OPEL ASTRA H SERVICE MANUAL – PDF DOWNLOAD
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OPEL ASTRA H SERVICE MANUAL – PDF DOWNLOAD
- Air-conditioning system in a car Opel Astra directly charge the refrigerant HFC-134a (R-134a) or a similar material operational, fully equivalent to the specified properties.
- The use of another refrigerant will result in serious damage to the air conditioning system and the need for complete replacement of the system.
- Is not recommended to release the refrigerant into the atmosphere.
- The refrigerant HFC-134a (R-134a), used in cars, no adverse effects on the ozone layer of the atmosphere.
- However, entering the atmosphere of the refrigerant can be a small contribution to global warming.
TABLE OF CONTENTS:
OPEL ASTRA H SERVICE MANUAL – PDF DOWNLOAD
1 IDENTIFICATION DATA ………………………………………………………………………………………………….. 6
1.1 Typical plate ………………………………………………………………………………………………………………….. 6
1.2 Engine number ………………………………………………………………………………………………………………. 7
1.3 Type, properties and volumes of working fluids …………………………………………………………………. 9
1.4 Recommended fuel …………………………………………………………………………………………………………. 9
1.5 Recommendations for the choice of the viscosity of motor oil (petrol engines) …………………….. 10
1.6 The air conditioning system refrigerant …………………………………………………………………………… 10
1.7 Type of coolant …………………………………………………………………………………………………………….. 10
1.8 Keys, locks, sunroof, anti-theft system ……………………………………………………………………………. 10
1.9 Power Windows – Windowlifter ……………………………………………………………………………………… 16
1.10 The combination of instruments and controls a car Opel Astra ……………………………………….. 18
1.11 Information display ……………………………………………………………………………………………………. 33
1.12 Wipers and washer …………………………………………………………………………………………………….. 44
1.13 Heating and ventilation system with air conditioning …………………………………………………….. 48
1.14 Electronic climate control system ………………………………………………………………………………… 48
1.15 Automatic mode electronic climate control …………………………………………………………………… 51
1.16 Incandescent interior lighting ……………………………………………………………………………………… 57
1.17 Rear-view mirrors ……………………………………………………………………………………………………… 58
1.18 Steering wheel ………………………………………………………………………………………………………….. 60
1.19 The cigarette lighter plug and power outlet …………………………………………………………………… 61
1.20 Ashtrays …………………………………………………………………………………………………………………… 62
1.21 Front box kit …………………………………………………………………………………………………………….. 63
1.22 Compartment for glasses ……………………………………………………………………………………………. 63
1.23 Roofs – Sun visors ……………………………………………………………………………………………………… 63
1.24 Seats ………………………………………………………………………………………………………………………… 64
1.25 Passive safety system …………………………………………………………………………………………………. 78
1.26 Start the engine …………………………………………………………………………………………………………. 82
1.27 Easytronic transmission ……………………………………………………………………………………………… 82
1.28 Driving with automatic transmission ……………………………………………………………………………. 85
1.29 Driving with a trailer …………………………………………………………………………………………………. 88
1.30 Installation of new tires ……………………………………………………………………………………………… 92
1.31 Condition of tires, rims ………………………………………………………………………………………………. 94
1.32 Start the engine by using an auxiliary start cable …………………………………………………………… 95
1.33 Spare wheel ………………………………………………………………………………………………………………. 98
1.34 Replacement of the wheel …………………………………………………………………………………………… 99
1.35 Towing Opel Astra ………………………………………………………………………………………………….. 101
1.36 Kit repair tire …………………………………………………………………………………………………………… 103
1.37 Motor Oil ……………………………………………………………………………………………………………….. 105
1.38 Coolant …………………………………………………………………………………………………………………… 106
1.39 Brake Fluid …………………………………………………………………………………………………………….. 107
1.40 Electrical Equipment ……………………………………………………………………………………………….. 107
2 TRANSMISION. STRENGTH ………………………………………………………………………………………… 109
2.1 General information …………………………………………………………………………………………………… 109
2.2 Transmission. Clutch – The flow of the hydraulic clutch (gearbox – F13 / F17 + / F23 / M2O / M32) 110
2.3 Clutch – Removal, inspection and installation of hard plates and the driven clutch plate (without SAC) 111
2.4 Transmission. Clutch – Removal and installation of piping and discharge hose coupling (gear – F13 / F17 / F17 + / F23 / M2O / M32) …………………………………………………………………………………….. 118
2.5 Clutch – Replacement of the clutch pedal……………………………………………………………………….. 124
2.6 Clutch – Manual Transmission ……………………………………………………………………………………… 125
2.7 Clutch – gears and gear lever ………………………………………………………………………………………… 127
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2.8 Clutch – Check transmission oil level …………………………………………………………………………….. 128
2.9 Clutch – Removal and installation of the transmission (F 13) ……………………………………………. 131
2.10 Transmission, removing and setting of the engine (dismantled) …………………………………….. 134
2.11 Clutch – Replacing the crankcase-Replacement of the transmission housing (gearbox F13) 140
2.12 Clutch – Removal and installation of rear cover gear (F 13) ………………………………………….. 142
2.13 Clutch – Removal and installation of the differential (gearbox F13) ……………………………….. 154
2.14 Clutch – Removal and installation of the main shaft (gearbox F13) ………………………………… 160
2.15 Automatic Transmission …………………………………………………………………………………………… 171
2.16 Clutch – Torque ……………………………………………………………………………………………………….. 172
2.17 Clutch – Gear Main channel ……………………………………………………………………………………… 172
2.18 Clutch – Adjust the cable selector switch automatic transmission ………………………………… 172
2.19 Propulsion mechanism. Clutch – Drive Mechanism ……………………………………………………… 173
2.20 Strength – Measurement of radial and lateral runout of the bearing wheels ……………………… 174
2.21 Strength inclined gap block – Measurement of oblique gap block bearing ………………………. 176
2.22 Installing shaft wheel. Clutch – Removal and installation of roller wheel ……………………….. 177
2.23 Internal hinge. Clutch – Replacement of internal velocity joints …………………………………….. 181
2.24 External hinge. Clutch – Replacement of external velocity joints …………………………………… 182
2.25 Clutch – Dismantling the outer constant velocity joints …………………………………………………. 183
3 CHASSIS…………………………………………………………………………………………………………………………. 184
3.1 The body of the front axle ……………………………………………………………………………………………. 188
3.2 Rear axle ……………………………………………………………………………………………………………………. 190
3.3 Shock Absorbers – rear axle ………………………………………………………………………………………….. 193
3.4 Spring rack with springs of the all-clear …………………………………………………………………………. 194
3.5 Spring rack …………………………………………………………………………………………………………………. 195
3.6 Stabilizer / Lever / swivel arm ………………………………………………………………………………………. 196
3.7 Continuous Damping Control System(CDC) ………………………………………………………………….. 197
3.8 Wheels and Tires ………………………………………………………………………………………………………… 199
3.9 Front Suspension ………………………………………………………………………………………………………… 206
3.10 Adjust the front suspension ……………………………………………………………………………………….. 208
3.11 The difference base chassis ……………………………………………………………………………………….. 210
3.12 Offset Wheel …………………………………………………………………………………………………………… 210
3.13 Removing and installation arm suspension ………………………………………………………………….. 211
3.14 Removing and installing racks CDC spring with shock absorbers ………………………………….. 212
3.15 Replacement of the front damping arm bushings …………………………………………………………. 216
3.16 Pipe rack spring – Replacement of the spring supporting tube rack ………………………………… 218
3.17 Replacement Stabilizer …………………………………………………………………………………………….. 221
3.18 Replacement of rotary lever ………………………………………………………………………………………. 222
3.19 Elastic beam rear suspension, Astra-G, Astra-H, Zafira – rear axle …………………………………. 223
3.20 Removing and installing wheel bearing ………………………………………………………………………. 223
4 STEERING GEAR ………………………………………………………………………………………………………….. 226
4.1 EHPS – How it works ………………………………………………………………………………………………….. 226
4.2 The visual differences between the systems, TRW and ZF ……………………………………………….. 229
4.3 The steering mechanism – How it works EHPS ZF ………………………………………………………….. 229
4.4 The wiring harness connector electrohydraulic module ……………………………………………………. 229
4.5 Casing steering ……………………………………………………………………………………………………………. 231
4.6 Steering gear – Steering Gear / tie rods …………………………………………………………………………… 232
4.7 Steering Gear – Checking wheel play …………………………………………………………………………….. 232
4.8 Steering Gear – Testing the efforts of the steering wheel ………………………………………………….. 232 4.9 Steering mechanism – Pumping system hydraulic power steering ……………………………………… 233
4.10 Steering Gear – Check tie-rod ends and seals ………………………………………………………………. 233
4.11 Steering Gear – Check constant velocity joints …………………………………………………………….. 233
4.12 Steering mechanism – Checking power steering leak ……………………………………………………. 235
4.13 Steering Gear – Check the level of the working fluid hydraulic ……………………………………… 235
4.14 Steering mechanism – Filling and removal of air from the hydraulic system ……………………. 236
4.15 Steering Gear – Replacement of the modulus of the steering column (CIM) ……………………. 236
4.16 Steering mechanism – Replacing the steering column …………………………………………………… 238
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4.17 Steering Gear – Replacement of steering ZF ……………………………………………………………….. 243
4.18 Steering Gear – Replacement of tie rod ………………………………………………………………………. 245
4.19 Steering Gear – Replacement of tie rod ………………………………………………………………………. 247
4.20 Steering Gear – Replacement of the steering mechanism TRW ……………………………………… 248
4.21 Steering Gear – Replacement covers on the steering mechanism ……………………………………. 250
4.22 Steering Gear – Replacement of pipelines hydraulic steering system with amplifier (ZF) …. 252
5 BRAKES …………………………………………………………………………………………………………………………. 254
5.1 General ……………………………………………………………………………………………………………………… 254
5.2 Front brakes ……………………………………………………………………………………………………………….. 256
5.3 Rear brakes ………………………………………………………………………………………………………………… 256
5.4 Power Brakes ……………………………………………………………………………………………………………… 257
5.5 Brake line ………………………………………………………………………………………………………………….. 257
5.6 Master Cylinder, brakes ………………………………………………………………………………………………. 258
5.7 Anti-lock braking system ESP MK60 ……………………………………………………………………………. 262
5.8 Check and adjust the brake system ………………………………………………………………………………… 267
5.9 Check brake fluid level in the cistern hydraulic braking …………………………………………………… 267
5.10 Removal of air from the hydraulic braking system ………………………………………………………. 268
5.11 Brake hoses …………………………………………………………………………………………………………….. 268
5.12 Adjust the parking brake system ………………………………………………………………………………… 269
5.13 Replacement of the brake pedal …………………………………………………………………………………. 270
5.14 Removing and installing front brake hoses …………………………………………………………………. 274
5.15 Replacement of tubes of the braking system ……………………………………………………………….. 276
5.16 Replacement of cistern hydraulic braking system ………………………………………………………… 277
5.17 Removing and installing brake booster vacuum line …………………………………………………….. 279
5.18 Replacement of Control Unit ABS (ESP MK60) …………………………………………………………. 280
5.19 Removing and installing brake caliper front wheel ………………………………………………………. 282
5.20 Removing and installing brake shoes lining the front wheel ………………………………………….. 284
5.21 Removal and installation of safety guard brakes the front wheel ……………………………………. 287
5.22 Replacing the brake disc front wheel ………………………………………………………………………….. 290
5.23 Removing and installing rear wheel brake shield …………………………………………………………. 291
5.24 Removal and installation of caliper brake rear wheel …………………………………………………… 292
5.25 Removing and installing brake pads rear wheel …………………………………………………………… 297
5.26 Adjust the drum brake mechanism …………………………………………………………………………….. 300
5.27 Replacing brake pads disc brake rear wheel ………………………………………………………………… 301
6 ON-BOARD ELECTRICAL ……………………………………………………………………………………………. 306
6.1 General ……………………………………………………………………………………………………………………… 306
6.2 Principle of AMU ……………………………………………………………………………………………………….. 306
6.3 Safety ………………………………………………………………………………………………………………………… 306
6.4 Check for voltage ……………………………………………………………………………………………………….. 306
6.5 Searches of the short circuit …………………………………………………………………………………………. 306
6.6 Check serviceability of earth ………………………………………………………………………………………… 306
6.7 Lack of checks on the precipice ……………………………………………………………………………………. 307
6.8 Wires, relays and fuses ………………………………………………………………………………………………… 307
6.9 Battery ………………………………………………………………………………………………………………………. 309
6.10 Generator ……………………………………………………………………………………………………………….. 313
6.11 Starter …………………………………………………………………………………………………………………….. 314
6.12 Voltage regulator …………………………………………………………………………………………………….. 315
6.13 Removing and installing windshield washer nozzles and rear window …………………………… 315
6.14 Removal and installation faroomyvateley …………………………………………………………………… 316
6.15 Removal and installation of the reservoir / pump for washer fluid …………………………………. 316
6.16 Removal and installation of front wiper levers …………………………………………………………….. 319
6.17 Removal and installation of electric motor cleaners windscreen ……………………………………. 320
6.18 Removing and installation of rear window wiper motor ……………………………………………….. 320
6.19 Removal and installation of rain sensor ………………………………………………………………………. 321
6.20 Removal and installation of instrument cluster ……………………………………………………………. 322
6.21 Removal and installation of information display ………………………………………………………….. 322
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6.22 On-board electrical equipment – Removal and installation of outdoor lighting panel switches / lighting devices …………………………………………………………………………………………………………………….. 323
6.23 On-board electrical equipment – Removing and installing the module gearshift paddles …… 324
6.24 On-board electrical equipment – Removal and installation of power switches console section of the dashboard …………………………………………………………………………………………………………………… 325
6.25 On-board electrical equipment – Removal, installation, switch mode of winter driving ……. 325
6.26 On-board electrical equipment – Removal and installation of switches, electric windows front and rear doors ………………………………………………………………………………………………………………………. 326
6.27 On-board electrical equipment – Removal and installation of remote control panel switches on the steering wheel …………………………………………………………………………………………………………………. 327
6.28 On-board electrical equipment – Removal and installation of sensor-switch hood (model with anti-theft system) ………………………………………………………………………………………………………………….. 329
6.29 On-board electrical equipment – Removal and installation of sensor-switch door lock ……… 329
6.30 Removal and installation of the loudspeaker ……………………………………………………………….. 330
6.31 On-board electrical equipment – Removal and installation of outdoor antenna ………………… 332
7 BODY ……………………………………………………………………………………………………………………………… 332
7.1 General ………………………………………………………………………………………………………………………. 332
7.2 Central and door locks …………………………………………………………………………………………………. 333
7.3 Removal and installation of body linings (moldings) ……………………………………………………….. 333
7.4 Decorative overlay on the back of the door …………………………………………………………………….. 333
7.5 Removing and installing fairing lattice …………………………………………………………………………… 334
7.6 Removal and installation of protection wheel arches ……………………………………………………….. 334
7.7 Removing and installing the front bumper / bumper moldings ………………………………………….. 335
7.8 Removal and installation of decorative radiator grille ……………………………………………………… 337
7.9 Removal and installation of front wings …………………………………………………………………………. 338
7.10 Removal, installation and adjustment of the hood ………………………………………………………… 340
7.11 Adjustable hood clearances ……………………………………………………………………………………….. 340
7.12 Removing and installing the cable drive release latch lock hood ……………………………………. 341
7.13 Removal, installation and adjustment of the back of the door ………………………………………… 341
7.14 Removal and installation of door lining the back of ……………………………………………………… 343
7.15 Removal and installation of the door back of ………………………………………………………………. 344
7.16 Removal, installation and adjustment of the side doors …………………………………………………. 344
7.17 Removing and installing lock side doors …………………………………………………………………….. 345
7.18 Removal and installation of exterior side door handles …………………………………………………. 346
7.19 Removing and installation of the base outside door handles ………………………………………….. 348
7.20 Removing and installing upholstery, side door …………………………………………………………….. 349
7.21 Care body car Opel Astra ………………………………………………………………………………………….. 350
8 PLANS…………………………………………………………………………………………………………………………….. 352
8.1 Legend – designations used on electrical circuits …………………………………………………………….. 352
8.2 The cooling system of engine (engines Z14 XEP, Z16 XEP, Z18 XEP and Z17DTL) …………. 356
8.3 Front and rear wiper / rain sensor / headlamp washers …………………………………………………….. 357
8.4 Power Windows ………………………………………………………………………………………………………….. 358
8.5 Switch stop-signalov/Vyklyuchatel reversing lamps / switches Control outdoor lighting / lighting devices ………………………………………………………………………………………………………………………………… 359
8.6 Rear combination lamps / Light, license plate / brake light upper level ……………………………… 360
8.7 Headlamps (except xenon) / Fog lights ………………………………………………………………………….. 361
8.8 Cabin Interior lighting / power take-off socket / cigarette lighter / Lighting trunk ……………….. 362
PLEASE NOTE:
- This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
- This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
- Require some other service manual or have any queries: please WRITE to us at [email protected]