🏷️ Basic Information

Make:

Opel / Vauxhall

Model:

Zafira

Generation:

A

Platform Code:

GM F-body (F3500)

👋 Introduction

Segment:

Compact MPV (Multi-Purpose Vehicle), known for its flexible seating and family-oriented design.

Competitors:

Ford Galaxy, Volkswagen Sharan, SEAT Alhambra, Renault Scenic, Chrysler Voyager.

Flexibility:

The Zafira's signature Flex7 seating system allows for easy conversion between seating configurations, offering exceptional practicality for families.

Practicality:

Designed with family needs in mind, offering ample interior space, versatile cargo options, and a comfortable ride.

Design Philosophy:

Focus on practicality, spaciousness, and versatility for family transportation.

📋 Manual Details

Covered Years:

1998, 1999, 2000

Total Pages:

296

Type:

Workshop Service Repair Manual

Language:

English

File Format:

PDF

📖 Manual Coverage

Engine:

Comprehensive coverage of engine disassembly, assembly, diagnosis, repair, and specifications. Includes detailed procedures for cooling system, lubrication system, fuel system, ignition system, emission control system, and engine management.

Transmission:

Detailed repair and overhaul procedures for manual and automatic transmissions, including clutch, gearbox, torque converter, and driveline components.

Brakes:

Complete information on brake system diagnosis, repair, and maintenance, including hydraulic systems, disc and drum brakes, ABS, and parking brake.

Electrical System:

In-depth coverage of the vehicle's electrical system, including battery, charging system, starting system, lighting, ignition, instrumentation, power windows, locks, and advanced diagnostic procedures with wiring diagrams.

Suspension And Steering:

Detailed instructions for the diagnosis, repair, and alignment of suspension and steering components, including shock absorbers, struts, control arms, ball joints, tie rods, power steering systems, and wheel alignment specifications.

Body And Chassis:

Procedures for bodywork repair, panel replacement, interior trim removal, glass replacement, and chassis component servicing.

Heating Ventilation And Air Conditioning (HVAC):

Diagnostic and repair procedures for the HVAC system, including refrigerant handling, component replacement, and system operation.

Exhaust System:

Information on diagnosis, repair, and replacement of exhaust components, including catalytic converter, mufflers, and pipes.

Fuel Tank And Lines:

Procedures for fuel tank, fuel pump, and fuel line removal, installation, and inspection.

Cooling System:

Detailed procedures for radiator, water pump, thermostat, hoses, and fan replacement and troubleshooting.

Ignition System:

Coverage of spark plugs, ignition coils, distributors (if applicable), and ignition timing adjustments.

Lighting System:

Headlight, taillight, interior lighting, and auxiliary lighting diagnosis and bulb replacement.

Instrumentation And Gauges:

Troubleshooting and repair of the instrument cluster, gauges, and warning lights.

Maintenance:

Routine maintenance procedures, fluid changes, filter replacements, inspection schedules, and general upkeep recommendations.

Troubleshooting:

Systematic troubleshooting guides with diagnostic charts, symptom-based problem identification, and corrective actions for various issues.

Repair:

Step-by-step repair instructions for all major vehicle components, including detailed disassembly, reassembly, and adjustment procedures.

Installation:

Procedures for the correct installation of replacement parts and accessories.

Diagnostics:

Detailed diagnostic strategies, fault code interpretation (where applicable), and testing procedures for various electronic and mechanical systems.

Body Repair:

Dent repair, panel replacement, welding procedures, and rust prevention techniques.

Interior Trim Removal:

Instructions for removing and refitting dashboard panels, door cards, headliner, and seats.

Glass Replacement:

Procedures for replacing windshields, side windows, and rear windows.

Special Tools:

References to specific special service tools required for certain procedures, often accompanied by illustrations.

Depth:

Comprehensive, covering everything from basic maintenance and adjustments to complete engine and transmission overhauls. Includes detailed torque specifications, wear limits, and technical data necessary for professional-level repairs.

📊 Manual Specifications

Readability:

High-resolution PDF, zoomable for clarity.

Compatibility:

Compatible with Windows, Mac, and Linux operating systems.

Software Requirement:

Requires Adobe Reader or a compatible PDF viewer.

Printability:

Fully printable, allowing users to print specific sections or the entire manual.

Digital Binding:

Instant download PDF, no physical binding.

Digital Paper Simulation:

Simulates standard workshop manual paper quality with clear text and diagrams.

⚙️ Engine Specifications

Engine Options 1998-2000:

1.6L 16V Ecotec (X16XEL), 1.8L 16V Ecotec (X18XE1), 2.0L 16V Ecotec (X20XEV). Also available with a 2.0L DTI (X20DTL/Y20DTL) diesel engine.

1.8L Ecotec (X18Xe1) Power:

Approx. 115 PS (113 bhp; 85 kW)

1.8L Ecotec (X18Xe1) Torque:

Approx. 170 Nm (125 lb-ft)

Injection Type:

Multi-point fuel injection (MPI) for gasoline engines.

Fuel Recommendation:

Unleaded gasoline with an octane rating of 95 (RON) for gasoline engines.

2.0L Diesel (X20Dtl/Y20Dtl) Power:

Approx. 82 PS (81 bhp; 60 kW)

🔧 Transmission

Manual Transmission:

5-speed manual transmission (e.g., F17, F23 variants).

Automatic Transmission:

4-speed automatic transmission (e.g., AF13, AF22 variants).

Clutch Type:

Dry single-plate clutch for manual transmissions.

📐 Dimensions

Length:

Approx. 4517 mm (177.8 in)

Width:

Approx. 1705 mm (67.1 in) without mirrors

Height:

Approx. 1685 mm (66.3 in)

Curb Weight Est:

Approx. 1450-1550 kg (3197-3417 lbs) depending on engine and configuration.

Gross Vehicle Weight Rating Gvwr Est:

Typically around 2100-2200 kg.

Cargo Volume Max:

Up to approx. 1800 liters with rear seats folded.

🛡️ Safety Features

Euro Ncap Early Ratings:

Early models received Euro NCAP ratings, typically around 3 or 4 stars for adult occupant protection, with varying results for child and pedestrian protection depending on testing methodology of the era.

ABS:

Anti-lock Braking System (ABS) available as an option or standard on higher trims.

Traction Control:

Traction Control System (TC/ASR) may be available on certain models.

Airbags:

Front airbags for driver and front passenger standard. Side airbags may be optional.

Seat Belts:

Three-point seat belts with pre-tensioners for front seats. All rear seats equipped with three-point seat belts.

💡 Technology Features

Audio System:

Factory fitted radio/cassette player or CD player with up to 6 speakers. Basic but functional audio systems for the era.

Cruise Control:

Optional cruise control system available on some models for enhanced long-distance comfort.

Early Phone Integration:

Limited to optional Bluetooth hands-free systems on later models of this generation, or basic mobile phone holders.

🔧 Maintenance

Oil Change Interval:

Typically every 15,000 km (approx. 9,300 miles) or 1 year, whichever comes first, though variations exist based on engine type and driving conditions. Check manual for specific engine.

Engine Oil Viscosity Gasoline:

Commonly specified as 5W-30 or 10W-40 meeting GM specifications like GM-LL-A-025 or equivalent API/ACEA standards.

Coolant Type:

GM-Gen 1 or Gen 2 coolant (blue or purple) or equivalent OAT/HOAT coolant meeting GM GVL 7700 specification.

Brake Fluid Type:

DOT 4 brake fluid.

Transmission Fluid Manual:

API GL-4 or GL-5 gear oil (viscosity typically 75W-85 or 75W-90).

Transmission Fluid Automatic:

GM Dexron III or equivalent ATF fluid.

Common Problems:

Potential issues include EGR valve clogging (diesel engines), ignition coil failure, thermostat housing leaks, ABS sensor faults, and occasional issues with the Flex7 seat mechanisms.

Timing Belt Replacement Interval:

100,000 km (approx. 60,000 miles) or 5-6 years for gasoline engines, check manual for specific interval and engine code.

📚 Vehicle History

Opel Legacy:

Opel, a German manufacturer with a long history dating back to 1898, known for producing reliable and practical vehicles.

Zafira First Generation:

Launched in 1999, the first-generation Zafira (A) was Opel's entry into the compact MPV segment, built on the Astra G platform. It popularized the 'mini-MPV' concept in Europe.

Manufacturing Locations:

Primarily manufactured in Germany (Bochum) and Poland (Gliwice) for European markets.

🏆 Awards & Recognition

Van Of The Year:

The Zafira was generally well-received and praised for its innovative Flex7 system, contributing to its strong sales performance and reputation as a practical family vehicle.