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Condition Value
expand_moreAir intake system
expand_moreIntake manifold
1.8 16V with gasoline straight-4 1.8 L 123 HP engine (2000.9–2005.8) 14.75 lbf⋅ft
Use new screws or nuts
2.2 16V with gasoline straight-4 2.2 L 145 HP engine (1998.11–2004.8) 7.38 lbf⋅ft
All other modifications 16.23 lbf⋅ft
Replace screws and nuts.
expand_moreAuxiliary assemblies
expand_moreAuxiliary drive belt tensioner
expand_more2.0 GSI Turbo with gasoline straight-4 2.0 L 189 HP engine (2001.9–2005.6)
With air-conditioning 18.44 lbf⋅ft
All other modifications 25.81 lbf⋅ft
expand_moreCarburetion
expand_moreInjection nozzle (injector)
First stage hand-screwed
Second stage 360°
expand_moreCharging
expand_moreTurbocharger oil feed line
expand_moreAt the turbocharger
Banjo screws 8.85 lbf⋅ft
Replace sealing rings.
Support 8.85 lbf⋅ft
expand_moreOn the engine block
Support 25.81 lbf⋅ft
Union nuts 14.75 lbf⋅ft
expand_moreTurbocharger oil return line
At the turbocharger 5.9 lbf⋅ft
Replace sealing rings.
On the engine block 22.13 lbf⋅ft
Replace sealing rings.
expand_moreCylinder head
expand_moreCamshaft bearing
2.0 DI 16V with diesel straight-4 2.0 L 80 HP engine (1999.10–2005.8) 11.06 lbf⋅ft
2.0 DTI 16V with diesel straight-4 2.0 L 99 HP at 4300 RPM, 230 N⋅m at 1950 RPM engine (1999.4–2005.8) 11.06 lbf⋅ft
expand_more2.2 16V with gasoline straight-4 2.2 L 145 HP engine (1998.11–2004.8)
Guide bearing 16.96 lbf⋅ft
Otherwise 6.64 lbf⋅ft
2.2 D with diesel straight-4 2.2 L 123 HP engine (2001.6–2005.6) 11.06 lbf⋅ft
All other modifications 5.9 lbf⋅ft
expand_moreCylinder head screws
expand_more2.0 DI 16V with diesel straight-4 2.0 L 80 HP engine (1999.10–2005.8)
expand_moreScrews 1 – 10
First stage 18.44 lbf⋅ft
Replace screws.
Second stage 65°
Third stage 65°
Fourth stage 65°
Fifth stage 65°
Sixth stage 15°
expand_moreScrews 11 – 14
Seventh stage 14.75 lbf⋅ft
Replace screws.
Eighth stage 30°
Ninth stage 5°
expand_more2.0 GSI Turbo with gasoline straight-4 2.0 L 189 HP engine (2001.9–2005.6)
Figure 1. Cylinder head, Cylinder head screws, 2.0 GSI Turbo with gasoline straight-4 2.0 L 189 HP engine (2001.9–2005.6).
Figure 1. Cylinder head, Cylinder head screws, 2.0 GSI Turbo with gasoline straight-4 2.0 L 189 HP engine (2001.9–2005.6).
First stage 18.44 lbf⋅ft
Replace screws. See figure 1.
Second stage 90°
Third stage 90°
Fourth stage 90°
Fifth stage 15°
expand_more2.2 16V with gasoline straight-4 2.2 L 145 HP engine (1998.11–2004.8)
expand_moreScrews 1 – 10
Figure 2. Cylinder head, Cylinder head screws, 2.2 16V with gasoline straight-4 2.2 L 145 HP engine (1998.11–2004.8), Screws 1 – 10.
Figure 2. Cylinder head, Cylinder head screws, 2.2 16V with gasoline straight-4 2.2 L 145 HP engine (1998.11–2004.8), Screws 1 – 10.
First stage 22.13 lbf⋅ft
Replace screws. See figure 2.
Second stage 75°
Third stage 75°
Fourth stage 15°
expand_moreScrews 11 – 14
Fifth stage 25.81 lbf⋅ft
Use screw-locking compound.
expand_more2.2 D with diesel straight-4 2.2 L 123 HP engine (2001.6–2005.6)
expand_moreScrews 1 – 10
First stage 18.44 lbf⋅ft
Replace screws.
Second stage 65°
Third stage 65°
Fourth stage 65°
Fifth stage 65°
Sixth stage 15°
expand_moreScrews 11 – 14
Seventh stage 14.75 lbf⋅ft
Replace screws.
Eighth stage 30°
Ninth stage 5°
expand_moreAll other modifications
Figure 3. Cylinder head, Cylinder head screws, All other modifications.
Figure 3. Cylinder head, Cylinder head screws, All other modifications.
First stage 18.44 lbf⋅ft
Replace screws. See figure 3.
Second stage 90°
Third stage 90°
Fourth stage 90°
Fifth stage 45°
expand_moreValve cover
2.2 16V with gasoline straight-4 2.2 L 145 HP engine (1998.11–2004.8) 6.64 lbf⋅ft
All other modifications 5.9 lbf⋅ft
expand_moreEngine block
expand_moreConnecting rod bearing
expand_more2.0 DI 16V with diesel straight-4 2.0 L 80 HP engine (1999.10–2005.8)
First stage 25.81 lbf⋅ft
Replace screws.
Second stage 45°
Third stage 15°
expand_more2.0 GSI Turbo with gasoline straight-4 2.0 L 189 HP engine (2001.9–2005.6)
First stage 25.81 lbf⋅ft
Replace screws.
Second stage 45°
Third stage 15°
expand_more2.2 16V with gasoline straight-4 2.2 L 145 HP engine (1998.11–2004.8)
First stage 18.44 lbf⋅ft
Replace screws.
Second stage 50°
Third stage 50°
Fourth stage 10°
expand_moreAll other modifications
First stage 18.44 lbf⋅ft
Replace screws.
Second stage 30°
expand_moreCrankshaft central screws
expand_more1.6 CNG with gasoline/natural gas straight-4 1.6 L 95 HP engine (2001.9–2005.6)
First stage 70.07 lbf⋅ft
Use new screw.
Second stage 45°
Third stage 15°
expand_more1.8 16V with gasoline straight-4 1.8 L 123 HP engine (2000.9–2005.8)
First stage 70.07 lbf⋅ft
Use new screw.
Second stage 45°
Third stage 15°
expand_more2.0 DI 16V with diesel straight-4 2.0 L 80 HP engine (1999.10–2005.8)
First stage 110.63 lbf⋅ft
Replace screws.
Second stage 45°
Third stage 15°
expand_more2.0 GSI Turbo with gasoline straight-4 2.0 L 189 HP engine (2001.9–2005.6)
First stage 95.88 lbf⋅ft
Replace screws.
Second stage 4050°
expand_more2.2 16V with gasoline straight-4 2.2 L 145 HP engine (1998.11–2004.8)
First stage 73.76 lbf⋅ft
Replace screws.
Second stage 75°
Third stage 15°
expand_more2.2 D with diesel straight-4 2.2 L 123 HP engine (2001.6–2005.6)
First stage 110.63 lbf⋅ft
Replace screws.
Second stage 45°
Third stage 15°
expand_moreAll other modifications
First stage 70.07 lbf⋅ft
Replace screws.
Second stage 45°
Third stage 15°
expand_moreCrankshaft pulley
2.0 GSI Turbo with gasoline straight-4 2.0 L 189 HP engine (2001.9–2005.6) 14.75 lbf⋅ft
expand_moreFlywheel
expand_more1.6 16V with gasoline straight-4 1.6 L 99 HP at 5800 RPM, 135 N⋅m at 3400 RPM engine (1999.4–2005.8)
First stage 25.81 lbf⋅ft
Second stage 30°
Third stage 15°
expand_more1.8 16V with gasoline straight-4 1.8 L 123 HP engine (2000.9–2005.8)
First stage 25.81 lbf⋅ft
Replace screws and nuts.
Second stage 30°
Third stage 15°
expand_more2.0 DI 16V with diesel straight-4 2.0 L 80 HP engine (1999.10–2005.8)
First stage 33.19 lbf⋅ft
Replace screws and nuts.
Second stage 30°
Third stage 15°
expand_more2.0 DTI 16V with diesel straight-4 2.0 L 99 HP at 4300 RPM, 230 N⋅m at 1950 RPM engine (1999.4–2005.8)
First stage 33.19 lbf⋅ft
Replace screws.
Second stage 30°
Third stage 15°
expand_more2.0 GSI Turbo with gasoline straight-4 2.0 L 189 HP engine (2001.9–2005.6)
First stage 47.94 lbf⋅ft
Replace screws. Use screw-locking compound.
Second stage 30°
Third stage 15°
expand_more2.2 16V with gasoline straight-4 2.2 L 145 HP engine (1998.11–2004.8)
First stage 39.09 lbf⋅ft
Clean the thread, use new screws and screw-locking compound.
Second stage 25°
expand_more2.2 D with diesel straight-4 2.2 L 123 HP engine (2001.6–2005.6)
First stage 33.19 lbf⋅ft
Replace screws and nuts.
Second stage 30°
Third stage 15°
expand_moreMain bearing
expand_more2.0 DI 16V with diesel straight-4 2.0 L 80 HP engine (1999.10–2005.8)
First stage 66.38 lbf⋅ft
Replace screws.
Second stage 60°
Third stage 15°
expand_more2.2 16V with gasoline straight-4 2.2 L 145 HP engine (1998.11–2004.8)
expand_moreM10
First stage 14.75 lbf⋅ft
Tighten new screws in inside-to-outside order.
Second stage 70°
Third stage 15°
M8 16.96 lbf⋅ft
Tighten from inside to outside.
expand_more2.2 D with diesel straight-4 2.2 L 123 HP engine (2001.6–2005.6)
First stage 66.38 lbf⋅ft
Replace screws.
Second stage 60°
Third stage 15°
expand_moreAll other modifications
First stage 36.88 lbf⋅ft
Replace screws.
Second stage 45°
Third stage 15°
expand_moreEngine control
expand_moreCamshaft drive belt deflection pulley
1.6 CNG with gasoline/natural gas straight-4 1.6 L 95 HP engine (2001.9–2005.6) 18.44 lbf⋅ft
expand_moreAll other modifications
Inlet camshaft 18.44 lbf⋅ft
Outlet camshaft 18.44 lbf⋅ft
expand_moreCamshaft timing gear
expand_more2.0 DI 16V with diesel straight-4 2.0 L 80 HP engine (1999.10–2005.8)
First stage 66.38 lbf⋅ft
Replace screws.
Second stage 60°
Third stage 30°
expand_more2.2 16V with gasoline straight-4 2.2 L 145 HP engine (1998.11–2004.8)
First stage 62.69 lbf⋅ft
Replace screws.
Second stage 30°
Third stage 15°
expand_more2.2 D with diesel straight-4 2.2 L 123 HP engine (2001.6–2005.6)
First stage 66.38 lbf⋅ft
Replace screws.
Second stage 60°
Third stage 30°
expand_moreAll other modifications
First stage 36.88 lbf⋅ft
Replace screws.
Second stage 60°
Third stage 15°
expand_moreChain tensioner
Cap 44.25 lbf⋅ft
Cap 44.25 lbf⋅ft
Balance shaft timing chain 7.38 lbf⋅ft
Camshaft timing chain 55.32 lbf⋅ft
Clean the thread.
Toothed belt guard 2.95 lbf⋅ft
expand_moreToothed belt guard at the bottom
2.0 GSI Turbo with gasoline straight-4 2.0 L 189 HP engine (2001.9–2005.6) 4.43 lbf⋅ft
All other modifications 2.95 lbf⋅ft
expand_moreToothed belt guard at the top
2.0 GSI Turbo with gasoline straight-4 2.0 L 189 HP engine (2001.9–2005.6) 4.43 lbf⋅ft
All other modifications 2.95 lbf⋅ft
Toothed belt tensioning roller 14.75 lbf⋅ft
expand_moreEngine lubrication
expand_moreOil drain plug
1.6 16V with gasoline straight-4 1.6 L 99 HP at 5800 RPM, 135 N⋅m at 3400 RPM engine (1999.4–2005.8) 33.19 lbf⋅ft
1.6 16V with gasoline straight-4 1.6 L 99 HP engine (1999.4–2005.8) 33.19 lbf⋅ft
expand_more1.8 16V with gasoline straight-4 1.8 L 123 HP engine (2000.9–2005.8)
Torx screws 10.33 lbf⋅ft
With hexagon-head screws 33.19 lbf⋅ft
2.2 16V with gasoline straight-4 2.2 L 145 HP engine (1998.11–2004.8) 18.44 lbf⋅ft
All other modifications 7.38 lbf⋅ft
Replace sealing rings.
expand_moreOil filter housing
2.0 DI 16V with diesel straight-4 2.0 L 80 HP engine (1999.10–2005.8) 14.75 lbf⋅ft
2.0 DTI 16V with diesel straight-4 2.0 L 99 HP at 4300 RPM, 230 N⋅m at 1950 RPM engine (1999.4–2005.8) 14.75 lbf⋅ft
2.2 16V with gasoline straight-4 2.2 L 145 HP engine (1998.11–2004.8) 18.44 lbf⋅ft
2.2 D with diesel straight-4 2.2 L 123 HP engine (2001.6–2005.6) 14.7518.44 lbf⋅ft
All other modifications 11.06 lbf⋅ft
expand_moreOil sump
1.6 16V with gasoline straight-4 1.6 L 99 HP at 5800 RPM, 135 N⋅m at 3400 RPM engine (1999.4–2005.8) 5.9 lbf⋅ft
Clean the thread and use screw-locking compound.
1.6 16V with gasoline straight-4 1.6 L 99 HP engine (1999.4–2005.8) 5.9 lbf⋅ft
Clean the thread and use screw-locking compound.
expand_more1.8 16V with gasoline straight-4 1.8 L 123 HP engine (2000.9–2005.8)
At the gearbox 29.5 lbf⋅ft
On the engine block 7.38 lbf⋅ft
Clean the thread and use screw-locking compound.
expand_more2.0 GSI Turbo with gasoline straight-4 2.0 L 189 HP engine (2001.9–2005.6)
At the gearbox 29.5 lbf⋅ft
expand_moreOil sump lower part
First stage 5.9 lbf⋅ft
Replace screws and nuts.
Second stage 30°
Oil sump top part 14.75 lbf⋅ft
expand_more2.2 16V with gasoline straight-4 2.2 L 145 HP engine (1998.11–2004.8)
At the gearbox 29.5 lbf⋅ft
On the engine block 16.96 lbf⋅ft
expand_moreAll other modifications
expand_moreAt the gearbox
M10 29.5 lbf⋅ft
M8 14.75 lbf⋅ft
On the engine block 14.75 lbf⋅ft
expand_moreEngine management
expand_moreCamshaft sensor
1.6 CNG with gasoline/natural gas straight-4 1.6 L 95 HP engine (2001.9–2005.6) 5.9 lbf⋅ft
Use screw-locking compound.
1.8 16V with gasoline straight-4 1.8 L 123 HP engine (2000.9–2005.8) 5.9 lbf⋅ft
All other modifications 4.43 lbf⋅ft
Glow plugs 7.38 lbf⋅ft
expand_moreKnock sensor
1.6 16V with gasoline straight-4 1.6 L 99 HP at 5800 RPM, 135 N⋅m at 3400 RPM engine (1999.4–2005.8) 9.59 lbf⋅ft
1.6 16V with gasoline straight-4 1.6 L 99 HP engine (1999.4–2005.8) 9.59 lbf⋅ft
2.2 16V with gasoline straight-4 2.2 L 145 HP engine (1998.11–2004.8) 16.96 lbf⋅ft
All other modifications 14.75 lbf⋅ft
expand_moreLambda sensor
1.8 16V with gasoline straight-4 1.8 L 123 HP engine (2000.9–2005.8) 29.5 lbf⋅ft
2.0 GSI Turbo with gasoline straight-4 2.0 L 189 HP engine (2001.9–2005.6) 29.5 lbf⋅ft
2.2 16V with gasoline straight-4 2.2 L 145 HP engine (1998.11–2004.8) 40.57 lbf⋅ft
All other modifications 22.13 lbf⋅ft
expand_moreEngine mounting
expand_moreEngine mounting
On chassis 25.81 lbf⋅ft
Replace screws.
On engine bracket 40.57 lbf⋅ft
Replace screws.
expand_moreExhaust system
expand_moreExhaust manifold
1.8 16V with gasoline straight-4 1.8 L 123 HP engine (2000.9–2005.8) 8.85 lbf⋅ft
Replace screws and nuts.
expand_more2.0 GSI Turbo with gasoline straight-4 2.0 L 189 HP engine (2001.9–2005.6)
First stage 5.9 lbf⋅ft
Note correct order of tensioning.
Second stage Wait 5 minutes.
Replace the nuts and use fitting paste
Third stage 5.9 lbf⋅ft
2.2 16V with gasoline straight-4 2.2 L 145 HP engine (1998.11–2004.8) 8.85 lbf⋅ft
All other modifications 16.23 lbf⋅ft
Replace screws and nuts.
expand_moreIgnition system
expand_moreSpark plugs
2.2 16V with gasoline straight-4 2.2 L 145 HP engine (1998.11–2004.8) 14.75 lbf⋅ft
All other modifications 18.44 lbf⋅ft

Please be noted that all capacities listed here are approximate. Check fluid levels when adding or refilling as recommended in your 2001 Vauxhall Zafira MPV user's manual. Keep in mind that all information here is provided “as is” without any warranty of any kind.

Before doing any DIY service please check your insurance policy and Vauxhall warranty policy for your region. In some regions DIY service may invalidate your warranty.

Conquer your fears and never give up!

DIY car service is not as difficult as it looks like and it might save you thousands of dollars per year. It might be even fun and a good thing to do with your kids on a weekend to teach them how basic machinery works. It's really hard to screw something up and damage your car permanently if you use right tools, follow Vauxhall Zafira MPV service manual and use right parts and fluids in prescribed amounts. Even modern cars stuffed with electronics can be serviced in your garage or even in your driveway. Changing engine oil, brake fluid, ATF, replacing brake pads, and etc. It's all may be done by yourself in a mater of a couple of hours.

Doing basic service for your 2001 Vauxhall Zafira MPV you're not only saving money, but also also improving your technical skills and learning something new.

Units:
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