2003 Vauxhall Zafira MPV First generation (MK1) Engine Fastener Tightening Specifications
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Condition | Value |
---|
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. |
With air-conditioning | 18.44 lbf⋅ft |
All other modifications | 25.81 lbf⋅ft |
First stage | hand-screwed |
Second stage | 360° |
Banjo screws | 8.85 lbf⋅ft |
Replace sealing rings. | |
Support | 8.85 lbf⋅ft |
Support | 25.81 lbf⋅ft |
Union nuts | 14.75 lbf⋅ft |
At the turbocharger | 5.9 lbf⋅ft |
Replace sealing rings. | |
On the engine block | 22.13 lbf⋅ft |
Replace sealing rings. |
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 |
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 |
First stage | 18.44 lbf⋅ft |
Replace screws. | |
Second stage | 65° |
Third stage | 65° |
Fourth stage | 65° |
Fifth stage | 65° |
Sixth stage | 15° |
Seventh stage | 14.75 lbf⋅ft |
Replace screws. | |
Eighth stage | 30° |
Ninth stage | 5° |
First stage | 18.44 lbf⋅ft |
Replace screws. See figure 1. | |
Second stage | 90° |
Third stage | 90° |
Fourth stage | 90° |
Fifth stage | 15° |
First stage | 22.13 lbf⋅ft |
Replace screws. See figure 2. | |
Second stage | 75° |
Third stage | 75° |
Fourth stage | 15° |
Fifth stage | 25.81 lbf⋅ft |
Use screw-locking compound. |
First stage | 18.44 lbf⋅ft |
Replace screws. | |
Second stage | 65° |
Third stage | 65° |
Fourth stage | 65° |
Fifth stage | 65° |
Sixth stage | 15° |
Seventh stage | 14.75 lbf⋅ft |
Replace screws. | |
Eighth stage | 30° |
Ninth stage | 5° |
First stage | 18.44 lbf⋅ft |
Replace screws. See figure 3. | |
Second stage | 90° |
Third stage | 90° |
Fourth stage | 90° |
Fifth stage | 45° |
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 |
First stage | 25.81 lbf⋅ft |
Replace screws. | |
Second stage | 45° |
Third stage | 15° |
First stage | 25.81 lbf⋅ft |
Replace screws. | |
Second stage | 45° |
Third stage | 15° |
First stage | 18.44 lbf⋅ft |
Replace screws. | |
Second stage | 50° |
Third stage | 50° |
Fourth stage | 10° |
First stage | 18.44 lbf⋅ft |
Replace screws. | |
Second stage | 30° |
First stage | 70.07 lbf⋅ft |
Use new screw. | |
Second stage | 45° |
Third stage | 15° |
First stage | 70.07 lbf⋅ft |
Use new screw. | |
Second stage | 45° |
Third stage | 15° |
First stage | 110.63 lbf⋅ft |
Replace screws. | |
Second stage | 45° |
Third stage | 15° |
First stage | 95.88 lbf⋅ft |
Replace screws. | |
Second stage | 40–50° |
First stage | 73.76 lbf⋅ft |
Replace screws. | |
Second stage | 75° |
Third stage | 15° |
First stage | 110.63 lbf⋅ft |
Replace screws. | |
Second stage | 45° |
Third stage | 15° |
First stage | 70.07 lbf⋅ft |
Replace screws. | |
Second stage | 45° |
Third stage | 15° |
2.0 GSI Turbo with gasoline straight-4 2.0 L 189 HP engine (2001.9–2005.6) | 14.75 lbf⋅ft |
First stage | 25.81 lbf⋅ft |
Second stage | 30° |
Third stage | 15° |
First stage | 25.81 lbf⋅ft |
Replace screws and nuts. | |
Second stage | 30° |
Third stage | 15° |
First stage | 33.19 lbf⋅ft |
Replace screws and nuts. | |
Second stage | 30° |
Third stage | 15° |
First stage | 33.19 lbf⋅ft |
Replace screws. | |
Second stage | 30° |
Third stage | 15° |
First stage | 47.94 lbf⋅ft |
Replace screws. Use screw-locking compound. | |
Second stage | 30° |
Third stage | 15° |
First stage | 39.09 lbf⋅ft |
Clean the thread, use new screws and screw-locking compound. | |
Second stage | 25° |
First stage | 33.19 lbf⋅ft |
Replace screws and nuts. | |
Second stage | 30° |
Third stage | 15° |
First stage | 66.38 lbf⋅ft |
Replace screws. | |
Second stage | 60° |
Third stage | 15° |
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. |
First stage | 66.38 lbf⋅ft |
Replace screws. | |
Second stage | 60° |
Third stage | 15° |
First stage | 36.88 lbf⋅ft |
Replace screws. | |
Second stage | 45° |
Third stage | 15° |
1.6 CNG with gasoline/natural gas straight-4 1.6 L 95 HP engine (2001.9–2005.6) | 18.44 lbf⋅ft |
Inlet camshaft | 18.44 lbf⋅ft |
Outlet camshaft | 18.44 lbf⋅ft |
First stage | 66.38 lbf⋅ft |
Replace screws. | |
Second stage | 60° |
Third stage | 30° |
First stage | 62.69 lbf⋅ft |
Replace screws. | |
Second stage | 30° |
Third stage | 15° |
First stage | 66.38 lbf⋅ft |
Replace screws. | |
Second stage | 60° |
Third stage | 30° |
First stage | 36.88 lbf⋅ft |
Replace screws. | |
Second stage | 60° |
Third stage | 15° |
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 |
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 |
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 |
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 |
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. |
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) | 14.75–18.44 lbf⋅ft |
All other modifications | 11.06 lbf⋅ft |
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. |
At the gearbox | 29.5 lbf⋅ft |
On the engine block | 7.38 lbf⋅ft |
Clean the thread and use screw-locking compound. |
At the gearbox | 29.5 lbf⋅ft |
First stage | 5.9 lbf⋅ft |
Replace screws and nuts. | |
Second stage | 30° |
Oil sump top part | 14.75 lbf⋅ft |
At the gearbox | 29.5 lbf⋅ft |
On the engine block | 16.96 lbf⋅ft |
M10 | 29.5 lbf⋅ft |
M8 | 14.75 lbf⋅ft |
On the engine block | 14.75 lbf⋅ft |
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 |
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 |
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 |
On chassis | 25.81 lbf⋅ft |
Replace screws. | |
On engine bracket | 40.57 lbf⋅ft |
Replace screws. |
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. |
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 |
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. |
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 2003 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.
Table of Contents
- Air Conditioning Compressor Oil Capacity
- Air Conditioning Refrigerant Capacity
- Automatic Transmission Fluid Capacity
- Brake Fluid Capacity
- Engine Oil Capacity
- Fluid and Lubricant Specifications
- Manual Transmission Oil Capacity
- Engine Fastener Tightening Specifications
- Front Suspension Fastener Tightening Specifications
- Rear Suspension Fastener Tightening Specifications
- Transmission Fastener Tightening Specifications
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 2003 Vauxhall Zafira MPV you're not only saving money, but also also improving your technical skills and learning something new.