VAUXHALL ZAFIRA Service Repair Manual 1998-2000

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🏷️ Basic Information Identification Make: Vauxhall Model: Zafira Model Code: A Generation: First Generation (A) Production Years Covered By Manual: 1998-2000 Platform: GM M platform 👋 Introduction Market Position Vehicle Segment: Compact MPV (Multi-Purpose Vehicle) / Minivan. Key Selling Points: Versatile seating (Flex7 system), practicality, family-oriented. Competitive Analysis Key Competitors: Ford Galaxy, Volkswagen Sharan, Renault Espace, Fiat Multipla. Key Features Vehicle Type: 7-seater MPV. Body Style: 5-door MPV. Seating System: Flex7 seating system (folding and removable seats). 📋 Manual Details Coverage Areas Regions Covered: Primarily European markets where Vauxhall/Opel vehicles are sold. Engine Coverage: All petrol and diesel engines offered for the Zafira A during 1998-2000 model years. Transmission Coverage: Manual and automatic transmissions. Chassis Systems Coverage: Suspension, steering, brakes, exhaust. Body And Interior Coverage: Body panels, doors, windows, seating, HVAC, trim. Electrical System Coverage: Wiring diagrams, lighting, ignition, starter, charging, comfort systems. Diagnostic Coverage: Troubleshooting guides, fault code interpretation (OBD-II if applicable). Page Count Estimated Page Count: Hundreds of pages (specific count not provided, but implied extensive coverage). Manual Type Type: Service and Repair Manual Purpose: Repair, maintenance, rebuilding, refurbishing, restoration. Language Language: English (assumed, typical for this market). Format Format: PDF Digital Features: Searchable text, hyperlinked table of contents. 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, cylinder head, pistons, crankshaft, timing, lubrication, cooling. Engine Fuel And Emissions: Fuel injection systems (MPI/DI), fuel pump, injectors, emissions control systems. Engine Ignition: Ignition timing, spark plugs, coils, sensors. Transmission Gearbox: Gearbox disassembly, assembly, clutch operation, gear shift mechanisms. Drivetrain: Drive shafts, CV joints, differential (if applicable). Suspension: Front and rear suspension components, shock absorbers, springs, bushings. Steering: Steering column, power steering system, rack and pinion. Brakes: Brake system hydraulics, discs, pads, calipers, ABS components (if equipped). Electrical Charging: Alternator, battery, charging circuits. Electrical Starting: Starter motor, ignition switch, immobilizer system. Lighting: Headlights, taillights, interior lights, fog lights, wiring. HVAC: Heating, ventilation, and air conditioning system components and service. Body Electrical: Power windows, central locking, mirrors, wipers, horn. Procedures Included Preventative Maintenance: Oil changes, filter replacements, fluid checks, belt inspections, spark plug replacement. Routine Repairs: Brake pad replacement, exhaust system repair, suspension component replacement, minor engine component repairs. Major Repairs: Engine rebuilds, transmission overhauls, major electrical system diagnostics and repair. Troubleshooting: Systematic diagnostic procedures for common and uncommon faults. Component Replacement: Step-by-step guides for replacing key components like alternators, starters, fuel pumps, water pumps, etc. Wiring Diagrams: Detailed schematics for all electrical systems. Specifications And Tolerances: Torque values, clearances, fluid capacities, diagnostic parameters. Technical Depth Depth: Comprehensive (from basic maintenance to full rebuilds and diagnostics). Target Audience: Professional mechanics and skilled DIY enthusiasts. 📊 Manual Specifications File Format File Type: PDF (Portable Document Format) Searchability: High (searchable text content). Printability: Yes (designed for printing specific sections or the entire document). Print Quality Image Resolution: High (suitable for clear viewing of diagrams and photos). Binding Type Digital Binding: N/A (PDF format, no physical binding). Paper Type Digital Paper Type: N/A (digital document, renders on screen or printed paper). ⚙️ Engine Specifications Primary Engine Engine Codes And Variants: X18XE (1.8L 16V Petrol), X20XEV (2.0L 16V Petrol), X20DTL (2.0L DTI Diesel), Y20DTH (2.0L DTI Diesel). Performance 1.8L 16V (X18Xe): Displacement: 1796 cc, Power: 115 PS (85 kW) @ 5400 rpm, Torque: 170 Nm (125 lb-ft) @ 3200 rpm. 2.0L 16V (X20Xev): Displacement: 1998 cc, Power: 136 PS (100 kW) @ 5600 rpm, Torque: 188 Nm (139 lb-ft) @ 4000 rpm. 2.0L Dti Diesel (X20Dtl/Y20Dth): Displacement: 1995 cc, Power: 82 PS (60 kW) @ 4200 rpm (X20DTL), 100 PS (74 kW) @ 4200 rpm (Y20DTH), Torque: 185 Nm (137 lb-ft) @ 2000 rpm (X20DTL), 215 Nm (159 lb-ft) @ 1900 rpm (Y20DTH). Fuel System Petrol Engines: Multi-point fuel injection (MPI), Electronic Engine Control (ECU). Diesel Engines: Direct Injection Turbo (DTI), Bosch VP44 injection pump (Y20DTH). Cooling System Coolant Type: Silicate-free OAT coolant (Orange/Pink), GM spec 6277M or equivalent. Coolant Capacity: Approx. 6.5 - 7.5 litres (varies slightly by engine). Lubrication Engine Oil Specification Petrol: API SJ/SL, ACEA A3/B3, viscosity 5W-30 or 10W-40. Engine Oil Specification Diesel: API CF/CF-4, ACEA B3/B4, viscosity 5W-40 or 10W-40. Oil Capacity Petrol: Approx. 4.5 litres (with filter). Oil Capacity Diesel: Approx. 5.5 litres (with filter). 🔧 Transmission Standard Standard Transmission: 5-speed manual gearbox (e.g., F23). Optional Optional Transmission: 4-speed automatic transmission (e.g., AF17/AF22). Features Clutch Type: Hydraulically operated single dry plate clutch. Manual Gearbox Oil: API GL-4 specification, SAE 75W-90 or 80W-90. Automatic Gearbox Fluid: GM Dexron III or equivalent. Automatic Gearbox Fluid Capacity: Approx. 7.0 - 8.0 litres (for complete fill). 📐 Dimensions Exterior Length: 4054 mm (159.6 in) Width: 1740 mm (68.5 in) Height: 1686 mm (66.4 in) Wheelbase: 2690 mm (105.9 in) Cargo Cargo Volume All Seats Up: 130 litres (4.6 cu ft) Cargo Volume With 5 Seats Folded: 470 litres (16.6 cu ft) Cargo Volume...

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Sku: 274025

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Tags: 1998 1999 2000 Car Cars Vauxhall ZAFIRA

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Description

🏷️ Basic Information

Identification

Make:

Vauxhall

Model:

Zafira

Model Code:

Generation:

First Generation (A)

Production Years Covered By Manual:

1998-2000

Platform:

GM M platform

👋 Introduction

Market Position

Vehicle Segment:

Compact MPV (Multi-Purpose Vehicle) / Minivan.

Key Selling Points:

Versatile seating (Flex7 system), practicality, family-oriented.

Competitive Analysis

Key Competitors:

Ford Galaxy, Volkswagen Sharan, Renault Espace, Fiat Multipla.

Key Features

Vehicle Type:

7-seater MPV.

Body Style:

5-door MPV.

Seating System:

Flex7 seating system (folding and removable seats).

📋 Manual Details

Coverage Areas

Regions Covered:

Primarily European markets where Vauxhall/Opel vehicles are sold.

Engine Coverage:

All petrol and diesel engines offered for the Zafira A during 1998-2000 model years.

Transmission Coverage:

Manual and automatic transmissions.

Chassis Systems Coverage:

Suspension, steering, brakes, exhaust.

Body And Interior Coverage:

Body panels, doors, windows, seating, HVAC, trim.

Electrical System Coverage:

Wiring diagrams, lighting, ignition, starter, charging, comfort systems.

Diagnostic Coverage:

Troubleshooting guides, fault code interpretation (OBD-II if applicable).

Page Count

Estimated Page Count:

Hundreds of pages (specific count not provided, but implied extensive coverage).

Manual Type

Type:

Service and Repair Manual

Purpose:

Repair, maintenance, rebuilding, refurbishing, restoration.

Language

Language:

English (assumed, typical for this market).

Format

Format:

Digital Features:

Searchable text, hyperlinked table of contents.

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, cylinder head, pistons, crankshaft, timing, lubrication, cooling.

Engine Fuel And Emissions:

Fuel injection systems (MPI/DI), fuel pump, injectors, emissions control systems.

Engine Ignition:

Ignition timing, spark plugs, coils, sensors.

Transmission Gearbox:

Gearbox disassembly, assembly, clutch operation, gear shift mechanisms.

Drivetrain:

Drive shafts, CV joints, differential (if applicable).

Suspension:

Front and rear suspension components, shock absorbers, springs, bushings.

Steering:

Steering column, power steering system, rack and pinion.

Brakes:

Brake system hydraulics, discs, pads, calipers, ABS components (if equipped).

Electrical Charging:

Alternator, battery, charging circuits.

Electrical Starting:

Starter motor, ignition switch, immobilizer system.

Lighting:

Headlights, taillights, interior lights, fog lights, wiring.

HVAC:

Heating, ventilation, and air conditioning system components and service.

Body Electrical:

Power windows, central locking, mirrors, wipers, horn.

Procedures Included

Preventative Maintenance:

Oil changes, filter replacements, fluid checks, belt inspections, spark plug replacement.

Routine Repairs:

Brake pad replacement, exhaust system repair, suspension component replacement, minor engine component repairs.

Major Repairs:

Engine rebuilds, transmission overhauls, major electrical system diagnostics and repair.

Troubleshooting:

Systematic diagnostic procedures for common and uncommon faults.

Component Replacement:

Step-by-step guides for replacing key components like alternators, starters, fuel pumps, water pumps, etc.

Wiring Diagrams:

Detailed schematics for all electrical systems.

Specifications And Tolerances:

Torque values, clearances, fluid capacities, diagnostic parameters.

Technical Depth

Depth:

Comprehensive (from basic maintenance to full rebuilds and diagnostics).

Target Audience:

Professional mechanics and skilled DIY enthusiasts.

📊 Manual Specifications

File Format

File Type:

PDF (Portable Document Format)

Searchability:

High (searchable text content).

Printability:

Yes (designed for printing specific sections or the entire document).

Print Quality

Image Resolution:

High (suitable for clear viewing of diagrams and photos).

Binding Type

Digital Binding:

N/A (PDF format, no physical binding).

Paper Type

Digital Paper Type:

N/A (digital document, renders on screen or printed paper).

⚙️ Engine Specifications

Primary Engine

Engine Codes And Variants:

X18XE (1.8L 16V Petrol), X20XEV (2.0L 16V Petrol), X20DTL (2.0L DTI Diesel), Y20DTH (2.0L DTI Diesel).

Performance

1.8L 16V (X18Xe):

Displacement: 1796 cc, Power: 115 PS (85 kW) @ 5400 rpm, Torque: 170 Nm (125 lb-ft) @ 3200 rpm.

2.0L 16V (X20Xev):

Displacement: 1998 cc, Power: 136 PS (100 kW) @ 5600 rpm, Torque: 188 Nm (139 lb-ft) @ 4000 rpm.

2.0L Dti Diesel (X20Dtl/Y20Dth):

Displacement: 1995 cc, Power: 82 PS (60 kW) @ 4200 rpm (X20DTL), 100 PS (74 kW) @ 4200 rpm (Y20DTH), Torque: 185 Nm (137 lb-ft) @ 2000 rpm (X20DTL), 215 Nm (159 lb-ft) @ 1900 rpm (Y20DTH).

Fuel System

Petrol Engines:

Multi-point fuel injection (MPI), Electronic Engine Control (ECU).

Diesel Engines:

Direct Injection Turbo (DTI), Bosch VP44 injection pump (Y20DTH).

Cooling System

Coolant Type:

Silicate-free OAT coolant (Orange/Pink), GM spec 6277M or equivalent.

Coolant Capacity:

Approx. 6.5 - 7.5 litres (varies slightly by engine).

Lubrication

Engine Oil Specification Petrol:

API SJ/SL, ACEA A3/B3, viscosity 5W-30 or 10W-40.

Engine Oil Specification Diesel:

API CF/CF-4, ACEA B3/B4, viscosity 5W-40 or 10W-40.

Oil Capacity Petrol:

Approx. 4.5 litres (with filter).

Oil Capacity Diesel:

Approx. 5.5 litres (with filter).

🔧 Transmission

Standard

Standard Transmission:

5-speed manual gearbox (e.g., F23).

Optional

Optional Transmission:

4-speed automatic transmission (e.g., AF17/AF22).

Features

Clutch Type:

Hydraulically operated single dry plate clutch.

Manual Gearbox Oil:

API GL-4 specification, SAE 75W-90 or 80W-90.

Automatic Gearbox Fluid:

GM Dexron III or equivalent.

Automatic Gearbox Fluid Capacity:

Approx. 7.0 - 8.0 litres (for complete fill).

📐 Dimensions

Exterior

Length:

4054 mm (159.6 in)

Width:

1740 mm (68.5 in)

Height:

1686 mm (66.4 in)

Wheelbase:

2690 mm (105.9 in)

Cargo

Cargo Volume All Seats Up:

130 litres (4.6 cu ft)

Cargo Volume With 5 Seats Folded:

470 litres (16.6 cu ft)

Cargo Volume With All Seats Removed:

1400 litres (49.4 cu ft)

Weights

Kerb Weight Approx:

1390 kg - 1530 kg (depending on engine/spec).

Gross Vehicle Weight Rating Gvwr:

Approx. 2000 kg - 2100 kg.

Wheels And Tires

Wheel Bolt Pattern:

5 x 110 mm

Wheel Size:

15-inch or 16-inch standard, 17-inch optional.

Tire Sizes:

Common sizes include 195/65 R15, 205/55 R16, 205/50 R17.

🛡️ Safety Features

Ratings

Euro Ncap Rating:

N/A (Euro NCAP testing for this model year often focused on individual components or less standardized scoring than modern ratings).

Active Features

Standard on most models, optional on some early variants.

Traction Control:

Optional on higher trims and later models.

Passive Features

Airbags:

Driver and front passenger airbags standard. Side airbags optional.

Seatbelts:

Three-point seatbelts for all seven occupants, pre-tensioners for front seats.

Child Seat Anchors:

ISOFIX mounting points for child seats in rear seating rows.

💡 Technology Features

Infotainment

Audio System:

Factory fitted radio/cassette or CD players, with options for upgraded head units.

Speaker Configuration:

Typically 4 or 6 speakers.

Driver Assistance

Cruise Control:

Optional on higher trim levels.

Connectivity

Phone Integration:

Limited or non-existent for this era; aftermarket solutions would be required.

🔧 Maintenance

Service Intervals

Oil And Filter Change Petrol:

Every 15,000 km (9,300 miles) or 1 year, whichever comes first.

Oil And Filter Change Diesel:

Every 10,000 km (6,200 miles) or 1 year, whichever comes first (older interval for diesel).

Air Filter Replacement:

Every 30,000 km (18,600 miles) or 2 years.

Fuel Filter Replacement Diesel:

Every 60,000 km (37,200 miles) or 3 years.

Spark Plug Replacement Petrol:

Every 60,000 km (37,200 miles) or 4 years (check specific plug type).

Timing Belt Replacement:

Every 120,000 km (74,500 miles) or 6 years (critical for all engines, requires replacement of tensioners and idlers).

Fluid Specifications

Brake Fluid:

DOT 4.

Power Steering Fluid:

GM Power Steering Fluid or Pentosin CHF 11 S.

Known Issues

Common Problem 1:

EGR valve clogging (diesel engines), leading to rough running and emissions issues.

Common Problem 2:

Front suspension wear (bushings, drop links), causing knocking noises and poor handling.

Common Problem 3:

Ignition coil failure (petrol engines), resulting in misfires and rough idling.

Common Problem 4:

DPF (Diesel Particulate Filter) issues or clogging on later diesel models (less prevalent on early 1998-2000 models but worth noting for potential later upgrades).

Common Problem 5:

Power steering pump leaks or failure.

Common Problem 6:

ABS sensor failures.

Common Problem 7:

Water pump leaks, particularly around the timing belt drive.

📚 Vehicle History

Brand Heritage

Vauxhall Legacy:

Vauxhall, a British automotive manufacturer, has a long history of producing popular and reliable vehicles, often sharing platforms with Opel in Germany.

Model Evolution

Zafira Introduction:

The Zafira A was launched in 1999 as Vauxhall/Opel's first compact MPV, based on the Astra G platform.

Flex7 System:

The innovative Flex7 seating system allowed for easy conversion between 5 and 7-seat configurations without seat removal, a major selling point.

Facelift:

A minor facelift occurred in 2003, but this manual covers the pre-facelift models.

Production

Production Location:

Primarily manufactured in Germany (Opel Rüsselsheim plant) and Poland (Opel Gliwice plant).

Production Period:

First generation (A) produced from 1999 to 2005.

🏆 Awards & Recognition

Recognitions

Industry Awards:

The Zafira was generally well-received and contributed significantly to Vauxhall/Opel's market share in the MPV segment.

Specific Accolades:

While specific major awards for the 1998-2000 models aren't widely cited, its practical design and Flex7 system were lauded by motoring press and consumers alike.