2005 Vauxhall Zafira MPV engine fastener tightening specifications

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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⋅ft14.75 lbf⋅ft20 N⋅m
Use new screws or nuts
All other modifications	16.23 lbf⋅ft16.23 lbf⋅ft22 N⋅m
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⋅ft18.44 lbf⋅ft25 N⋅m


All other modifications	25.81 lbf⋅ft25.81 lbf⋅ft35 N⋅m

expand_moreCarburetion

expand_moreInjection nozzle (injector)


First stage	hand-screwed
Second stage	360°360°360°

expand_moreCharging

expand_moreTurbocharger oil feed line

expand_moreAt the turbocharger


Banjo screws	8.85 lbf⋅ft8.85 lbf⋅ft12 N⋅m
Replace sealing rings.
Support	8.85 lbf⋅ft8.85 lbf⋅ft12 N⋅m

expand_moreOn the engine block


Support	25.81 lbf⋅ft25.81 lbf⋅ft35 N⋅m


Union nuts	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m

expand_moreTurbocharger oil return line


At the turbocharger	5.9 lbf⋅ft5.9 lbf⋅ft8 N⋅m
Replace sealing rings.
On the engine block	22.13 lbf⋅ft22.13 lbf⋅ft30 N⋅m
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⋅ft11.06 lbf⋅ft15 N⋅m
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⋅ft11.06 lbf⋅ft15 N⋅m
2.2 D with diesel straight-4 2.2 L 123 HP engine (2001.6–2005.6)	11.06 lbf⋅ft11.06 lbf⋅ft15 N⋅m
All other modifications	5.9 lbf⋅ft5.9 lbf⋅ft8 N⋅m

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⋅ft18.44 lbf⋅ft25 N⋅m
Replace screws.
Second stage	65°65°65°
Third stage	65°65°65°
Fourth stage	65°65°65°
Fifth stage	65°65°65°
Sixth stage	15°15°15°

expand_moreScrews 11 – 14


Seventh stage	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
Replace screws.
Eighth stage	30°30°30°
Ninth stage	5°5°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).


First stage	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
Replace screws. See figure 1.
Second stage	90°90°90°
Third stage	90°90°90°
Fourth stage	90°90°90°
Fifth stage	15°15°15°

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⋅ft18.44 lbf⋅ft25 N⋅m
Replace screws.
Second stage	65°65°65°
Third stage	65°65°65°
Fourth stage	65°65°65°
Fifth stage	65°65°65°
Sixth stage	15°15°15°

expand_moreScrews 11 – 14


Seventh stage	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
Replace screws.
Eighth stage	30°30°30°
Ninth stage	5°5°5°

expand_moreAll other modifications


First stage	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
Replace screws. See figure 1.
Second stage	90°90°90°
Third stage	90°90°90°
Fourth stage	90°90°90°
Fifth stage	45°45°45°

expand_moreValve cover


All other modifications	5.9 lbf⋅ft5.9 lbf⋅ft8 N⋅m

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⋅ft25.81 lbf⋅ft35 N⋅m
Replace screws.
Second stage	45°45°45°
Third stage	15°15°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⋅ft25.81 lbf⋅ft35 N⋅m
Replace screws.
Second stage	45°45°45°
Third stage	15°15°15°

expand_moreAll other modifications


First stage	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
Replace screws.
Second stage	30°30°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⋅ft70.07 lbf⋅ft95 N⋅m
Use new screw.
Second stage	45°45°45°
Third stage	15°15°15°

expand_more1.8 16V with gasoline straight-4 1.8 L 123 HP engine (2000.9–2005.8)


First stage	70.07 lbf⋅ft70.07 lbf⋅ft95 N⋅m
Use new screw.
Second stage	45°45°45°
Third stage	15°15°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⋅ft110.63 lbf⋅ft150 N⋅m
Replace screws.
Second stage	45°45°45°
Third stage	15°15°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⋅ft95.88 lbf⋅ft130 N⋅m
Replace screws.
Second stage	40–50°40–50°40–50°

expand_more2.2 D with diesel straight-4 2.2 L 123 HP engine (2001.6–2005.6)


First stage	110.63 lbf⋅ft110.63 lbf⋅ft150 N⋅m
Replace screws.
Second stage	45°45°45°
Third stage	15°15°15°

expand_moreAll other modifications


First stage	70.07 lbf⋅ft70.07 lbf⋅ft95 N⋅m
Replace screws.
Second stage	45°45°45°
Third stage	15°15°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⋅ft14.75 lbf⋅ft20 N⋅m

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⋅ft25.81 lbf⋅ft35 N⋅m
Second stage	30°30°30°
Third stage	15°15°15°

expand_more1.8 16V with gasoline straight-4 1.8 L 123 HP engine (2000.9–2005.8)


First stage	25.81 lbf⋅ft25.81 lbf⋅ft35 N⋅m
Replace screws and nuts.
Second stage	30°30°30°
Third stage	15°15°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⋅ft33.19 lbf⋅ft45 N⋅m
Replace screws and nuts.
Second stage	30°30°30°
Third stage	15°15°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⋅ft33.19 lbf⋅ft45 N⋅m
Replace screws.
Second stage	30°30°30°
Third stage	15°15°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⋅ft47.94 lbf⋅ft65 N⋅m
Replace screws. Use screw-locking compound.
Second stage	30°30°30°
Third stage	15°15°15°

expand_more2.2 D with diesel straight-4 2.2 L 123 HP engine (2001.6–2005.6)


First stage	33.19 lbf⋅ft33.19 lbf⋅ft45 N⋅m
Replace screws and nuts.
Second stage	30°30°30°
Third stage	15°15°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⋅ft66.38 lbf⋅ft90 N⋅m
Replace screws.
Second stage	60°60°60°
Third stage	15°15°15°

expand_more2.2 D with diesel straight-4 2.2 L 123 HP engine (2001.6–2005.6)


First stage	66.38 lbf⋅ft66.38 lbf⋅ft90 N⋅m
Replace screws.
Second stage	60°60°60°
Third stage	15°15°15°

expand_moreAll other modifications


First stage	36.88 lbf⋅ft36.88 lbf⋅ft50 N⋅m
Replace screws.
Second stage	45°45°45°
Third stage	15°15°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⋅ft18.44 lbf⋅ft25 N⋅m

expand_moreAll other modifications


Inlet camshaft	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
Outlet camshaft	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m

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⋅ft66.38 lbf⋅ft90 N⋅m
Replace screws.
Second stage	60°60°60°
Third stage	30°30°30°

expand_more2.2 D with diesel straight-4 2.2 L 123 HP engine (2001.6–2005.6)


First stage	66.38 lbf⋅ft66.38 lbf⋅ft90 N⋅m
Replace screws.
Second stage	60°60°60°
Third stage	30°30°30°

expand_moreAll other modifications


First stage	36.88 lbf⋅ft36.88 lbf⋅ft50 N⋅m
Replace screws.
Second stage	60°60°60°
Third stage	15°15°15°

expand_moreChain tensioner

expand_moreAll Vauxhall diesel straight-4 2.0 L X 20 DTL engines


Cap	44.25 lbf⋅ft44.25 lbf⋅ft60 N⋅m

expand_moreAll Vauxhall diesel straight-4 2.2 L Y 22 DTR engines


Cap	44.25 lbf⋅ft44.25 lbf⋅ft60 N⋅m


Toothed belt guard	2.95 lbf⋅ft2.95 lbf⋅ft4 N⋅m

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⋅ft4.43 lbf⋅ft6 N⋅m
All other modifications	2.95 lbf⋅ft2.95 lbf⋅ft4 N⋅m

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⋅ft4.43 lbf⋅ft6 N⋅m
All other modifications	2.95 lbf⋅ft2.95 lbf⋅ft4 N⋅m


Toothed belt tensioning roller	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m

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⋅ft33.19 lbf⋅ft45 N⋅m
1.6 16V with gasoline straight-4 1.6 L 99 HP engine (1999.4–2005.8)	33.19 lbf⋅ft33.19 lbf⋅ft45 N⋅m

expand_more1.8 16V with gasoline straight-4 1.8 L 123 HP engine (2000.9–2005.8)


Torx screws	10.33 lbf⋅ft10.33 lbf⋅ft14 N⋅m
With hexagon-head screws	33.19 lbf⋅ft33.19 lbf⋅ft45 N⋅m


All other modifications	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m
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⋅ft14.75 lbf⋅ft20 N⋅m
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⋅ft14.75 lbf⋅ft20 N⋅m
2.2 D with diesel straight-4 2.2 L 123 HP engine (2001.6–2005.6)	14.75–18.44 lbf⋅ft14.75–18.44 lbf⋅ft20–25 N⋅m
All other modifications	11.06 lbf⋅ft11.06 lbf⋅ft15 N⋅m

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⋅ft5.9 lbf⋅ft8 N⋅m
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⋅ft5.9 lbf⋅ft8 N⋅m
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⋅ft29.5 lbf⋅ft40 N⋅m
On the engine block	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m
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⋅ft29.5 lbf⋅ft40 N⋅m

expand_moreOil sump lower part


First stage	5.9 lbf⋅ft5.9 lbf⋅ft8 N⋅m
Replace screws and nuts.
Second stage	30°30°30°


Oil sump top part	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m

expand_moreAll other modifications

expand_moreAt the gearbox


M10	29.5 lbf⋅ft29.5 lbf⋅ft40 N⋅m
M8	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m


On the engine block	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m

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⋅ft5.9 lbf⋅ft8 N⋅m
Use screw-locking compound.
1.8 16V with gasoline straight-4 1.8 L 123 HP engine (2000.9–2005.8)	5.9 lbf⋅ft5.9 lbf⋅ft8 N⋅m
All other modifications	4.43 lbf⋅ft4.43 lbf⋅ft6 N⋅m


Glow plugs	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m

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⋅ft9.59 lbf⋅ft13 N⋅m
1.6 16V with gasoline straight-4 1.6 L 99 HP engine (1999.4–2005.8)	9.59 lbf⋅ft9.59 lbf⋅ft13 N⋅m
All other modifications	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m

expand_moreLambda sensor


1.8 16V with gasoline straight-4 1.8 L 123 HP engine (2000.9–2005.8)	29.5 lbf⋅ft29.5 lbf⋅ft40 N⋅m
2.0 GSI Turbo with gasoline straight-4 2.0 L 189 HP engine (2001.9–2005.6)	29.5 lbf⋅ft29.5 lbf⋅ft40 N⋅m
All other modifications	22.13 lbf⋅ft22.13 lbf⋅ft30 N⋅m

expand_moreEngine mounting


On chassis	25.81 lbf⋅ft25.81 lbf⋅ft35 N⋅m
Replace screws.
On engine bracket	40.57 lbf⋅ft40.57 lbf⋅ft55 N⋅m
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⋅ft8.85 lbf⋅ft12 N⋅m
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⋅ft5.9 lbf⋅ft8 N⋅m
Note correct order of tensioning.
Second stage	Wait 5 minutes.
Replace the nuts and use fitting paste
Third stage	5.9 lbf⋅ft5.9 lbf⋅ft8 N⋅m

expand_more2.0 with gasoline straight-4 2.0 L 197 HP engine (2002.6–2005.6)


First stage	5.9 lbf⋅ft5.9 lbf⋅ft8 N⋅m
Note correct order of tensioning.
Second stage	Wait 5 minutes.
Replace the nuts and use fitting paste
Third stage	5.9 lbf⋅ft5.9 lbf⋅ft8 N⋅m


All other modifications	16.23 lbf⋅ft16.23 lbf⋅ft22 N⋅m
Replace screws and nuts.

expand_moreIgnition system

expand_moreSpark plugs


All other modifications	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m

Please be noted that all capacities listed here are approximate. Check fluid levels when adding or refilling as recommended in your 2005 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.

Maintenance Items

Engine Fastener Tightening Specifications
Front Suspension Fastener Tightening Specifications
Rear Suspension Fastener Tightening Specifications
Transmission Fastener Tightening Specifications

Service Intervals

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 2005 Vauxhall Zafira MPV you're not only saving money, but also also improving your technical skills and learning something new.

2005 Vauxhall Zafira MPV generations

In 2005 Vauxhall offered 2 generations of the Zafira MPV. Engine fastener tightening specifications may vary in different generations. Be sure that you are looking at the rigt modification.

Second generation (MK2)

T Platform (T-body, GM2700, GM3000) 1979-2012

2005 Vauxhall Zafira MPV First generation (MK1) Engine Fastener Tightening Specifications

Table of Contents

Conquer your fears and never give up!

2005 Vauxhall Zafira MPV generations

Second generation (MK2)

Vauxhall Zafira MPV First generation (MK1) model years

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