The Zafira, produced between 1999 and 2005, is a versatile compact MPV renowned for its practical design and flexible seating arrangements, accommodating up to seven passengers. Based on the Astra G platform and originating from Australia, this vehicle was engineered to meet the needs of families and individuals requiring adaptable space for both passengers and cargo. Its innovative Flex7 seating system, a key feature, allows for effortless conversion between passenger and cargo configurations, maximizing utility. The Zafira offered a range of typically 1.8L and 2.2L gasoline engines, alongside 2.0L diesel options, providing a balance of performance and efficiency for everyday driving.
This comprehensive factory service and repair workshop manual provides detailed information for the Zafira models from 1999 to 2005. It covers all essential systems, including the engine, transmission, electrical systems, chassis, brakes, and bodywork, offering step-by-step instructions for maintenance, repair, and troubleshooting. The manual is designed to assist owners, mechanics, and technicians in understanding and maintaining the vehicle's integrity and performance. With its factory-level detail, easy-to-read text, and high-quality diagrams and exploded pictures, this resource ensures accurate diagnostics and effective repair procedures, supporting the longevity and optimal functioning of your Zafira.
Country Of Origin:
Australia (rebadged Opel/Vauxhall)
Vehicle Segment:
Compact MPV (Multi-Purpose Vehicle) / Seven-seater family car
Key Competitors:
Ford Focus C-Max, Renault Scénic, Volkswagen Golf SV, Citroën Picasso
Practicality:
Versatile seating arrangement (up to 7 seats), modular interior for cargo flexibility
Target Audience:
Families, individuals requiring flexible cargo and passenger space
Primary Coverage:
Complete Factory Service and Repair Workshop Manual
Document Type:
Workshop Manual / Service Manual / Repair Manual
Engine:
Engine Removal/Installation, Crankcase/Piston/Cylinder, Cylinder Head/Valves, Engine Lubrication and Cooling, Engine Fuel System, Fuel Injection System, Engine Combustion System
Transmission:
Gearbox & Clutch, Transmission System, Crankshaft/Transmission/Balancer
Electrical:
Electrical System, Battery/Charging System, Alternator/Starter Clutch, Ignition System, Lights/Meters/Switches, Wiring Diagrams
Chassis:
Chassis, Frame/Body Panels/Exhaust System, Suspension, Front Wheel and Steering System, Rear Wheel System, Wheels & Tyres
Bodywork:
Frame/Body Panels/Exhaust System, Body & Fixtures, Fenders and Exhaust Pipe
Maintenance:
Periodic checks & Adjustments, Maintenance
Repair:
Complete disassembly of the machine, step-by-step instructions for all covered systems
Diagnostics:
Troubleshooting
Installation:
Installation requirements for the manual software
Depth Level:
Comprehensive factory-level detail, suitable for DIY enthusiasts and experienced mechanics
Instruction Style:
Easy-to-read text sections with top quality diagrams and instructions, highly detailed exploded pictures and diagrams
Software Requirements:
Windows 2000 Pro SP3/SP4 (32-bit), Pentium 166 MHz, 48MB RAM, 3GB HDD; Windows XP Pro SP2 (32-bit), Pentium II 300 MHz, 64MB RAM, 3GB HDD. Not compatible with 64-bit operating systems.
Installation Process:
Extract to ISO, burn to DVD (Image Mode) or mount to virtual drive, run AUTORUN.EXE. Choose STANDALONE installation. User Name: TIS, Password: (Blank).
Digital Features:
Searchable text, interactive diagrams (implied by 'top quality diagrams')
Diagram Quality:
Top quality diagrams and highly detailed exploded pictures
Binding:
N/A (Digital PDF)
Engine Options:
Typically 1.8L and 2.2L Opel/Vauxhall Ecotec gasoline engines, and 2.0L diesel engines. Specific engine codes are not detailed in the product info, but the manual covers various configurations.
Horsepower Range:
Approximately 115 hp to 147 hp (gasoline), 100 hp to 125 hp (diesel) depending on engine variant.
Torque Range:
Approximately 170 Nm to 200 Nm (gasoline), 230 Nm to 270 Nm (diesel) depending on engine variant.
Fuel Delivery:
Multi-point fuel injection (gasoline), Direct injection (diesel)
Transmission Type:
5-speed Manual Transmission
Optional Transmission:
Optional 4-speed Automatic Transmission
Clutch Type:
Hydraulic clutch actuation
Seating Capacity:
5 or 7 seats
Cargo Volume Seats Up:
Approx. 150-200 liters (with 7 seats deployed)
Cargo Volume Seats Folded:
Approx. 440-530 liters (with 3rd row folded), up to 1,700+ liters (with all rear seats folded)
Curb Weight:
Approx. 1,500 - 1,650 kg
Euro Ncap Rating:
4 stars (for the European Zafira A model, which the Holden Zafira is based on)
Braking System:
ABS (Anti-lock Braking System), EBD (Electronic Brakeforce Distribution)
Airbags:
Front airbags for driver and passenger, optional side airbags
Seat Belts:
Pretensioner seatbelts with load limiters for front seats, ISOFIX child seat anchorage points
Audio System:
Factory fitted radio/CD player with standard speaker configuration. Higher trims may include upgraded sound systems.
Cruise Control:
Optional cruise control available on many models.
Connectivity Options:
Basic connectivity, typically through audio system inputs (e.g., auxiliary input on later models). No integrated Bluetooth or advanced infotainment systems common in later vehicles.
Oil Change Interval:
Typically every 15,000 km or 12 months, whichever comes first (varies by engine and oil type, refer to specific manual for exact recommendation).
Air Filter Replacement:
Recommended every 30,000 km or 24 months, or as needed based on driving conditions.
Spark Plug Replacement:
Varies by spark plug type; platinum/iridium plugs often have intervals of 60,000 km to 100,000 km.
Engine Oil Type:
API SJ/SL or ACEA A3/B3/B4 specifications, SAE 5W-30 or 5W-40 viscosity grade recommended (check specific engine and climate).
Coolant Type:
Ethylene glycol-based coolant with silicate inhibitors (e.g., G11 or equivalent), mixed 50/50 with distilled water.
Brake Fluid Type:
DOT 4 brake fluid
Transmission Fluid Manual:
API GL-4, SAE 75W-85 or 75W-90 gear oil (for manual transmission).
Transmission Fluid Automatic:
Dexron III or equivalent ATF (for automatic transmission).
Common Problems:
Potential issues include EGR valve clogging (diesel), starter motor solenoid failure, suspension component wear (bushings, ball joints), and occasional electrical gremlins. The 'Flex-Fix' system (integrated bicycle carrier) could also be a point of failure.
Diesel Specific Issues:
Diesel particulate filter regeneration issues on high-mileage vehicles, glow plug failures.
Holden Role:
Holden, the Australian automotive manufacturer, rebadged and sold the Opel/Vauxhall Zafira as part of its model lineup, targeting the Australian market.
Platform Origin:
Based on the Opel/Vauxhall Astra G platform.
Generation:
First generation Zafira (Zafira A), produced from 1999 to 2005 for the Holden market.
Manufacturing Origin:
Primarily manufactured by Opel in Germany and rebadged for Holden.
General Recognition:
The Zafira A platform was generally well-received for its practicality and innovative Flex7 seating system, contributing to the popularity of compact MPVs.
