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Contents

2

Introduction

4

Your Vauxhall/Opel Zafira Manual

4

Project Vehicles

4

Acknowledgements

4

Safety First

5

General Hazards

5

Special Hazards

5

Roadside Repairs

6

If Your Car Won’t Start and the Starter Motor Doesn’t Turn

6

If Your Car Won’t Start Even Though the Starter Motor Turns as Normal

6

Jump Starting

7

Wheel Changing

8

Using the Puncture Repair Kit

9

Weekly Checks

10

Identifying Leaks

10

Towing

10

Sump Oil

10

Underbonnet Check Points

11

1.6 Litre Petrol

11

1.8 Litre Petrol

11

2.2 Litre Petrol

12

1.9 Litre Diesel

12

Engine Oil Level

13

Coolant Level

13

Before You Start

13

Car Care

13

Tyre Condition and Pressure

14

Tyre Tread Wear Patterns

14

Shoulder Wear

14

Centre Wear

14

Brake Fluid Level

15

Screen Washer Fluid Level

15

Wiper Blades

16

Battery

16

Electrical Systems

17

Lubricants, Fluids and Tyre Pressures

18

Routine Maintenance and Servicing — Petrol Models

19

Degrees of Difficulty

19

19

Servicing Specifications — Petrol Models

20

Maintenance Schedule — Petrol Models

21

Component Location — Petrol Models

22

Underbonnet View of a 1.6 Litre Model

22

Underbonnet View of a 1.8 Litre Model

22

Underbonnet View of a 2.2 Litre Model

23

Front Underbody View

23

Rear Underbody View

24

Maintenance Procedures

24

General Information

24

Regular Maintenance

24

Every 10 000 Miles or 6 Months

25

Removing the Oil Filler Cup

25

Using an Oil Filler Removal Tool to Slacken the Canister-Type Filter

25

Engine Oil and Filter Renewal

25

Every 20 000 Miles or 12 Months

26

Unscrew the Filter Cup

26

Withdraw Together with the Element

26

Separate the Element from the Cap

26

Power Steering Fluid Level Check

27

Clutch Hydraulic Fluid Level Check

27

Brake Pad and Disk Check

27

Brake Fluid Pipe and Hose Check

27

Front Suspension and Steering Check

28

Driveshaft Check

28

Exhaust System Check

28

Rear Suspension Check

28

Bodywork and Underbody Condition Check

29

Roadwheel Bolt Tightness Check

29

Electrical Systems Check

29

Road Test

29

Every 40 000 Miles or 2 Years

30

Pollen Filter Renewal

30

Auxiliary Drivebelt Condition Check

30

Checking

30

Every 2 Years, Regardless of Mileage

31

Handbrake Operation and Adjustment Check

31

Headlight Beam Alignment Check

31

Hydraulic Fluid Renewal

31

Coolant Renewal

32

Exhaust Emission Check

32

Cooling System Draining

32

Cooling System Flushing

32

Every 40 000 Miles or 4 Years

33

Air Claner Element Renewal

33

Spark Plug Renewal

33

Disconnect Wiring Connector from Inlet Air Temperature Sensor

33

Every 100 000 Miles or 10 Years

34

Measuring a Spark Plug Electrode Gap Using a Feeler Blade

34

Measuring a Spark Plug Electrode Gap Using a Wire Gauge

34

Routine Maintenance and Servicing — Diesel Models

35

Coolant Renewal

35

Driveshaft Check

35

Handbrake Operation and Adjustment Check

35

Hinge and Lock Lubrication

35

Hose and Fluid Leak Check

35

Pollen Filter Renewal

35

Power Steering Fluid Level Check

35

Rear Suspension Check

35

Servicing Specifications — Diesel Models

36

Maintenance Schedule — Diesel Models

37

Component Location — Diesel Models

38

Underbonnet View of an SOHC Engine Model

38

Primary Operations

39

Secondary Operations

39

Regular Maintenance

39

Maintenance Procedures — Diesel Models

40

Engine Oil Drain Plug Location

40

Unscrew the Filter Cap and Withdraw It Together with the Element

40

Remove the Two O-Ring Seals

40

Hose and Fluid Leak Check

41

Fuel Filter Water Draining

41

Power Steering Fluid Reservoir Filler Cap

41

The Fluid Level Should be up to the MAX Mark on the Dipstick

41

Brake Pad and Disc Check

42

Check for Wear in the Hub Bearings by Grasping the Wheel

42

Check the Condition of the Driveshaft Gaiters and the Retaining Clips

42

Hinge and Lock Lubrication

43

Bodywork Damage/Corrosion Check

43

Corrosion Protection Check

43

Exhaust Mountings

43

Service Interval Indicator Reset

44

Fuel Filter Renewal

44

Instruments and Electrical Equipment

44

Steering and Suspension

44

Using Home-Made Tool to Slacken Filter Housing Cover Retaining Ring

45

Unscrew and Remove the Cover Retaining Ring

45

Lift the Cover Together with the Filter Element

45

Recover the 0-Ring Seal

45

Hanbrake Operation and Adjustment Check

46

Turn Drivebelt Tensioner Using Spanner on the Pulley Centre Bolt

46

Lock Tensioner by Inserting a Drill Bit through Hole on Tensioner

46

Handbrake Cable Adjuster Nut

46

Remote Control Battery Renewal

47

Hydraulic Fluid Renewall

47

Radiator Flushing

47

Engine Flushing

47

Air Cleaner Element Renewal

48

Cooling System Filling

48

Antifreeze Mixture

48

Open Bleed Screw in Coolant Pipe above the Exhaust Manifold

48

Every 50 000 Miles or 6 Years

49

Every 80 000 Miles or 10 Years

49

1.6 and 1.8 Litre Petrol Engine In-Car Repair Procedures

51

Specifications

51

Compression Test — General Information

53

Top Dead Centre for no 1 Piston — Locating

53

How to Use the Chapter

53

Engine Description

53

Camshaft Cover — Removal and Refitting

54

Align the Camshaft Sprocket Timing Marks on 1.6 Litre Engines

54

Notch on Crankshaft Pulley Rim with Mark at Base of Timing Belt Cover

54

Locate Rubber Seal into Grooves of Camshaft Cover

54

Crankstlaft Pulley- Removal and Refitting

55

Timing Belt Covers — Removal and Refitting

55

Upper Cover

55

Lower Cover

55

Timingt Belt — Removal and Refitting

56

Centre Cover (1.8 Litre Engines)

56

Rear Cover

56

Auxiliary Drivebelt Tensioner Retaining Bolt

56

Timing Belt Sprockets, Tensioner and Idler Pulley

57

Camshaft Sprockets

57

Insert Tool into Slots on End of Camshafts to Lock Camshafts

57

Camshaft Sprocket Closure Bolts

57

VVT Oil Control Valves

58

Camshaft Oil Seals

58

Valve Clearances

58

Crankshaft Sprocket

58

Camshaft and Followers

59

Using Feeler Blades, Measure Intake Valve Clearances

59

Camshaft Bearing Cap Numbering Sequence

59

Camshaft Bearing Cap Numbers

59

Use a Valve Lapping Tool to Remove the Cam Followers

60

Apply a Smear of Sealant to the Right-Hand Bearing Caps

60

Camshaft Bearing Cap Tightening Sequence

60

Camshaft Bearing Support Retaining Bolts

60

Cylinder Head

61

Preparation for Refitting

62

Refitting

62

Cylinder Head Bolt Loosening Sequence

62

Cylinder Head Bolt Tightening Sequence

62

Sump

63

Oil Pump

63

Tighten Cylinder Head Bolts to Specified Stage 1 Torque Setting

63

Remove Securing Screws and Withdraw Oil Pump Cover from Rear Housing

63

Unscrew the Oil Pressure Relief Valve Cap

64

Withdraw the Spring

64

Check Oil Pump Rotor Endfloat Using a Straight-Edge and Feeler Gauge

64

Oil Filler Housing

65

Crankshaft Oil Seals

65

Flywheel

65

Right-Hand

65

Inspection

66

Renewal

66

Left-Hand Mounting

66

Front Mounting/Torque Link

66

Rear Mounting/Torque Link

67

Rear Engine Mounting/Torque Link Retaining Bolts and Nut

67

2.2 Litre Petrol Engine In-Car Repair Procedures

69

Valve Timing

71

Operations with Engine in Car

71

Vauxhall/Opel Camshaft Locking Tool

71

Camshaft Cover

72

Crankshaft Pulley/Vibration Damper

72

Crankshaft Pulley and Timing Chain Cover Timing Marks

72

Locking Camshaft Sprockets in Position Using Vauxhall/Opel Tool

72

Timing Chain Cover

73

Turn Pulley until Flat on Centre Hub Locates with Oil Pump Drive

73

Fit a New Securing Bolt to the Pulley

73

Tighten Crankshaft Pulley Whilst Preventing Pulley Rotation

73

Timing Chain Tensioners

74

Camshaft Chain Tensioner

74

Carefully Lever Old Crankshaft Oil Seal out of Cover

74

Using a Suitable Drift Tap in the New Oil Seal

74

Timing Chains and Sprockets

75

Balance Shaft Chain Tensioner

75

Chain Tensioner and Guide Rails

75

Turn Inner Piston Screw Clockwise until It Locks in Position

75

Camshaft Chain and Sprockets

76

Balance Shaft Chain and Sprockets

76

Align Silver Link with Triangular Timing Mark on Exhaust Sprocket

76

Copper-Coloured Link with Diamond Timing Mark on Intake Sprocket

76

Undo the Retaining Bolts and Remove the Tension Rail and Guide Rails

77

Using a Drift to Lock the Balance Shaft Sprocket

77

Refit the Timing Chain Crankshaft Sprocket

77

Turning the Camshaft Slightly Using an Open-Ended Spanner

77

Use New Retaining Bolts When Refitting the Sliding Rail

78

Refit Balance Shaft Crankshaft Sprocket

78

Refit the Balance Shaft Sprockets Using New Securing Bolts

78

The Arrow Points Upwards on the Intake Sprocket

78

Alignment Marks Made on Camshaft Sprockets for Refitting

79

Use Container Used to Keep Followers and Hydraulic Tappets in Order

79

Keep Hydraulic Tappets in Labelled Containers with Clean Engine Oil

79

Lubricate Tappets with Clean Engine Oil before Refitting

79

Apply Silicone Sealing Compound Thinly to Surface Areas Arrowed

80

Refitting no 11 Cap to Flywheel/Driveplate End of Intake Camshaft

80

Refit New Retaining Bolts to the Camshaft Sprockets

80

Remove Two Coolant Hoses from Front of Cylinder Head

80

Using a Tap to Clean out the Threads in the Cylinder Block

81

Check Dowels Are in Position to Locate Cylinder Head Gasket

81

Ensuring Gasket Is Fitted with Its OBEN/TOP Marking Uppermost

81

Tightening Cylinder Head down through Its Stages, Using an Angle Gauge

81

Fit Four New Retaining Bolts to Timing Chain End Cylinder Head

82

Two of Bolts Are Inside Timing Chain Housing

82

Undo Two Sump to Transmission Bolts and also Sump-To-Lower Cylinder

82

Apply Continuous Bead of Silicone Sealer Around Sump

82

Balance Shaft

83

Undo Retaining Screws and Remove the Pump Cover Plate

83

Removing the Inner and Outer Rotors

83

Using a Feeler Blade to Check Inner-To-Outer Rotor Clearance

83

Flywheel/Driveplate

84

Manual Transmission Models

84

Automatic Transmission Models

84

Undo the Retaining Bolt

84

1.9 Litre SOHC Diesel Engine In-Car Repair Procedures

87

Compression Test

89

Leakdown Test

89

Open the Cover on the Fuse/Relay Box

89

Remove the Fuel Pump Relay

89

Top Dead Centre for no 1 Piston

90

Release the Hose Support Clip

90

Lift off the Plastic Cover over the Top of the Engine

90

Undo Central Bolt and Remove Auxiliary Drivebelt Tensioner Assembly

90

Valve Timing

91

Screw Fastening Stud of Special Tool into Oil Pump Housing

91

Position Ring of Tool Attached to Fastening Stud/Crankshaft Sprocket

91

Undo Retaining Bolt to Release Vacuum Lines from Camshaft Cover

91

Timing Belt

92

Move Leak-Off Hose Assembly Rearward, then Lift Camshaft Cover

92

Fit the Seal to the Camshaft Cover Groove

92

Crankshaft Pulley/Vibration Damper Retaining Bolts

92

Camshaft Sprocket

93

Using Screwdriver Resting on Pivot Bolt, Move Adjusting Lever

93

Tensioner Pointer Is Aligned with the Mark on the Backplate

93

High-Pressure Fuel Pump Sprocket

94

Tensioner Assembly

94

Remove the Bolt and Washer

94

Slide Sprocket off End of the Crankshaft

94

Camshaft Oil Seal

95

Idler Pulley

95

Slacken/Remove Retaining and Remove Timing Belt Tensioner Assembly

95

The Slot on Tensioner Backplate Must Locate over Peg on Engine Bracket

95

Thickness of each Shim Should be Stamped on One of Its Surfaces

96

Camshaft Bearing Cap Retaining Bolts

96

Carefully Release Oil Pipe from Its Location in the Cylinder Head

96

Undo Support Bracket Bolts, Release Retaining Clips

97

Cylinder Head Gasket Thickness Identification Hole

97

Using Dial Test Indicator to Measure Piston Protrusion

98

Place New Gasket in Position with Words ALTO/TOP Uppermost

98

Intermediate Shaft Bearing Housing Support Bracket Retaining Bolts

98

Air Conditioning Compressor Mounting Bracket Retaining Bolts

99

Removing Oil Baffle Plate from Inside the Sump

99

Renew Pick-Up/Strainer Sealing Ring Prior to Refitting

99

Apply Continuous Bead of Silicone Sealing Compound to Sump Flange

99

Oil Filter Housing

100

Oil Pump Housing Retaining Bolts

100

Undo Retaining Screws and Lift off Oil Pump Cover

100

Oil Pump Inner and Outer Rotor Identification Dots

100

Oil Filter Housing Retaining Bolts

101

Fit New Sealing Ring to Oil Filter Housing Supply Channel

101

Screw in Self-Tapping Screw and Pull on Screw with Pliers

101

Using Socket as Tubular Drift to Fit the New Oil Seal

101

Flywheel/Drive Plate

102

Engine/Transmission Mounting

102

Fitting New Oil Seal Housing, with Integral Oil Seal, over Crankshaft

102

After Fitting, Remove Protector Sleeve from the Housing

102

Unscrew Two Rear Mounting/ Torque Link Retaining Bolts

103

Right-Hand Mounting Retaining Bolts

103

Left-Hand Mounting Bracket-To-Transmission Bracket Retaining Bolts

103

Left-Hand Mounting-To-Body Retaining Bolts

103

1.9 Litre DOHC Diesel Engine In-Car Repair Procedures

105

Vauxhall/Opel Special Tool Is Required to Set TDC Position

108

Vauxhall/Opel Special Tool to Set the Camshaft Position

108

Undo Central Mounting Bolt and Remove Drivebelt Tensioner Assembly

108

Undo Retaining Bolts and Remove Right-Hand Engine Mounting

108

Positioning Ring of Tool Attached to Fastening Stud

109

Upper Timing Belt Cover Retaining Bolts

110

Undo Bolt and Remove Auxiliary Drivebelt Idler Pulley

110

Undo the Two Lower Bolts

110

Remove the Engine Bracket from the Engine

110

Slide the Sprocket off the End of the Crankshaft

112

Engage Holding Tool with Holes in Fuel Pump Sprocket

112

Use Suitable Puller to Release Fuel Pump Sprocket Taper

112

Once Taper Releases, Withdraw the Sprocket

112

Camshaft Housing

113

Slot on Tensioner Backplate Must Locate over Peg on Engine Bracket

113

Slacken and Remove Retaining Bolt and Remove Idler Pulley from Engine

113

Disconnect Wiring Connectors at Fuel Injectors

113

Camshaft

114

Disconnect Two Vacuum Hoses from Vacuum Pipe Assembly

114

Undo Two Retaining Bolts and Move Pipe Assembly to One Side

114

Release Retaining Clips and Remove the Charge Air Hose

114

Undo Three Retaining Bolts and Remove the Oil Filler Housing

115

Slacken Intake Camshaft Drive Gear Retaining Bolt

115

Exhaust Camshaft Drive Gear Retaining Bolt

115

Unscrew and Remove Two Previously-Slackened Retaining Bolts

115

Camshaft Followers and Hydraulic Tappets

116

Refit Camshaft Positioning Tool to Valve Timing Checking Hole

116

Unscrew Closure Bolt from Intake Camshaft Side of Camshaft Housing

116

Fit Camshaft Positioning Tool for the Intake Camshaft

116

Withdraw each Camshaft Follower

117

Hydraulic Tappet in Turn, and Place Them in Their Respective Container

117

Clip the Follower Back Onto the Tappet

117

Refit Tappet to Its Original Bore

117

Undo the Retaining Screws and Lift the Oil Pump Cover

120

Unscrew the Oil Pressure Relief Valve Bolt

120

Prime Oil Pump by Filling It with Clean Engine Oil

121

Bend down Tabs on Edge of Gasket to Retain It on Oil Pump Housing

121

Engine Removal and Overhaul Procedures

123

Engine Overhaul

127

Engine Removal

127

Engine and Transmission Unit

127

Petrol Engine Models

128

Diesel Engine Models

128

All Models

128

Disconnect Two Positive Cables from the Junction Box Terminals

128

Unscrew Nut/Remove Bolt Securing Steering Column Intermediate Shaft

129

Prise out Clip Securing Clutch Hydraulic Hose to End Fitting

129

Detach the Hose from the End Fitting

129

Engine Mounting Bracket-To-Engine Bracket Retaining Bolt

129

Cylinder Head and Valves

131

Using Valve Spring Compressor, Compress Valve Spring

131

Extract Two Split Collets by Hooking Them out Using Small Screwdriver

131

Remove the Valve Spring Cap

131

Valve Components

132

Straight-Edge and Feeler Gauge to Check Cylinder Head Distortion

132

Using a Micrometer to Measure Valve Stem Diameter

132

Grinding-In a Valve

132

Pistons/Connecting Rods

133

Refit the Valve Spring and Fit the Spring Cap

133

Compress Valve and Locate Collets in Recess on the Valve Stem

133

Check Crankshaft Endfloat Using a Dial Gauge

133

Cylinder Block

134

Main Bearing Cap Identification Marks

134

Lug at Base of Cap Is Used to Identify Intake Manifold Side

134

Unscrew Retaining Bolts and Remove Piston Oil Spray Nozzles

134

Using a Feeler Blade to Remove a Piston Ring

135

Main and Big-End Bearings

136

Piston Rings

136

Typical Bearing Failures

136

Measuring a Piston Ring End Gap Using a Feeler Gauge

137

Fitting the Oil Control Spreader Ring

137

Fitting a Main Bearing Shell to the Cylinder Block

137

Liberally Lubricate each Bearing Shell in Cylinder Block

137

Fill Side Grooves of no 5 Bearing Cap with Sealant

138

Tighten Bolts to Specified Stage 1 Torque Setting

138

Apply Continuous Bead of Sealant to Groove in Cylinder Block

138

Tightening Cylinder Block Lower Casing Bolts through Specified Angles

138

Piston/Connecting Rods

139

Press Bearing Shells into Connecting Rods and Caps

139

Piston Ring End Gap Positions

139

Ensure Piston Ring End Gaps Are Correctly Spaced, Fit Ring Compressor

139

Cut-Out on Piston Skirt Must be on same Side as Oil Spray Jet

140

Cooling, Heating and Air Conditioning Systems

141

General Information and Precautions

142

Cooling System Hoses

142

Radiator

142

Insert Drill Bit through Holes Provided on Radiator Brackets

143

Condenser Right-Hand Upper Retaining Bolt

143

Undo Two Bolts each Side

143

Remove Radiator Mounting Brackets, Noting Their Orientation

143

Thermostat

144

Removing Thermostat Housing Cover

144

Removing the Thermostat from the Housing

144

Disconnect Charge Air Hose from Throttle Housing

144

Electric Cooling Fan

145

Coolant Temperature Sensor

145

Undo Bolt Securing Fan Motor Resistor to Housing

145

Undo Three Bolts and Remove Motor from the Housing

145

Coolant Pump

146

Thermostat Housing Retaining Bolts

146

Removing Coolant Pipe from Pump Housing

146

Coolant Pump Drive Sprocket Access Cover

146

Unscrew the Rear Bolts

147

Withdraw Coolant Pump from Timing Housing

147

Undo Coolant Pump Retaining Bolts

147

Remove Pump from Cylinder Head

147

Heating and Ventilation System

148

Heater/Ventilation System Components

148

Heater Blower Motor

148

Heater Blower Motor Resistor

148

Mixed Air Valve Servo Motor

149

Heater Matrix

149

Heater Control Assembly

149

Air Distribution Housing

149

Air Conditioning System

150

Air Conditioning System Components

150

Air Conditioning Service Ports

150

Compressor

150

Evaporator

151

Auxiliary Cooling Fan

151

Condenser

151

Unclip the Relays from the Auxiliary Cooling Fan Housing

151

Fuel and Exhaust Systems — Petrol Engines

153

Air Cleaner Assembly and Intake Ducts

155

Accelerator Pedal/Position Sensor

155

Unleaded Petrol

155

Disconnect Wiring Connector from Side of Inlet Air Temperature Sensor

155

Fuel Injection System

156

Fuel Gauge Sender Unit

156

Fuel Pressure Connection Valve on Fuel Rail

156

Fuel Pressure Connection Valve on High-Pressure Fuel Pump

156

Fuel Supply Pump

157

Fuel Tank

157

Insert Removal Tools down through Slots on Side of In-Tank Module

157

Push the Tools down into the Slots

157

Throttle Housing

158

Disconnect Fuel and Vapour Lines at Underbody Quick-Release Connectors

158

Unclip Handbrake Cables from Fuel Tank Retaining Straps

158

Undo Bolt Securing Filler Pipe to the Underbody

158

Fuel Injection Systems

159

Fuel Injection System Components

159

Throttle Housing Retaining Bolts

159

Unclip and Remove Ashtray Insert

159

Multec-S Injection System Components

160

Inlet Air Temperature Sensor

160

Fuel Injectors and Fuel Rail

160

Crankshaft Speed/Position Sensor

160

Oxygen Sensors

161

Simtec 75.1 Injection System Components

161

Airflow Meter

161

Camshaft Sensor

161

Simtec 81.1 Injection System Components

162

Manifold Pressure Sensor

162

Knock Sensor

162

Electronic Control Unit

162

Release Clips

163

Disconnect Wiring Connectors at Fuel Pressure Sensor

163

Disconnect Fuel Feed Hose Quick-Release Connector

163

Unscrew Union Nuts Securing Fuel Pipe to Pump and Rail

163

High-Pressure Fuel Pump

164

Fuel Pressure Regulator

164

Fuel Pressure Sensor

164

Crankshaft Sensor

164

Intake Manifold

165

Unbolt the Crankshaft Sensor

165

Unbolt the Knock Sensor

165

Lift up Locking Bars and Disconnect Two ECU Wiring Connectors

165

Disconnect Wiring Connector from Evaporative Emission Control

166

Disconnect Wiring Harness Block Connector on Left-Hand Side

166

Exhaust Manifold

167

Exhaust System

168

Front Pipe and Intermediate Pipe

168

Front Pipe/Catalytic Converter

168

Tailpipe

168

Fuel and Exhaust Systems — Diesel Engines

169

High-Pressure Diesel Injection System

171

Warnings and Precautions

171

Repair Procedures and General Information

171

Typical Plastic Plug and Cap Set for Sealing Disconnected Fuel Pipes

171

Slacken Clips and Detach Intake Duct from Charge Air Pipe

172

Undo Retaining Bolt and Release Air Cleaner Housing Mounting Bracket

172

Detach Air Intake Duct at Front of Air Cleaner Housing

172

Disconnect Water Drain Tube from Base of Air Cleaner Housing

172

Fuel System

173

Fuel Filter Crash Box

173

Diesel Injection System Electrical Components

173

Unclip and Remove the Ashtray Insert

173

Camshaft Position Sensor

174

Charge (Boost) Pressure Sensor

174

DOHC (Z19DTH) Engines

174

EGR Pipe to EGR Valve Retaining Bolts

174

Turbocharger Wastegate Solenoid

175

SOHC (Z19DT and DTL) Engines

175

Disconnect the Fuel Pressure Sensor Wiring Connector

175

Unscrew the Three Retaining Nuts

175

Fule Rail

176

Counter-Hold Fuel Pipe Union on Pump with Second Spanner

176

Undo the Two Bolts at the Top

176

Move the Wiring Trough and Harness to One Side

176

Fuel Injectors

177

Unscrew Union Nuts Securing High-Pressure Fuel Pipes to Fuel Rail

177

Unscrew Union Nuts Securing High-Pressure Fuel Pipe to Fuel Pump

177

Disconnect the Fuel Return Hose

177

Remove the Copper Washer from the Injector Base

178

Undo Two Bolts and Remove Breather Pipe from Cylinder Head

178

Disconnect the Injector Wiring Connectors

178

Disconnect the Fuel Leak-Off Hose Connection at each Injector

178

Plug or Cap the Leak-Off Hose Union on each Injector

179

Counter-Hold Injector Union When Unscrewing Fuel Pipe Unions

179

Unscrew Injector Clamp Bracket Retaining Nut then Remove Washer

179

Using Small Slide Hammer to Free Injector Body from Cylinder Head

179

Unscrew Two Nuts and Free Wiring Harness and Coolant Pipes

180

Undo Two Nuts above the Vacuum Reservoir

180

Intake Manifold Changeover Flap Actuator Drive

181

Bolt at Base of the Vacuum Reservoir

181

Bolt at the Right-Hand Side of the Oil Separator

181

Remove Mounting Bracket Complete with Oil Separator

181

Intercooler

182

Turbocharger

182

Exhaust Manifold and Turbocharger

182

Heat Shield Retaining Nuts and Bolts

183

Release Retaining Clip and Disconnect Breather Hose

183

Undo Turbocharger Charge Air Pipe Upper Retaining Bolt

183

Slacken the Clip and Move the Pipe to One Side

183

Front Pipe

184

Intermediate Pipe

184

Unscrew Turbocharger Oil Supply Pipe Banjo Union

184

Exhaust Manifold Retaining Nuts

184

Catalytic Converter/Particulate Filter

185

Heat Shield

185

Exhaust Tailpipe Retaining Clamp

185

Emissions Control Systems

187

Crankcase Emissions Control

187

Exhaust Emission Control

187

Diesel Engines

188

Evaporative Emission Control

188

Fuel Evaporation Emission Control

188

Exhaust Gas Recirculation System

188

Crankcase Emission Control

189

Testing

189

Catalytic Converter Renewal

189

Mixture Regulation Oxygen Sensor Renewal

189

Particulate Filter Temperature Sensor Renewal

190

Differential Pressure Sensor Renewal

190

EGR Valve Renewal

190

Unscrew Temperature Sensor and Remove It from Exhaust Manifold

190

Catalytic Converter

191

EGA Valve Heat Exchanger Renewal

191

Lift off the Valve and Recover the Gasket

191

Throttle Housing, and Intercooler

191

42 Slacken the Retaining Clips and Remove the

191

Release the Retaining Clip and Disconnect

191

Undo the Retaining Nut and Bolt and Release

191

The Metal EGR Pipe Clamp from the EGR Valve

191

Heat Exchanger. Separate the Pipe from the Heat Exchanger and Recover the Gasket from

191

Starting and Charging Systems

193

Battery Disconnection

194

Charging

194

Traditional and Low Maintenance Battery

194

Maintenance-Free Battery

194

Battery and Battery Tray

195

Charging System

195

Unscrew Battery Negative Terminal Retaining Nut

195

Unscrew the Retaining Bolt and Remove the Battery Clamp

195

Auxiliary Drivebelt Tensioner

196

Alternator

196

Auxiliary Drivebelt Tensioner Mounting Bolt

196

Removing Auxiliary Drivebelt Tensioner

196

Starting System

197

Undo the Retaining Nut

197

Disconnect the Wiring Terminal

197

Alternator Mounting Bracket Bolts Arrowed

197

Starter Motor

198

Remove the Oil Filler Cap

198

Unscrew the Two Bolts

198

Release the Engine Breather Hose

198

Ignition Switch

199

Oil Pressure Warning Light Switch

199

Undo Nuts and Disconnect Starter Solenoid Wiring Connectors

199

Unscrew Nut and Disconnect Earth Lead from Starter Motor Stud Bolt

199

Oil Level Sensor

200

Pre/Post-Heating System

200

Glow Plugs

200

Slide off Retaining Clip and Free Oil Level Sensor Wiring Connector

200

Pre/Post-Heating System Control Unit

201

Unscrew Glow Plugs and Remove Them from the Cylinder Head

201

Ignition System — Petrol Engines

203

Ignition Module

204

Ignition Timing

204

For Access to the Diagnostic Socket

204

Disconnect Wiring Connector from Ignition Module

204

Clutch

205

Semi-Automatic Clutch

205

Clutch Hydraulic System

206

Bleeding Procedure

206

Conventional Method

206

Using a One-Way Valve Kit

206

Master Cylinder

207

Release Cylinder

207

Extract Retaining Clip and Disconnect Hydraulic Pipe

207

Disconnect Fluid Supply Hose from the Reservoir

207

Clutch Pedal

208

Clutch Release Cylinder Hydraulic Pipe Union Nut

208

Clutch Release Cylinder Retaining Bolts

208

Extract Retaining Clip and Remove Hydraulic Hose End Fitting

208

Clutch Assembly

209

Vauxhall Special Jig for Removing Clutch Pressure Plate/Friction Disc

209

Thrust Piece in Contact with Diaphragm Spring

209

Fingers

209

Using the Vauxhall Jig

210

Mount Large Bolt and Washer into Vice, then Fit Pressure Plate over It

210

Fit Large Washers and Nut to Bolt and Hand-Tighten

210

Tighten Nut until Spring Adjuster Is Free to Turn

210

Without Using the Vauxhall Jig

211

Fit the Pressure Plate Assembly over the Friction Disc

211

Centralise Friction Disc Using a Clutch Aligning Tool or Similar

211

Manual Transmission

213

Transmission Oil

214

F17+Transmission

214

Differential Cover Plate Securing Bolts

214

Transmission Oil Level Plug

214

Gearchange Mechanism

215

M32 Transmission

215

Draining

215

Transmission Oil Filler Plug

215

Remove Lower Facia Panel on the Passenger’s Side

216

Release Retaining Clips and Remove Footwell Trim Panels

216

Undo Gear Lever Console Trim Retaining Frame Lower Screw

216

Lift off Frame and Unclip the Diagnostic Socket

216

Gearehange Mechanism

217

Gear Lever Housing

217

Selector Cables

217

Lock the Selector Mechanism

217

Oil Seals

218

Reversing Light Switch

218

Driveshaft Oil Seals

218

Input Shaft Oil Seal

218

Transmission

219

Transmission Overhaul

219

Transmission Oil Level Check

219

Prise out Clip to Disconnect Clutch Hydraulic Hose

219

Automatic Transmission

221

Transmission Fluid

222

AF22 Transmission

222

AF40 Transmission

222

Transmission Fluid Drain Plug

222

Selector Cable

223

Transmission Fluid Filler Plug

223

To Unlock the Selector Lever

223

Unclip the Ashtray Housing from the Base of the Facia

223

Selector Lever Assembly

224

Selector Lever Trim Panel Retaining Screws

224

Turn Selector Cable Lock 90° Anti-Clockwise to Release Cable

224

Move Transmission Selector Lever Forwards so that It Is in P Position

224

Selector Lever Assembly Components

225

Mode Switches

225

Selector Lever Position Switch

225

Selector Lever Lock Switch

225

Transmission Input/Output Speed Sensor

226

Electronic Control Unit Mounting Bolts

227

Automatic Transmission Overhaul

228

Check that the Torque Converter Is Fully Entered

228

Easytronic Transmission

229

Transmission Oil Filler/Level Plug

230

Transmission Shift Module

231

Unclip Ashtray Housing from Base of the Facia

231

Undo Two Selector Lever Trim Panel Retaining Screws

231

Unscrew Two Quick-Release Catches

231

Release the Retaining Clips and Remove the

231

Clutch Module with MTA Control Unit

232

Driveshaft Oil Seal

232

Groove Visible When Shift Module Is in Neutral

232

Using Screwdriver to Move Transmission Shift Forks into Neutral

232

Easytronic Transmission Overhaul

233

Driveshafts

235

To Remove the Track Rod End from the Swivel Hub

236

Unscrew Nut Securing Connecting Link to the Anti-Roll Bar

236

Unscrew Retaining Nut and Withdraw Clamp Bolt from Swivel Hub

236

To Expand Lower Portion of Swivel Hub

236

Intermediate Shaft

237

Intermediate Shaft Bearing

237

Release Inner End of Driveshaft from Differential/Intermediate Shaft

237

Intermediate Shaft Bearing Housing Retaining Bolts

237

Driveshaft Joint Gaiters

238

Outer CV Joint

238

Release Rubber Gaiter Retaining Clips by Cutting through Them

238

Cut Gaiter Open and Remove It from the Driveshaft

238

Inner CV Joint

239

Fit New Snap-Ring to Constant Velocity Joint

239

Pack Joint with Grease Supplied in the Repair Kit

239

The Snap-Ring or Circlip Engages in Its Groove

239

Driveshaft Overhaul

240

Expand Joint Retaining Snap-Ring Using Circlip Pliers

240

Remove Joint by Tapping It off Driveshaft with a Hammer and Punch

240

Slide New Rubber Gaiter and Retaining Clips Onto Driveshaft

240

Braking System

241

Hydraulic System

242

Hydraulic Pipes and Hoses

243

Bleeding Sequence

243

Bleeding

243

Basic (Two-Man} Method

243

Front Brake Pads

244

Pull out the Spring Clip

244

Disconnect the Hydraulic Hose from the Strut Bracket

244

Push in Caliper Piston by Levering Caliper Body

244

Remove Spring from Caliper Mounting Bracket

245

Remove the Dust Caps from the Upper and Lower Guide Bo!Ts

245

Unscrew the Upper/Lower Guide Bolt

245

Lift the Caliper and Brake Pads off the Mounting Bracket

245

Arrow on Backing Plate Points in Direction of Forward Rotation

246

Fit Inner Pad to Caliper

246

Fit the Outer Pad to the Caliper

246

Slide the Caliper into Position in the Mounting Bracket

246

Push Handbrake Operating Lever Downwards and Detach Cable End Fitting

247

Prise out the Handbrake Outer Cable Retaining Clip

247

Withdraw the Handbrake Cable from the Caliper Bracket

247

Unscrew Upper Guide Pin Bolt

247

Measure the Thickness of the Pad Friction Material

248

Using Caliper Retracting Tool to Retract Piston as Far as the Stop

248

Unscrew It until Next Piston Cut-Out Is Visible through of Caliper

248

Brush Dust and Dirt from Caliper, Piston and Mounting Bracket

248

Front/Rear Brake Disc

249

Unclip ABS Wheel Speed Sensor Wiring Guide from Brake Hydraulic Hose

249

Disconnect Hydraulic Hose from the Strut Bracket

249

Unbolt and Remove Front Brake Caliper Complete with Disc Pads

249

Front Brake Caliper

250

Rear Brake Caliper

250

Remove the Securing Screw

250

Withdraw the Disc from the Hub

250

Rear Caliper Brake Hose Union Bolt

251

Disconnect Clutch Hydraulic Pipe from Fluid Reservoir

251

Master Cylinder Mounting Nuts

251

Brake Pedal

252

Vacuum Servo Unit

252

Right-Hand Drive Petrol Models

252

Unscrew Quick-Release Catch on the Left-Hand Side

252

Ease Vacuum Hose out of the Servo Unit Rubber Grommet

253

Vacuum Servo Unit Check Valve and Hose

254

Hadbrake Lever

254

Handbrake Cables

254

Primary Cable

254

Stop-Light Switch

255

Handbrake Warning Light Switch

255

Anti-Lock Braking and Traction Control Systems

255

Remove All Tension from the Cables

255

Anti-Lock Braking and Traction Control System Components

256

Hydraulic Modulator

256

Electronic Control Unit (ECU)

256

Wheel Speed Sensors

256

Vacuum Pump

257

Steering Angle Sensor

257

Disconnect Quick-Release Fitting and Detach Vacuum Hose from Pump

257

Undo the Four Mounting Bolts

257

Suspension and Steering

259

Front Swivel Hub

261

Depress Retaining Tab and Release Wheel Speed Sensor Wiring Connector

261

Push Locking Tab Downward and Disconnect Wheel Speed Sensor Wiring

261

Depress Locking Tab and Release Wiring Connector from Suspension Strut

261

Use Balljoint Separator Tool to Remove the Track Rod End

262

Unscrew Nut and Remove Clamp Bolt Securing Lower Arm Balljoint

262

Expand the Lower Portion of the Swivel Hub

262

Tap End of the Driveshaft with a Soft-Faced Hammer

262

Front Hub Beaings

263

Front Suspension Strut

263

Undo Three Bolts Securing Bearing Assembly to the Swivel Hub

263

Remove the Bearing Assembly and Brake Shield from the Hub

263

Overhaul

264

Unclip ABS Wheel Speed Sensor Wiring Guide from Hydraulic Hose

264

Extract the Retaining Clip

264

Release Hydraulic Hose from the Suspension Strut

264

Counter-Hold Strut Piston Rod with an allen Key or Suitable Bit

265

Remove the Strut Upper Mounting

265

Upper Spring Seat with Rubber Gaiter

265

Locate Spring on Strut so that Lower End Is against Raised Stop

265

Front Suspension Lower Arm

266

Front Suspension Lower Balljoint

266

Front Subframe

266

Front Suspension Lower Arm Inner Mounting Located on Subframe

266

Disconnect Power Steering Positive Cable from Junction Box Terminal

267

Disconnect Power Steering Wiring at Block Connector

267

Undo Nut and Remove Bolt Securing Front Engine Mounting

267

Unscrew the Subframe Front Mounting Bolts

267

Front Anti·roll Bar

268

Rear Hub Bearings

268

Anti-Roll Bar Clamp Mounting Bolts

268

Remove the Clamps from the Rubber Bushes

268

Rear Shock Absorber

269

Rear Suspension Coil Spring

269

Rear Suspension Torsion Beam and Trailing Arms

269

Unscrew/Remove Shock Absorber Lower Mounting Bolt from Trailing Arm

269

Steering Wheel

270

Push Handbrake Operating Lever on Brake Caliper Downwards

270

Prise out Handbrake Outer Cable Retaining Clip

270

Withdraw Handbrake Cable from the Caliper Bracket

270

Ignition Switch/Steering Column Lock

271

Steering Column

271

Disconnect Wiring Harness Connector for Steering Wheel Switches

271

Unscrew the Steering Wheel Retaining Bolt

271

Steering Column Intermediate Shaft

272

Unscrew Steering Column Lower Fastening Clamp Bolt

272

Slide Column Upward to Disengage the Locating Tongue

272

Unscrew Intermediate Shaft Upper Clamp Bolt

272

Steering Gear Rubber Gaiters

273

Steering Gear

273

Electro-Hydraulic Power Steering Pump

273

Steering Gear Rubber Gaiter Outer Securing Clip

273

Power Steering Hydraulic System

274

Track Rod End

274

Track Rod

274

Hold Track Rod While Loosening Track Rod End Securing Locknut

274

Wheel Alignment and Steering Angles

275

Definitions

275

Checking and Adjustment

275

Bodywork and Fittings

277

Maintenance

278

Maintenance of Upholstery and Carpets

278

Minor Body Damage

278

Minor Scratches

278

Rust Holes or Gashes

279

Filling and Respraying

279

Plastic Components

279

Major Body Damage Repair

280

Front Bumper

280

Rear Bumper

280

Undo the Upper Screw

280

Bonnet

281

Bonnet Release Cable

281

Pull out the Centre Pins and Extract the Two Expanding Rivets

281

Pull Bumper Upward/Outward at Sides to Disengage the Side Guide Rails

281

Bonnet Lock Spring

282

Front Door

282

Detach Outer Cable from Release Handle Frame

282

Slip Inner Cable End Fitting out of the Lever

282

Door Inner Trim Panel

283

Rear Door

283

Front Door Lock Striker on the B-Pillar

283

Disconnecting Wiring from the Front Edge of the Rear Door

283

Door Handles and Lock Components

284

Door Interior Handle

284

Front Door Exterior Handle

284

Prise Bottom/Ides of Panel Away from Door to Release Internal Clips

284

Rear Door Exterior Handle

285

Remove Screw from the Rear Edge of the Door

285

Gain Access to the Handle Locking Screw

285

Turn Handle Locking Screw Anticlockwise until It Reaches Its Stop

285

Front Door Lock Cylinder

286

Front Door Exterior Handle Frame

286

Disengage Exterior Handle Front Pivot from Frame

286

Pull out Centre Pin and Remove Inner Trim Panel Plastic Guides

286

Release the Retaining Clip and Disconnect the

286

Release the Retaining Clip and

286

Rear Door Exterior Handle Frame

287

Front Door Lock

287

Rear Door Lock

287

Slacken Exterior Handle Frame Front Retaining Crew Five Turns

287

Door Window Glass and Regulator

288

Front Door Window Glass

288

Release Retaining Clip Disconnect Lock Operating Rod

288

Withdraw Lock from Its Location, then Lift Locking Bar

288

Rear Door Window Glass

289

Using Plastic Wedge Lift up Door Window Outer Waist Seal

289

Remove the Seal from the Door

289

Remove Door Window Inner Waist Seal from the Door Aperture

289

Tailgate and Support Struts

290

Rear Door Fixed Window Glass

290

Window Regulator

290

Tailgate

290

Tailgote Lock Components

291

Support Struts

291

Tailgate Lock

291

Tailgate Exterior Handle

291

Exterior Mirrors and Associated Components

292

Tailgate Trim Strip Inner Retaining Nuts on Right-Hand Side

292

Disconnect Wiring Connector and Remove Trim Strip from the Tailgate

292

Twist Number Plate Light Bulbholders and Remove Them

292

Windscreen and Fixed Window Glass

293

Sunroof

293

Body Exterior Fittings

293

Mirror Glass

293

Seats

294

Body Trim Strips and Badges

294

Front Seat Removal

294

Disconnect Windscreen Wiper Motor Wiring Connector

294

Rear Seat Removal

295

Undo Retaining Screw and Remove the Seat Cushion Release Handle

295

Depress Retaining Catch with Small Screwdriver

295

Push in Centre Pins and Remove Two Plastic Rivets

295

Seat Belt Tensioning Mechanism

296