and reliable German engineering, aiming to provide versatile and family-oriented transportation.
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