Vauxhall Astra and Zafira (petrol) : service and repair manual

301 Pages·2001·25.684 MB·English

by  Martynn J. Randall and Andrew K. Legg

VAUXHALL/OPEL
ASTRA & ZAFIRA
Feb 1998 to Apr 2000 (R to W registration) Petrol
Haynes Service and Repair Manual
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Includes Roadside Repairs and MOT Test Checks
Vauxhall Astra and Zafira
Service arid Repair Manual
A K Legg and Martynn Randall
laemimi
Models covered <37s*344-wafi)
Astra Hatchback, Saloon & Estate and Zafira MPV models with petrol engines, including special/limited editions
1A litre (1389cc), 1.6 litre {1598cc), 1.8 litre (1796cc) & 2.0 litre (1998cc)
For coverage of diesel models, see manual no. 3797
Does NOT cover bi-fuel models, 2,0 litre turbo or 2.2 litre engines,
Coupe or 2001 model year vehicles (introduced Sept '00)
t> Haynu PufeHdilng 2003 ABCO£ Printed In the USA
FGHU
A book in the Haynes Seivlce and Repair Manual Series Haynes Publishing
Sparkford, Yeovil. Somerset BA22 7JJ, England
All lights reserved. Nu part of this hook may be reproduced or transmitted
In any form or by any means, electronic or mechanical, Including Hfiryftes North America, Inc
photocopying, recording or by any Information storage or retrieval system,
Without permission In writing from the copyright holder. 861 Lawrence Drive. Newbury Park, California 91320, USA
ISBN 1 85960 75® 6 E49,2d JRit1iuoSen dCseO H UI'aARybBnrEaeusV vOoIiEr CEOEX, France
British Library Cataloguing in Publication Data Haynes Publishing Nordiska AB
A catalogue necotd for Ihts book is available from the British Library. Box 1504, 751 45 UPPSALA, Svenge
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Contents
LIVING WITH YOUR VAUXHALL ASTRA/ZAFIRA
Safety first! Page 0*5
Introduction Page 0*6
Roadside Repairs
If your car won't start Page 0*7
Jump starting Page 0-8
Wheel changing Page 0*9
Identifying leaks Page 0*10
Towing Page 0»10
Weekly Checks
Introduction Page 0«11
Undsrbonnet check points Page 0«11
Engine oil level Page 0*12
Coolant level Page 0*13
Brake (and clutch) fluid level Page 0«13
Tyrs condition and pressure Page 0«14
Screen washer fluid level Page 0*15
Power steering fluid level Page 0-15
Wiper blades Page 0*16
Battery Page 0*16
Electrical systems Page 0*17
Lubricants and fluids Page 0*18
Tyre pressures Page 0*18
MAINTENANCE
Routine Maintenance and Sen/icing
Vauxhall Astra/Zafira models Page 1«1
Servicing specifications Page 1«2
Maintenance schedule Page 1*3
Maintenance procedures Page 1*8
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Contents
REPAIRS AND OVERHAUL
Engine and Associated Systems
SOHC petrol engine In-car engine repair procedures Page 2A«1
DOHC petrol engine in-car engine repair procedures Page 2B»1
Engine removal and overhaul procedures Page 2C«1
Cooling, heating and air conditioning systems Page 3«1
Fuel and exhaust systems Page 4A»t
Emission control systems Page 4B*1
Starting and charging systems Page 5A«1
Ignition system Page 5B«1
Transmission
Clutch Page 8*1
Manual transmission Page 7A«1
Automatic transmission Page 7B»1
Drives hafts Page 8»1
Brakes and suspension
Braking system Page 9«1
Suspension and steering Page 10«1
Body equipment
Bodywork and fittings Page 11*1
Body electrical system Page 12«1
Wiring Diagrams
Vauxhail Astra Page 12*26
Vauxhail Zafira Page 12*48
REFERENCE
Dimensions and weights Page REF*1
Conversion factors Page REF«2
Buying spare parts Page REF»3
Vehicle identification Page REF«3
General repair procedures Page REF»4
Jacking and vehicle support Page REF-5
Disconnecting the battery Page REF»5
Tools and working facilities Page REF«8
MOT test checks Page REF«8
Faultfinding. Page REF«12
Glossary of technical terms Page REF«21
Index
Page REF*26
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o»4 Advanced Driving
Advanced driving
For many people, the process of learning to these skills, all driving situations can be
drive' doesn't go much further than learning approached and negotiated in a safe,
how to pass the driving test because of a methodical way, leaving nothing to chance.
common belief that good drivers are made by
'experience'. Concentration means applying your mind to
safe driving, completely excluding anything
Learning to drive by experience1 teaches that's not relevant. Driving Is usually the most
three driving skills: dangerous activity that most of us undertake
in our daily routines. It deserves our full
• Quick reactions, {Whoops, that was attention.
close!)
H Good handling skills. (Horn, swerve, Observation means not lust looking, but
brake, horn). seeing and seeking out the information found
_ Reliance on vehide technology. {Great in the driving environment.
Many peopfe see the words 'advanced stuff this ABS, stop in no distance even in
driving' and believe that it won't Interest them the wet...) Anticipation means asking yourself what Is
or that it is a style of driving beyond their own happening, what you can reasonably expect
abilities. Nothing could be further from the Drivers whose skills are 'experience based' to happen and what could happen
truth. Advanced driving is straightforward generally have a lot of near misses and the unexpectedly. (One of the commonest words
sate, sensible driving - the soft of driving we odd accident. The results can be seen every used in compiling accident reports is
should all do every time we get behind the day in our courts and our hospital casualty 'suddenly'.)
wheel. departments.
Planning is the link between seeing
An average of 10 people are killed every day Advanced drivers have learnt to control the something and taking the appropriate
on UK roads and 870 more are Injured, some risks by controlling the position and speed of actron. For many drivers, planning is the
seriously. Lives are ruined daily, usually their vehicle. They avoid accidents and near missing link.
because somebody did something stupid. misses, even if the drivers around them make
Something like 95% of all accidents are due mistakes. If you want to become a safer and more skilful
to human erTor, mostly driver failure. driver and you want to enjoy your driving more,
Sometimes we make genuine mistakes - The key skills of advanced driving are contact the Institute of Advanced Motorists at
everyone does. Sometimes we have lapses of concentration, effective all-round www.ism org.uk, phone [phone], or
concentration. Sometimes we deliberately observation, anticipation and planning. write to I AW House. 510 Ohiswick High Road,
take risks. When good vehicle handling Is added to London W4 5RG for an information pack.
Safety First! 0.5
Working on your car can b9 dangerous. • Mains voltage is also dangerous. Make Special hazards
This page shows just some of the potential sure that any mains-operated equipment is
risks and hazards, with the aim of creating a correctly earthed. Mains power points should Hydrofluoric acid
safety-conscious attitude. be protected by a residual current device
General hazards (PCD) circuit breaker. » This extremely corrosive acid is formed
when certain types of synthetic rubber, found
Fume or gas Intoxication in some O-rings, oil seals, fuel hoses etc, are
Scalding • Exhaust fumes are exposed to temperatures above 40CC. The
• Don't remove the radiator or expansion poisonous; they often rubber changes Into a charred or sticky
tank cap while ttie engine is hot. contain carbon substance containing the acid. Once formed,
• Engine oil, automatic transmission fluid or monoxide, which is the acid remains dangerous for years. If It
power steering fluid may also be dangerously rapidly fatal If inhaled. gets onto the skin, It may be necessary to
hot U the engine has recently been running. Never run the amputate the limb concerned.
engine in a • When dealing with a vehicle which has
Burning confined space suffered afire, or with components salvaged
• Beware of bums tram the exhaust system such as a garage from such a vehicle, wear protective gloves
and from any part of the engine. Brake discs with the doors shut. and discard them after use.
and drums can also be extremely hot • Fuel vapour i3 also The battery
immediately after use. poisonous, as ere the vapours from some
cleaning solvents and paint thinners. • Batteries contain sulphuric acid, which
Crushing attacks clothing, eyes and skin. Take care
• When working under or near Poisonous or irritant substances when topping-up or carrying the battery.
a raised vehicle. • Avoid skin contact with batteiy acid and • The hydrogen gas given off by the battery
always with any fuel, fluid or lubricant, especially Is highly explosive. Never cause a spark or
supplement the antifreeze, brake hydraulic fluid and Diesel allow a naked light nearby. Be careful when
iack with axle fuel. Don't syphon them by mouth. If such a connecting and disconnecting battery
stands, or use substance Is swallowed or gets into the eyes, chargers or jump leads.
drive-on l'| seek medical advice. Air bags
ramps. • Prolonged contact with used engine oil can
N9VOT cause skin cancer. Wear gloves or use a • Air bags can cause injury if they go off
venture barrier cream if necessary. Change out of oil- accidentally. Take care when removing the
under a car which soaked clothes and do not keep oily rags in steering wheel and/or facia. Special storage
is only supported by a jack. your pocket. instructions may apply.
' Take care if loosening or tightening high- • Air conditioning refrigerant forms a Diesel injection equipment
torque nuts when the vehicle is on stands. poisonous gas if exposed to a naked flame
Initial loosening and final tightening should be (including a cigarette). It can also cause skin • Diesel Injection pumps supply fuel at very
done with the wheels on the ground. burns on contact. high pressure. Take care when working on
the fuel Injectors and fuel pipes.
Fire Asbestos
A
• Fuel Is highly flammable; fuel vapour Is • Asbestos dust can cause cancer If Inhaled Warning: Waver expose the /lands,
explosive. or swallowed. Asbestos may be found in lace or any other part of the body
• Don't let fust 3pill onto a hot engine. gaskets and in brake and clutch linings. to Injector spray; the fuel can
» Do not smoke or allow naked lights When dealing with such components it is penetrate the skin with potentially fatal
(including pilot Ilght3) anywhere near a safest to assume that they contain asbestos. resufti.
vehlcls being worked on. Also beware of
creating sparks
(electrically or by use of tools).
• Fuel vapour Is heavier than air, so don't
work on the fuel system with the vehicle over DO 'V V; • DON*
an inspection pit.
• Another cause of fire is an electrical • Doysaeye p»cteotk»wh9r>tW(^power'. *Ddtft etWrrpttb lift a heavy .component
overload or short-cfrcult. Take care when tools, andwtwn wotW'hg '(KltorfM; while. which may be beyond your capability-get
repairing or modifying the vehicle wiring. .'sBetetes.
• Do wear gkfc*e or use barrtercreaflrto .
• Keep a fire extinguisher handy, of a type protect your hwxtswhennecesifey-,..;1 • Efciril rush to finish, a job, or take
suitable for use on fuel and electrical fires. urvetflled-short «iits. •
Electric shock % j t• hDeota gl elta swoemtl ewohneen t ow ochrWecnkg a^etpdrotdat Qona Jtifyte.1 ^Ifc^ijklll^lttlrigtootawhlch may «Kp
• Ignition HT
voltage can be J lOohH.^mte-tooteorpartB.|yfng tfo.un4 -.
dangerous, oULofitte ^ofri^n^riwh^lcaflWtB.' ••iirt>em90fr£o*»cer'trtp overthera-Mop x
especially to ' ^ ap oll ahd ftiel spfllsatonce. -
peopEe wrth heart • Do retrieve tjrt9S,.*rtart^qh'efc, f}efpr«
problems or a .wwMnjttn'itwwhtolp ^BtpediityWte, .•Tjw'l AtoW children or'pets to ptaySh or.
pacemaker. Dont etectrtoal system.' 1' . , . j*»avetyclebdflg workmen.
work on or near ttie J
ignition system with f"~T~i T^T' eqiJpment ha6«aatev^ng k^rtttlnS! ;
the engine running or ' J ^ > \ adequate for the fob.
the ignition switched on.
o.6 Introduction
Vauxhall Astra 5-door Saloon ... ... and Estate models
Th« Vauxhall Astra-G mode) was Introduced Your Vauxhall Astra References to the 'left' or 'right' are in the
in lhe UK in February 1998 as a replacement sense of a person in the driver's seat, facing
lor the previous Astra, the 'F' model. It was and Zafira manual forward.
available in Saloon, Hatchback and Estate
Acknowledgements
versions with 1.4, 1.6,1.8 and 2.0 litre petrol
engines. The 1.6 litre engines are in either 8- The aim of this manual is to help you get the Certain Illustrations are the copyright of
valve or 16-valve form, and the 1.4, 1.8 and best value from your vehicle. It can do so in Vauxhall Motors Limited, and are used with their
2.0 litre engines are 16-valve. Models may be several ways. It can help you decide what permission. Thanks are also due to Oraper Tools
titled with a five-speed manual transmission or work must be done (even should you choose Limited, who provided some of the workshop
tour-speed automatic transmission mounted to get it done by a garage), provide tools, and to all those people at Sparkfcxd who
on the left-hand side of the engine. Information on routine maintenance and helped in the production of this manual.
All models have front-wheel-drive with fulfy- servicing, and give a logical course of action We take great pride in the accuracy of
Independent front suspension, and semi-in- and diagnosis when random faults occur. information given In this manual, but
dependent rear suspension with a torsion However, it is hoped that you will use the vehicle manufacturers make alteration!
beam and trailing arms. manual by tackling the work yourself. Or and design changes during the production
Electro/Hydraulic power steering (PAS) is simpler jobs, it may even be quicker than run of a particular vehicle of which they do
fitted as standard lo all models, whil3t Anti- booking the car into a garage and going there not inform us. No liability can be accepted
Lock Braking (ABS) is available as an option. twice, to leave and collect it. Perhaps most by the authors or publishers for lose,
The Zafira range was launched in June important, a lot of money can be saved by damage or injury caused by any errors In,
1999, available with 1.B and 1.8 litre DOHC avoiding the costs a garage must charge to or omissions from, the information given.
16V petrol engines. Whilst the 2afira shares cover its labour and overheads.
1he same drive train and suspension as the The manual has drawings and descriptions Project vehicles
Astra, the body is that of a Multi Personnel to show the function of the various com- The main vehicle used in the preparation of
Vehicle (MPV). Not only does the Zafira have ponents, so that their layout can be this manual, and which appears In many of the
7 seats arranged In three rows, it quickly understood. Then the tasks are described and photographic sequences, was a Zafira fitted
converts to a spacious load carrier - thanks to photographed in a clear step-by-step with a 1.8 litre engine. Other vehicles used
the 'Flex 7' system, which allows the rear sequence. included 1.6 litre SOHC and OOHC models.
seats to fold completely flat into the floor
giving an uninterrupted load space.
Both models have a full-sized driver's side
airbag fitted as standard, and side impact air-
bags available as an option. Passenger's side
airbags became standard equipment from
January 1999. Cruise control is available as an
option on certain models.
In February 2000, the Astra was also
available with a 2.2 litre petrol engine, whilst in
October 2000 a 2.0 litre turbocharged petrol
version was introduced. These two engines,
along with the various diesei engines fitted to
the Astra and Zafira range, are not covered in
this manual.
For the home mechanic, the Vauxhall Astra/
Zafira is a straightforward vehicle to maintain
and repair since design features have been
incorporated to reduce the actual cost of
ownership to a minimum, and most of the
items requiring frequent attention are easily
accessible. Vauxhall Zafira
Roadside repairs 0.7
The following pages are intended to help in dealing with
common roadside emergencies and breakdowns. You will find
more detailed fault finding information at the back ol the
manual, and repair information in the main chapters.
If your car won't start If your car won't start
and the starter motor even though the starter
doesn't turn motor turns as normal
If It's a model with automatic transmission, make sure the • Is there fuel in the tank?
selector is in P or N. • Is there moisture on electrical components under the
Open the bonnet and make sure that the battery terminals bonnet? Switch off the ignition, then wipe off any obvious
are clean and tight. dampness with a dry cloth. Spray a water-repellent aerosol
Switch on the headlights and try to start the engine. If the product (WD-40 or equivalent) on ignition and fuel system
headlights go very dim when you're trying to start, the electrical connectors like those shown in the photos.
battery is probabfy flat. Get out of trouble by jump starting Pay special attention to the ignition coil wiring connector
(see next page) using a friend's car. and HT leads.
A Check the condition and security of the BCheck the engine wiring harness at the CCheck the wiring to the DIS ignition
battery connections. left-hand roar of the engine compart- 1m odule (1.6 engine).
ment.
< Check the wiring to theairftow meter
{1.8 engine).
Check that electrical connections are secure (with the ignition switched off) and spray them Remove the engine top cover, and
with a water dispersant spray like WD-40 if you suspect a problem due to damp. check the wiring for the ignition coils
(1,8 engine).
o.8 Roadside repairs
Jump starting
Jumpstating wW get feu out
of trouble, but >wi mtwf conrac (
When jump-starting a car using a • Make sure that the booster battery is CE3 MiaN*«r DMA thebattery jw
booster battery, observe the following the same voltage as the discharged tteffrjtfw first piece. Thar* am
precautions; one in the vehicle. r tlma pOtaMltleS
lha battery hat bait drained by
• Before connecting the booster repeated attempts to start, or by
battery, make sure that the ignition is • If the battery is being jump-started barring tha tights on.
switched off. from the battery in another vehicle,
the two vehicles MUST NOT TOUCH 2JJtt char&ng system It not working
• Ensure that all electrical equipment each other. property (alternator drkabe/tataak
(lights, heater, wipers, etc) is or broken, attemetor wiring fault or
switched off. alternator Itself faulty}.
• Make sure that the transmission is in 3 The tottery Haetfls at fault
• Take note of any special precautions neutral (or PARK, in the case of (etectrolyta low, or battery tram oat).
printed on the battery case. automatic transmission).
Make sure that the jump leads win not
come Into contact with the fan, dhve-
belts or other moving parts of the
engine.
Start the engine using the booster
battery and run it at idle speed. Switch
on the lights, rear window demister and
heater blower motor, then disconnect
the jump leads in the reverse order of
connection. Turn off the lights etc.
Roadside repairs 0.9
Wheel changing
Some of the details shewn here will vary A Warning: Do not change a wheel In a situation where you risk being hit by
according to model. For instance, the location another vehicle. On busy roads, try to stop in a lay-by or a gateway. Be wary of
of the spare whael and jack is not the same on passing traffic while changing the wheel - It Is easy to become distracted by
all cars. However, the basic phnciples apply the job in hand.
10 all vehicles.
Preparation
Z When a puncture occurs, stop as soon as D If you have one. use a warning triangle to • Chock the wheel diagonally opposite the
it is safe to do so. alert other drivers of your presence. one being removed - a couple of large
_j Park on firm level ground, if possible, • Apply the handbrake and engage first or stones will do for this.
and well out of the way of other traffic. reverse gear (or Park on models with C If the ground is soft, use a flat piece of
Use hazard warning lights if necessary. automatic transmission). wood to spread the load under the jack.
Changing the wheel
IOn Astra models the jack and wheel 2 The spare wheel is beneath a cover in the 3 On models with steel wheels, use the
braes are stowed under the spare wheel luggage compartment on Astra models. special tool to pull the wheel trim from
beneath the luggage compartment floor. Raise the cover, remove the screw and the wheel. On models with alloy wheels,
On Zafira models they are beneath a cover at lift out the spare wheel. Place it beneath the use the screwdriver provided inserted at the
the rear of the luggage compartment floor. sill as a precaution against the jack failing. On wheel bolt holes, to prise off the trim. Where
Zafira models, the spare wheel is under the an anti-theft device is fitted, use the tool
rear of the vehicle. Lift the rear of the luggage provided to remove the trim. Loosen each
compartment floor, and slacken the bolt in the wheel bolt by half a turn.
floor, using the wheel brace. Unhook the
catch, lower the spare, and detach the cable.
The spare can now be lifted out.
4 All models have depressions in the sill 5 Remove the bolts and lift the wheel from 6 Lower the vehicle to the ground, then
vertical web, which indicate the points at the vehicle. Place it beneath the sill in finally tighten the wheel bolts in a
which the Jack head is to be attached. On place of the spare as a precaution diagonal sequence. Refit the wheel trim.
Astra models, the depressions are concealed against the jack falling. Fit the spare wheel Note that the wheel bolts should be tightened
by flaps in the outer sill bodywork. Prise out and tighten the bolts moderately with the to the specified torque at the earliest
the flaps to access the jacking points. wheel brace opportunity.
Position the jack head under the jacking point
Finally...
and make sure that the slot in the head
engages correctly with the vertical web of the
sill. Turn the handle until the base of the jack • Remove the wheel chocks.
touches the ground then make sure that the
base is located directly below the sill. Raise • Stow the jack and tools in the correct locations In the car.
the vehicle until the wheel is clear of the
C Check the tyre pressure on the wheel just fitted. If It is low, or if you don't have a pressure
ground. If the tyre is flat make sure that the
gauge with you, drive slowly to the nearest garage and inflate the tyre to the right pressure.
vehicle is raised sufficiently to allow the spare
wheel to be fitted. • Have the damaged tyre or wheel repaired as soon as possible.