This factory service and repair manual for the 2004 Chevrolet Zafira takes a compact van apart in order. The vehicle is a four-door mini passenger van in Base trim; the engines are two naturally aspirated gasoline fours with twin overhead camshafts, 2.2 liters and 134 cubic inches, or 1.8 liters and 110. Engine mechanical work comes with its own specifications for each unit, and the transaxle, braking, steering, suspension and electrical sections follow with procedures, torque values, wiring diagrams and diagnostics.
Engines covered
- 2.2L inline-four (134 cu in) — DOHC, naturally aspirated, gasoline
- 1.8L inline-four (110 cu in) — DOHC, naturally aspirated, gasoline
Body styles covered
- 4-door mini passenger van
Trims covered
- Base
Known issues on the 2004 Zafira. NHTSA lists no recall for this year and no complaint from an owner, so there is no known failure to work around. The manual's usefulness lies elsewhere — in the exact figures. Valve clearances, timing values, ignition and fuel specifications and fastener torques are given for both the 134- and 110-cubic-inch engines, and the same treatment continues into the transaxle and the brake, steering and suspension hardware, with diagnostics that begin at the symptom the driver reports.
