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Astra F (1991-1998, petrol)
General information
Maintenance
Introduction to Opel Astra F cars
Dimensions and weight characteristics
Characteristics of vehicle components
Lubricants and working fluids
Engine bay — 1.4L C 14 NZ engine
Engine bay — 1.6L C 16 SE engine
Engine bay — C 20 XE 2.0L engine
Bottom view of the front — C 16 SE engine
Bottom view of the rear of the car
Every 400 km or weekly
Every 15,000 km or 12 months of operation
Every 30,000 km or 24 months of operation
Every 60,000 km or 4 years of operation
Every 120,000 km or 8 years of operation
Power unit
Engine in car
Single Overhead Camshaft Engine Characteristics
Twin Overhead Cam Engine Specifications
General information about the engine
Compression check
Top Dead Center for Piston #1 — Location
Camshaft Cover — Removal and Installation
Crankshaft pulley — removal and installation
Timing Belt Covers — Removal and Installation
Distributor belt — removal, installation and adjustment
Timing Belt Sprockets — Removal and Installation
Belt tension indicator (1.4 and 1.6 L engines) — removal and installation
Camshaft Seals — Replacement
Camshaft — Removal, Inspection and Installation
Cylinder head — removal and installation
Oil pump — removal and installation
Oil pump — disassembly, inspection, assembly
Crankshaft Seals — Removal
Flywheel/Drive Disc — Removal, Inspection, and Installation
Oil Cooler (TWC Engine) — Removal and Installation
Engine removed
Indications for engine removal
Engine — removal and installation (manual transmission remains on the car)
Engine/manual transmission assembly — removal and installation
Engine — removal and installation (automatic transmission on a car)
Engine/automatic transmission assembly — removal and installation
Engine repair — disassembly procedure
Cylinder head — disassembly
Cylinder head and valve parts — cleaning and inspection
Cylinder head — assembly
Piston/Connecting Rod Assembly — Removal
Crankshaft — Removal
Cylinder Block/Crankshaft — Cleaning and Inspection
Piston/Connecting Rod Assembly — Inspection
Crankshaft — inspection
Main and connecting rod bearings — inspection
Engine Repair — Assembly Sequence
Piston rings — installation
Crankshaft — Installation and Checking the Main Bearing Clearance
Piston/Connecting Rod Assembly — Installation and Clearance Check
Engine — first start after repair
Exhaust gas toxicity control
Cooling system
Technical specifications
Cooling systems — general information
Coolant Hoses — Disconnecting and Replacing
Radiator — removal, inspection and installation
Expansion tank — removal and installation
Thermostat — Removal, Checking and Installation
Cooling system fan — checking, removal and installation
Cooling system switches — checking, removing and installing
Coolant Temperature Gauge Sensor
Coolant level sensor
Coolant pump — removal and installation
Heating and ventilation
Heating and ventilation system parts
Interior ventilation and heating system — general information
Heating/Ventilation Control Tree — Removal and Installation
Heating/Ventilation Control Cables — Replacement
Heater Fan Electric Motor — Removal and Installation
Heater core — removal and installation
Ventilation nozzles of the ventilation/heating system — removal and installation
Fuel supply (carburetor)
Technical specifications
General information about carburetor engines
Air Purifier Temperature Control — Check
Fuel pump — checking, removal, installation
Fuel level indicator sensor — removal and installation
Fuel vapor trap — removal and installation
Fuel filter — replacement
Fuel tank — removal and installation
Throttle Cable — Removal, Installation and Adjustment
Accelerator pedal — removal and installation
Carburetor — removal and installation
Carburetor — diagnostics of faults, repair and adjustment
Carburetor float and needle valve — removal, inspection and installation
Secondary chamber vacuum diaphragm throttle control
Carburetor Economizer Diaphragm — Replacement
Carburetor Accelerator Pump Diaphragm — Replacement
Automatic air damper — removal, installation, adjustment
Vacuum regulator for opening the automatic air damper — removal, installation and adjustment
Intake manifold — removal and installation
Exhaust manifold — removal and installation
Exhaust system — general information
Exhaust system — replacement of parts
Fuel supply (injector)
General information about fuel injection
Fuel pump — checking, removal and installation
Fuel filter — removal and installation
Fuel tank — removal and installation
Throttle Cable — Removal, Installation and Adjustment
Unleaded petrol — general information
Catalytic Converter — General Information
Fuel injection systems
Multec Single Point Fuel Injection System Components — Removal and Installation
Electronic control unit
Multec Multi-Point Fuel Injection System Components — Removal and Installation
Motronic M1.5.2 Fuel Injection System Components — Removal and Installation
Fuel injection system parts (Motronic M2.5) — removal and installation
Electronic Traction Control (ETC)
Electronic Traction Control (ETC) Components
Intake manifold (single point injection Multec) — removal and installation
Intake manifold (Multec multipoint injection) — removal and installation
Intake manifold (Motronic M1.5.2 injection system) — removal and installation
Intake manifold (Motronic M2.5 injection system) — removal and installation
Exhaust manifold — removal and installation
Exhaust system — general information
Exhaust system — replacement of parts
Emission control
Emission Control Systems — General Information
Crankcase Emission Control System Components
Exhaust gas cleaning system
Fuel Evaporative Control System — Check
Activated Carbon Box — Replacement
Fuel Tank Vent Valve — Replacement
Exhaust Gas Recirculation System — Check
Exhaust Gas Recirculation Valve — Cleaning and Replacement
Ignition system
Technical specifications
General information and warnings
Ignition system of carburetor engines — check
Ignition system of injection engines — check
Ignition distributor (carburetor) — removal, repair and installation
Ignition distributor (injector 1.4 and 1.6 l) — removal, repair and installation
Ignition distributor (injector 1.8 and 2.0 l) — removal, repair and installation
Ignition coil — removal, inspection and installation
Coil Booster Module — Removal and Installation
Transmission
Clutch
Technical specifications
General information about the clutch
Clutch cable — removal and installation
Clutch pedal — removal and installation
Clutch assembly — removal, inspection and installation
Clutch release bearing — removal, inspection and installation
Mechanical gearbox
Technical specifications
General information about manual transmission
Gearbox Oil — Draining and Filling
Gear shift mechanism — adjustment
Gear shift mechanism — removal, repair and installation
Speedometer drive — removal and installation
Manual transmission seals — replacement
Reverse Light Switch — Removal, Installation and Testing
Manual gearbox — removal and installation
Manual gearbox — repair, general information
Automatic gearbox
Technical specifications
General information about automatic transmission
Shifter Cable — Removal, Installation and Adjustment
Selector lever — removal and installation
Seals (drive shafts) on the differential side
Reverse Light Switch/Starter Inhibitor Circuit
Gearbox Mode Switches — Removal and Installation
Working fluid temperature sensor — removal and installation
Input/Output Speed Sensors — Removal and Installation
Electronic control unit — removal and installation
Automatic transmission — removal and installation
Automatic transmission repair — general information
Drive shafts
Technical specifications
General information about drive shafts
Drive shafts — removal
Drive shafts — installation
Drive shaft repair — general information
Chassis
Brake system
Technical specifications
Anti-lock braking system (ABS)
Hydraulic system — air release (bleeding)
Hydraulic system pipes and hoses — inspection, removal and installation
Front Brake Pads — Removal
Front Brake Caliper — Removal, Repair and Installation
Brake disc — inspection, removal, installation
Front Brake Disc Shield — Removal and Installation
Rear Brake Pads — Removal
Rear Brake Drum — Removal, Checking and Installation
Rear Brake Wheel Cylinder — Removal, Repair and Installation
Rear Brake Linings (Rear Disc Brakes) — Replacement
Rear Wheel Brake Caliper (Rear Disc Brakes) — Removal, Repair and Installation
Handbrake pads (rear disc brakes) — replacement
Rear Brake Disc Support — Removal and Installation
Brake pedal — removal and installation
Hydrovacuum booster — removal and installation
Brake booster check valve — checking, removing and installing
Master Brake Cylinder — Removal, Repair and Installation
Handbrake — adjustment
Handbrake lever — removal, repair and installation
Handbrake cables — removal and installation
Rear Circuit Pressure Regulating Valve — Removal, Installation and Adjustment
Brake light switch — removal and installation
Brake System Warning Lights — General Information
Anti-lock braking system ABS, components — removal and installation
Car suspension
Suspension specifications
Front and rear suspension design
Front suspension strut — removal and installation
Front suspension strut — repair
Front Wheel Hub Bearing — Replacement
Lower control arm front suspension — removal and installation
Front Lower Arm Bushings — Replacement
Front Lower Arm Ball Joint — Replacement
Anti-roll bar rod — removal and installation
Front Anti-Roll Bar Bushings — Removal
Front Suspension Subframe — Removal and Installation
Rear hub — removal and installation
Rear shock absorber — removal, inspection and installation
Rear shock absorber rubber bushings — replacement
Rear Suspension Coil Spring — Removal and Installation
Rear Anti-Roll Bar — Removal and Installation
Rear suspension torsion beam / trailing arms — removal and installation
Rear Suspension Trailing Arm Bushings — Replacement
Rear Suspension Level Control System — General Information
Rear Suspension Level Control System Components — Removal and Installation
Steering
Technical characteristics of the steering system
Steering wheel — removal and installation
Steering wheel — centering
Steering column lock — removal and installation
Steering column — removal and installation
Steering column — disassembly and assembly
Elastic coupling of the steering wheel shaft — removal
Rubber Corrugated Steering Gear Boot — Replacement
Steering gear — removal and installation
Steering gear — repair
Power steering hydraulic system — bleeding
Power steering pump drive belt — removal, installation and adjustment
Power Steering Pump — Removal and Installation
Power Steering Fluid Reservoir — Removal and Installation
Power Steering Fluid Cooling Lines — Removal and Installation
Tie Rod/Ball Joint — Removal and Installation
Transverse steering rod — removal and installation
Wheel installation — general information
Body
Exterior
General information about the body
Front and rear bumpers — removal and installation
Radiator grille — removal and installation
Windshield fairing panel — removal and installation
Hood and hinges — removal and installation
Bonnet Lock Parts — Removal and Installation
Hood Latch Drive Cable — Removal and Installation
Doors — removal, installation and adjustment
Door handle and lock parts — removal and installation
Window glass doors and window lifters — removal and installation
Rear Door, Hinges and Support Pillars — Removal and Installation
Rear Door Handle and Lock Parts — Removal and Installation
Exterior body equipment — removal and installation
Interior
Central locking components — removal and installation
Electrical equipment of drop-down windows — removal and installation
Mirrors — repair, removal and installation
Windshield and Rear Window Glass — General Information
Rear small side windows — removal and installation
Sliding Roof Parts — Removal and Installation
Seats — removal and installation
Front seat belt tensioner system
Electrical equipment
Equipment and devices
Technical specifications
General information, precautions
Finding defects in electrical equipment — general information
Battery — Checking and Charging
Battery — Removal and Installation
Charging system — check
Generator Drive Belt — Removal, Installation and Tensioning
Current generator — removal and installation
Stabilizer and brushes — inspection and replacement
Starting system — check
Starter motor — removal and installation
Starter motor — repair
Fuse Box — Removal and Installation
Fuses and relays — checking and removing
Switches — removal and installation
Instrument panel — removal and installation
Instrument cluster components — removal and installation
Clock and multifunction display — removal and installation
Auxiliary warning system
Auxiliary Warning System Components — Removal and Installation
Trip computer — general information
Sound signal — removal and installation
Speedometer Flexible Shaft — Removal and Installation
Windscreen wiper arms — removal and installation
Rear Door Wiper Motor and Arm — Removal and Installation
Windshield/Rear Door Washer System Components — Removal and Installation
Headlight Washer Parts — Removal and Installation
Radio and cassette player — removal and installation
Loudspeakers — Removal and Installation
Radio antenna — removal and installation
Anti-theft device
Anti-theft device components — removal and installation
Electrical circuits
Explanations of the car electrical equipment diagrams
Key to electrical schematics
Wiring diagram for battery, starter, alternator and radiator fan (pre-February 1992)
Carburetor Wiring Diagram (Before February 1992)
Fuel injection electrical diagram (before February 1992)
Automatic transmission electrical diagram (before February 1992)
Electrical diagram for diesel and turbodiesel (before February 1992)
Electrical circuits: control, information display, radio, clock, instruments (before February 1992)
Electrical diagrams for lighting devices and headlights (before February 1992)
Electrical circuits: door locking, anti-theft system, heating fan (before February 1992)
Electrical diagrams: windscreen wiper, horn, outside mirror (before February 1992)
Electrical diagrams: ABS, traction control system (before February 1992)
Electrical diagrams: battery, starter, generator, carburetor (since March 1992)
Fuel injection electrical diagram (since March 1992)
Automatic transmission electrical diagram (since March 1992)
Direct Ignition Wiring Diagram (since March 1992)
Electrical diagram for diesel and turbodiesel (since March 1992)
Electrical circuits: control, radio, clock, instruments, headlights (since March 1992)
Electrical diagrams for lighting devices and headlights (since March 1992)
Electrical circuits: door locking, anti-theft system, heating fan (since March 1992)
Electrical diagrams: windscreen wiper, washer, horn (since March 1992)
Electrical diagrams: ABS, traction control system (since March 1992)
Astra G (1998-2004, petrol)
General information
User manual
Introduction to the Opel Astra G manual
General technical data of cars
Unlocking the door
Seat adjustment
Steering column adjustment
Optimal driver's seat position
Putting on a seat belt
Adjusting the rear view mirrors
Ignition and engine start switch
Heated rear window and outside mirror
Drying glass covered with droplets of moisture or ice
Controls and instruments
Decoding nomograms on controls
Switches and buttons
Manual transmission
Automatic transmission
Control lights on the instrument panel
Control devices on the panel
Setting the time and date
Jump starting the engine from another car's battery
Towing a car
Using a vehicle as a towing vehicle
Place for attaching the warning triangle and first aid kit
Spare wheel
Fuses and protected circuits
Replacing bulbs in a car
Engine oil level
Diesel engine fuel filter
Cooling liquid
Hydraulic brake fluid
Windshield and headlight washers
Towing a trailer or van
Car care
Troubleshooting a car on the road
Starting the engine from an auxiliary battery
Changing a wheel on a car
Determining the cause of leaks
Weekly checks in the engine compartment
Checking the engine oil level
Checking the coolant level
Checking and restoring the brake fluid level
Checking the condition of the tires and tire pressure
Types and causes of tire tread wear
Checking the fluid level in the windshield washer reservoir
Checking the fluid level in the power steering reservoir
Windscreen wiper blades
Battery care
Checking lamps and fuses
Recommended lubricants and fluids
Maintenance
Technical data of the car
Location of components and assemblies in the engine compartment
Description of maintenance procedures
Service every 7500 km or 6 months
Service every 15,000 km or 12 months
Checking the car in road conditions
Service every 30,000 km or 2 years
Service every 60,000 km or 4 years
Every 2 years regardless of mileage
Power unit
Single shaft engines
Technical data
General information
Compression is the procedure for checking and interpreting the results obtained
The order of setting the piston of the 1st cylinder at TDC of the compression stroke
Cylinder Head Cover — Removal and Installation
Crankshaft pulley — removal and installation
Timing Belt Covers — Removal and Installation
Timing Belt for Camshaft Drive — Removal and Installation
Tensioner and sprockets — removal and installation
Camshaft Seal — Replacement
Camshaft Bearing Housing and Camshaft — Removal and Installation
Hydraulic tappets — removal and installation
Cylinder head — removal and installation
Oil pan — removal and installation
Oil pump — removal, inspection and installation
Flywheel/torque converter drive disc — removal and installation
Crankshaft seals — replacement
Powertrain Mounts — Removal and Installation
Twin shaft engines
Technical data
Description of engines
Compression — the order of testing and interpretation of the obtained results
The order of setting the piston of the 1st cylinder at TDC of the compression stroke
Cylinder Head Cover — Removal and Installation
Crankshaft pulley — removal and installation
Timing Belt Covers — Removal and Installation
Timing Belt for Camshaft Drive — Removal and Installation
Tensioner and sprockets — removal and installation
Camshaft Seal — Replacement
Camshaft and tappets — removal and installation
Cylinder head — removal and installation
Oil pan — removal and installation
Oil level sensor — removal and installation
Oil pump — removal, disassembly and installation
Flywheel/torque converter drive disc — removal and installation
Crankshaft seals — replacement
Balance Mechanism — Removal and Installation (2.0L Engines Only)
Engine repair
Technical data (gaps and dimensions in mm)
Compression Test — Description and Interpretation
Engine Overhaul — General Information
Engine — removal and installation
Power unit — dismantling and installation
Engine Overhaul — Disassembly Procedure
Cylinder head — disassembly
Cylinder head and valves — cleaning and checking
Cylinder head — assembly
Pistons and connecting rods — removal
Crankshaft — removal
Cylinder Block — Cleaning and Checking
Connecting rod and piston group — check
Crankshaft — check
Main and connecting rod bearings — inspection
Engine Overhaul — Assembly Procedure
Piston rings — installation
Crankshaft — installation and checking clearances in main bearings
Connecting rod and piston group — installation and checking of clearances in connecting rod bearings
Engine — Starting after major repairs
Cooling and heating
Technical data
Cooling system — general information
Cooling system — fluid replacement
Checking the condition of the hoses
Radiator — removal and installation
Thermostat — removal and installation
Fan — checking, removal and installation
Cooling system sensors and devices — removal and installation
Coolant pump — removal and installation
Interior ventilation and heating system parts — removal and installation
Air conditioning system — general information
Fuel and exhaust systems
Technical data
General information
Air filter — removal and installation
Throttle cable — removal, installation and adjustment
Throttle Pedal — Removal and Installation
Injection systems — general information
Decompression of the fuel system
Fuel pump — removal and installation
Fuel level sensor — removal and installation
Fuel tank — removal and installation
Throttle body — removal and installation
Single-injector system sensors and devices — removal and installation
Sensors and devices of multi-nozzle injection systems — removal and installation
Intake manifold — removal and installation
Exhaust manifold — removal and installation
Exhaust system parts — removal and installation
Catalyst
Starting and charging system
Technical data
Battery — check and charge
Battery — Removal and Installation
Charging system — check
Generator Drive Belt — Removal, Tension Adjustment and Installation
Generator Drive Belt Tensioner — Removal and Installation
Generator — removal and installation
Generator — brush replacement
Engine starting system — check
Starter — removal and installation
Starter — check and repair
Oil Pressure Sensor — Removal and Installation
Oil level sensor — removal and installation
Ignition system
Technical data
Ignition system — general information
Ignition system — check
Ignition unit — removal and installation
Transmission
Clutch
Technical data
General information
Clutch hydraulic drive — air removal
Clutch Master Cylinder — Removal and Installation
Clutch slave cylinder — removal and installation
Clutch pedal — removal and installation
Clutch — removal, inspection and installation
Mechanical gearbox
Technical data
General information
Gearbox oil change
Gear shift mechanism — adjustment
Gear Shift Mechanism — Removal and Installation
Gearbox seals — replacement
Reverse signal switch — checking, removing and installing
Gearbox — removal and installation
Gearbox disassembly — general information
Gearbox — Checking the oil level
Automatic gearbox
Technical data
General information
Automatic Transmission — Fluid Replacement
Transmission Control Cable — Adjustment
Transmission Control Cable — Removal and Installation
Automatic transmission seals — replacement
Transmission Control System Switches — Removal, Installation and Adjustment
Automatic transmission — removal and installation
Machine
Drive shafts
Technical data
General information
Half shafts — removal and installation
Axle joints — inspection and replacement
Axle joint covers — replacement
Chassis
Brake system
Technical data
General information
Hydraulic brakes — air removal
Brake tubes and hoses — replacement
Front brake pads — replacement
Rear Disc Brake Pads — Removal and Installation
Rear Drum Brake Pads — Replacement
Brake discs — inspection, removal and installation
Rear Brake Drums — Removal, Inspection and Installation
Front Brake Caliper — Removal, Disassembly and Installation
Rear Brake Caliper — Removal and Installation
Rear Drum Brake Wheel Cylinder — Removal, Disassembly and Installation
Brake Master Cylinder — Removal, Disassembly and Installation
Brake pedal — removal and installation
Vacuum brake booster — checking, removal and installation
Vacuum booster check valve — removal and installation
Parking brake — adjustment
Handbrake lever — removal and installation
Handbrake cables — removal and installation
Brake light switch — removal, installation and adjustment
Parking Brake Warning Light Switch — Removal and Installation
Anti-lock braking system and TC-system of sensor control of adhesion of front drive wheels with the road surface — general information
Anti-lock ABS and TC brake system assemblies and units — removal and installation
Dosing valve — removal and installation
Features of operation of the brake system
Car suspension
Technical data
General information
Front Wheel Hub Bracket (Steering Knuckle) — Removal and Installation
Front Wheel Bearings — Replacement
Front subframe — removal and installation
Front suspension strut — removal, disassembly and installation
Stabilizer bar and tie rods — removal and installation
Suspension arm — removal and installation
Ball joint — removal and installation
Rear wheel hub with bracket — removal and installation
Rear Wheel Bearings — Checking and Replacing
Rear shock absorbers — removal, inspection and installation
Rear suspension springs — removal and installation
Torsion beam and rear suspension arms — removal and installation
Rubber bushings of rear suspension arms — replacement
Rear Suspension Height Adjustment Pneumatic System — General Information
Rear Suspension Height Adjustment Valve and Air Intake Line — Removal and Installation
Steering
Steering wheel — removal and installation
Steering column — removal and installation
Intermediate shaft of the steering column — removal and installation
Steering Gear Covers — Replacement
Steering gear — removal and installation
Electric power steering pump — removal and installation
Bleeding air from the power steering circuit
Tie rod ends — removal and installation
Steering rods — removal and installation
Wheel alignment angles — general information
Body
Interior
Interior rear view mirror — removal and installation
Front seats — removal and installation
Rear seats — removal and installation
Front seat belt tensioner — removal and installation
Seat belts — removal and installation
Seat belt height adjuster — removal and installation
Interior trim panels — removal and installation
Central floor section — removal and installation
Glove box — removal and installation
Front Interior Trim Panel — Removal and Installation
Exterior
Technical data
General information
Body — maintenance and repair
Body repair — minor damage
Body repair — significant damage
Hinges and Locks — Maintenance and Repair
Windshield and fixed glass — replacement
Bumpers — removal and installation
Radiator grille — removal and installation
Box under the windshield (lining of the engine compartment niche) — removal and installation
Hood — removal, installation and adjustment
Hood hinges — removal and installation
Bonnet Lock Parts — Removal and Installation
Hood Lock Drive Cable — Removal and Installation
Doors — removal, installation and adjustment
Inner door handle — removal and installation
Outside Door Handle — Removing and Stopping
Door locks — removal and installation
Drum switch lock — removal and installation
Door lock retainer
Door glass — removal and installation
Window lifter — removal and installation
Trunk lid — removal and installation
Trunk lid hinge — removal and installation
Trunk Lid Parts — Removal and Installation
Rear Compartment Cover — Removal and Installation
Rear Compartment Lid Hinges — Removal and Installation
Rear Compartment Lid Parts — Removal and Installation
Centralized locking system parts — removal and installation
Electric window lifter parts — removal and installation
Outside rear view mirror — removal and installation
Optical element of the outside mirror — removal and installation
Exterior Mirror Parts — Removal and Installation
Windscreen, Rear Window and Corners — General Information
Sunroof glass panel — removal and installation
Hatch components and parts — removal and installation
Wing Guards — Removal and Installation
Fuel filler cap — removal and installation
Exterior body trim parts — removal and installation
Electrical equipment
Equipment and devices
Technical data
General information
Finding the source of a fault in an electrical system — general description
Fuses and Relays — General Information
Switches — Removal and Installation
Outdoor Lighting Lamps — Removal and Installation
Interior Lighting Lamps — Removal and Installation
Outdoor lighting fixtures — removal and installation
Headlight Beam Adjustment — General Information
Instrument cluster — removal and installation
Display — removal and installation
Cigarette lighter — removal and installation
Sound signal — removal and installation
Windscreen wiper arms — removal and installation
Windshield wiper motor and drive — removal and installation
Rear Window Wiper Motor and Drive — Removal and Installation
Windscreen Washer Parts — Removal and Installation
Receiver/radio/CD player/navigation unit — removal and installation
Receiver Remote Control Switches — Removal and Installation
Speakers — Removal and Installation
Antenna — removal and installation
Anti-theft system and immobilizer — general information
Airbags — general information and deactivation
Pneumatic safety system devices — removal and installation
Wiring diagrams Opel Astra
General description and designations of electrical circuits Astra
Scheme 2. Starting and charging systems
Scheme 3. Engine control systems X14XE and X16XEL
Scheme 4. Engine control systems X14XE and X16XEL (continued) and electric window drive
Scheme 5. Engine management system X16SZR
Scheme 6. Engine control system X18XE-1
Scheme 7. Engine management system X18XE-1 (continued), ABS with traction control system and speed sensor (cars without ABS)
Diagram 8. X20XEV engine management system
Diagram 9. X20XEV Engine Management System (continued)
Scheme 10. Engine cooling system, information display
Scheme 11. Front lighting
Scheme 12. Fog lights, side lights, headlights, reversing lights and turn signals
Diagram 13. Number plate light, brake lights, interior light, rear window defroster and cigarette lighter
Scheme 14. Multifunctional timer
Scheme 15. Glove compartment illumination, sound signal, sunroof and central lock
Scheme 16. Power steering, outside mirrors, cruise control and heater
Diagram 17. Typical air conditioning system and automatic transmission
Scheme 18. Automatic transmission (continued)
Scheme 19. Multifunctional display
Scheme 20. Display on the instrument panel
Wiring diagrams Opel Zafira
General description and designations of electrical circuits Zafira
Scheme 2. Starting and charging systems
Scheme 3. Engine management systems X16XEL
Scheme 4. Engine management systems X16XEL (continued)
Scheme 5. Engine control system X18XE-1
Scheme 6. Engine management system X18XE-1 (continued), ABS with traction control system and speed sensor (cars without ABS)
Scheme 7. Windscreen washer/wiper and auxiliary heating
Scheme 8. Engine cooling system, information display
Scheme 9. Front lighting
Scheme 10. Fog lights, side lights, headlights, reversing lights and turn signals
Diagram 11. Number plate light, brake lights, interior light, rear window defroster and cigarette lighter
Scheme 12. Multifunctional timer
Scheme 13. Glove compartment illumination, sound signal, sunroof and central lock
Scheme 14. Power steering, outside mirrors, cruise control and heater
Diagram 15. Typical air conditioning system and automatic transmission
Diagram 16: Automatic Transmission (continued)
Scheme 17. Multifunctional display
Scheme 18. Display on the instrument panel
Astra G (1998-2004)
General information
Introduction to manual
Introduction to the Operation and Repair Manual
Opel Astra and Zafira cars — summary
Vehicle Identification Numbers
Purchase of spare parts
Service technology, tools and workplace equipment
Jacking and towing
Starting the engine from an auxiliary power source
Checking the vehicle's readiness for operation
Automotive chemicals, oils and lubricants
Troubleshooting
User manual
Technical data of cars
Instrument panel
Information display
Additional electronic devices
Vehicle access and protection
Car interior lighting
Elements of vehicle safety systems
Car interior equipment
Heating, ventilation and climate control
Vehicle Operation Techniques
Maintenance
General information about maintenance
Schedule of current maintenance
Routine Maintenance Specifications
General information about settings and adjustments
Checking fluid levels
Checking the condition of the tires and their inflation pressure, rotating the wheels
Changing engine oil and oil filter
Checking the condition and replacing the auxiliary drive belt
Removal sediment from a diesel engine fuel filter
Checking the condition and replacing the hoses located in the engine compartment
Checking the condition of the cooling system components
Checking, servicing and charging the battery
Checking the condition and replacing the windshield wipers
Inspection of suspension and steering components, checking the condition of the drive shaft protective covers
Checking the brake system
Checking electrical equipment
Monitoring the condition of the anti-corrosion coating of the car body and underbody
Lubrication of locks, hinges and stops
Resetting the service interval indicator
Replacing the air cleaner filter element — diesel models produced before 09.2000
Replacing the cabin filter
Replacing the fuel filter — diesel models produced before 09.2000
Checking idle speed and exhaust gas composition
Replacing the air cleaner filter element — all petrol and diesel models produced since 10.2000
Replacing the fuel filter — diesel models produced since 10.2000
Replacing spark plugs, checking the condition of high-voltage wiring
Replacing the Fuel Filter — Petrol Models
Power unit
SOHC gasoline engines
General information about engines
Specifications of all engines
Checking the compression pressure in the cylinders
Engine condition diagnostics using a vacuum gauge
Bringing the piston of the first cylinder to the position of the top dead center of the compression stroke (TDC)
Removal and installation the timing cover
Removal and installation the crankshaft pulley
Removal and installation the timing belt cover
Removal and installation the timing belt
Removal and installation the timing belt tensioner and timing drive gears
Replacing the camshaft seal
Removal, condition check and installation of the camshaft with the timing mechanism housing
Removal, inspection and installation of valve drive components
Removal and installation the cylinder head
Removal and installation the oil pan
Removal, maintenance and installation of the oil pump
Removal, checking condition and installing flywheel/drive disk
Replacing crankshaft seals
Checking the condition and replacing the powertrain suspension supports
DOHC gasoline engines
Bringing the piston of the first cylinder to the position of the top dead center of the compression stroke (TDC)
Removal and installation the timing cover
Removal and installation the crankshaft pulley
Removal and installation the timing belt cover
Removal and installation the timing belt
Removal and installation of crankshaft/camshaft gears and intermediate rollers
Replacing camshaft seals
Removal and installation of camshafts and valve lifters, checking the condition of components
Removal and installation the cylinder head
Removal and installation the oil pan
Removal and installation the engine oil level sensor
Removal, maintenance and installation of the oil pump
Removal, checking condition and installing flywheel/drive disk
Replacing crankshaft seals
Checking the condition and replacing the powertrain suspension supports
Removal, installation and adjustment of the crankshaft balancing mechanism (2.0 l engines)
Diesel engines 1.7 and 2.0
Bringing the piston of the first cylinder to the position of the top dead center of the end of the compression stroke (TDC)
Checking and adjusting valve timing (2.0L engines)
Removal and installation the timing cover
Removal and installation the crankshaft pulley
Removal and installation the timing belt cover
Removal and installation timing chain tensioners (2.0L engines)
Removal and installation the timing belt
Removal and installation the timing belt tensioner and timing gears (1.7 l engines)
Removal and installation of timing chains and sprockets, checking the condition of components (2.0 l engines)
Replacing the camshaft oil seal (1.7L engines)
Checking and adjusting valve clearances (1.7L DOHC engines)
Removal and installation of camshaft(s) and valve train components
Removal and installation the timing case (1.7L DOHC engines)
Removal and installation the cylinder head
Removal and installation the oil pan
Removal, maintenance and installation of the oil pump
Replacing the oil pump seal (1.7L engines)
Removal and installation the oil cooler
Removal, checking condition and installing flywheel/drive disk
Replacing crankshaft seals
Checking the condition and replacing the powertrain suspension supports
Engine repair
General and major engine repairs
Removal the power unit from the car — methods and precautions
Removal, disconnecting and installing the engine
Alternative options for engine repair schemes
Engine disassembly sequence
Disassembling the cylinder head
Cleaning and checking the condition of the cylinder head
Cylinder head assembly
Removal connecting rod and piston assemblies
Removal the crankshaft
Cleaning and checking the condition of the cylinder block
Honing of cylinder mirrors
Checking the condition of the connecting rod and piston group components
Checking the condition of the crankshaft
Checking the condition of the main and connecting rod bearings of the crankshaft
Engine assembly procedure
Installing piston rings
Installing the crankshaft and checking the main bearing clearances
Installation of connecting rod and piston assemblies and checking the size of working clearances in the connecting rod bearings of the crankshaft
Test run and running-in of the engine after major repairs
Cooling system
General information about the cooling and heating system
Cooling system specifications
Antifreeze — general information
Disconnecting and replacing cooling system hoses
Maintenance of the cooling system (emptying, flushing and filling)
Removal, installation and checking of the thermostat operation
Removal and installation the cooling system radiator
Checking the proper functioning, removing and installing the cooling system fan
Checking the proper functioning, removal and installation of electrical components of the engine cooling system control circuit
Checking the condition of the water pump
Removal and installation the water pump
Supply system
Power and exhaust system specifications
General information and precautions
Relieving pressure in the fuel system of gasoline engines
Checking the condition and replacing fuel lines and their fittings
Removal air from the fuel system of a diesel engine
Removal contaminants from the fuel system of a diesel engine
Removal and installation air intake tract components
Removal, installation and adjusting the throttle cable — petrol models
Removal and installation the accelerator pedal
Removal and installation the fuel pump — petrol models
Removal and installation the fuel level sensor
Removal and installation the fuel tank
Removal and installation the throttle body — petrol models
Injection system (gasoline)
General information and precautions
The operating principle of fuel injection systems
Checking the proper functioning of the fuel injection system
Removal and installation of components of the Multec central fuel injection system
Removal and installation of components of distributed fuel injection systems Multec-S and Simtec-70
Intake air temperature control system (models with central injection) — operating principle and serviceability check
Removal and installation the intake manifold
Removal and installation the exhaust manifold
Injection system (diesel)
Diesel engine injection and turbocharging systems
Checking and adjusting maximum engine speed
Checking and adjusting fuel injection timing settings
Removal and installation of electrical components of the power supply system
Signals and voltages at the control module terminals
Removal and installation of fuel injection pump
Removal and installation fuel injectors
Removal and installation a turbocharger
Removal and installation the intermediate cooler (intercooler)
Removal and installation the intake manifold
Removal and installation the exhaust manifold
Exhaust system
Exhaust system — general information, removal and installation
Emission Control Systems — General Information
Checking the proper functioning and replacing components of exhaust gas toxicity reduction systems
Charge and launch system
General information and precautions
Battery — general information, checking the condition, replacement, storage and commissioning
Checking the condition and replacing battery wires
Checking the proper functioning and condition of the charging system components
Removal and installation the alternator drive belt tensioner
Removal and installation the generator
Replacing generator brushes
Checking the proper functioning of the components of the starting system
Removal and installation the starter
Checking the condition and repairing the starter
Ignition system (gasoline)
General information and precautions
Ignition system specifications for all engines
Electronic ignition (and injection) control system for gasoline engines
Checking the proper functioning of the ignition system
Troubleshooting — General Information and Preliminary Checks
On-Board Diagnostic System OBD — General Information
Using an Oscilloscope to Monitor the Operation of a Control System
Removal and installation the ignition module
Checking and setting the ignition timing
Removal and installation the ignition switch
Removal and installation the oil pressure sensor
Removal and installation the engine oil level sensor
Removal and installation the engine oil temperature sensor (diesel models)
Preheat system (diesel)
Pre-heating system — general information
Checking the proper functioning of the preheating system
Removal, checking and installation glow plugs
Removal and installation of preheating system components
Transmission
Manual gearbox
General information about manual transmission
Manual transmission specifications
Adjusting the gear shift drive
Removal and installation the gear shift mechanism
Replacing oil seals
Checking the proper functioning, removing and installing the reverse light switch sensor
Removal and installation the speed sensor (VSS)
Transmission oil change
Removal and installation of manual transmission
Manual transmission repair — general information
Automatic gearbox
General information about automatic transmission
Automatic transmission specifications
Adjusting the gear selection mechanism
Removal and installation the gear selection cable
Removal and installation the AT selector lever assembly
Replacing oil seals
ATF Cooler — General Information
Removal and installation of electrical components of the AT control system
Removal and installation of AT
Major repairs of AT — general information
Clutch
General information about clutches and drive shafts
Clutch and Drive Shaft Specifications
Clutch — General information and component condition check
Removal and installation the clutch master cylinder
Removal and installation the clutch slave cylinder assembly with release bearing
Bleeding air from the hydraulic circuit of the clutch release drive
Removal and installation the clutch pedal
Removal, inspection and installation of clutch components
Drive shafts
Drive shafts — general information
Removal and installation drive shafts
Checking the condition and replacing constant velocity joints (CV joints)
Replacement of protective covers of CV joints
Chassis
Brake system
General information about the brake system
Brake system specifications
Anti-lock Brake System (ABS) and Traction Control System (TCS) — General Information and Error Codes
Bleeding the brake system
Checking the condition and replacing brake lines and hoses
Replacing the front disc brake pads
Replacing the rear wheel disc brake pads
Replacing the shoes of the rear wheel drum brake mechanisms
Checking the condition, removing and installing the brake disc
Removal, inspection and installation of the brake drum
Removal, repair and installation of front wheel disc brake calipers
Removal, repair and installation of rear wheel disc brake calipers
Removal, maintenance and installation of wheel cylinders of drum brake mechanisms of rear wheels
Removal and installation the master brake cylinder
Removal and installation the foot brake pedal
Checking the proper functioning/tightness, removing and installing the brake booster assembly
Removal, checking the correct operation and installation of the brake booster check valve
Removal and installation the brake booster servo vacuum pump (diesel models)
Checking the proper functioning of the brake booster servo vacuum pump (diesel models)
Adjusting the parking brake drive
Removal and installation the parking brake lever
Removal and installation parking brake cables
Removal, installation and adjustment of the brake light switch sensor
Removal and installation the parking brake arming indicator light switch sensor
Removal and installation of ABS and TCS components
Removal, installation and adjustment of the pressure regulator valve in the hydraulic circuits of the rear wheel brake mechanisms
Wheel suspension
General information about suspension and steering
Suspension and steering specifications
Removal and installation the steering knuckle
Checking the condition and replacing the hub assembly
Removal and installation the front subframe
Removal, repair and installation of the front suspension strut
Removal and installation the front anti-roll bar
Removal, repair and installation of the lower arm of the front suspension
Replacing the lower ball joint
Removal and installation the rear hub assembly
Checking the condition and replacing the rear wheel bearings
Removal, checking the condition and installing the rear shock absorber
Removal and installation rear suspension coil springs
Removal and installation the rear suspension torsion beam
Replacement of rubber-metal hinges of torsion beam longitudinal arms
Rear axle ride height adjustment system — general information and adjustment
Removal and installation the air valve and the rear axle ride height adjuster line (Station wagon models)
Steering
Removal and installation the steering wheel
Removal and installation the steering column
Removal, condition check and installation of the intermediate shaft of the steering column
Replacing the protective covers of the steering gear housing
Removal and installation the steering gear
Removal and installation the steering pump
Removal air from the hydraulic system of the power steering
Removal and installation tie rod ends
Removal and installation the steering rod
Wheel alignment angles
Body
Exterior
General information and precautions
Body specifications
Car body and underbody components care
Repair of minor damage to body panels
Repair of seriously damaged body panels
Maintenance of car hinges and locks
Replacement of windshield and other fixed glass
Removal and installation bumpers
Removal and installation front fenders
Removal and installation the decorative radiator grille
Removal, installation and adjustment of the hood
Removal and installation hood hinges
Removal and installation bonnet lock components
Removal and installation the hood latch release cable
Removal and installation door rear view mirrors
Removal and installation the glass of the door rearview mirror
Removal and installation components of the electric drive of rear-view mirrors
Removal and installation windshield fairing panel components
Removal and installation wheel arch protection liners — general information
Removal and installation the fuel filler door
Removal and installation of body trim elements
Interior
Caring for Vinyl Trim Elements
Caring for upholstery and carpeting
Removal and installation of single lock components
Removal and installation of electric window lift components (if the vehicle is equipped accordingly)
Removal and installation the interior rearview mirror
Removal and installation front seats
Removal and installation rear seats
Removal and installation emergency seat belt tensioner modules for front seats
Removal and installation seat belts
Removal and installation the upper adjustable seat belt anchors
Removal and installation of interior trim panels
Removal and installation the center console
Removal and installation the glove box
Removal and installation the instrument panel
Doors and windows
Removal, installation and adjustment of doors
Removal and installation the inner door handle
Removal and installation the outer door handle
Removal and installation door locks
Removal and installation front door lock cylinders
Removal and installation the door lock striker
Removal and installation of door glass
Removal and installation the window regulator
Removal and installation the trunk lid (Sedan models)
Removal and installation the trunk lid hinges
Removal and installation trunk lid components
Removal and installation the tailgate (Hatchback and Station Wagon models)
Removal and installation tailgate hinges
Removal and installation tailgate components
Removal and installation the upper sunroof glass
Removal and installation sunroof components
Ventilation and heating
Removal and installation air duct deflectors
Removal and installation the resistive assembly of the heater fan drive motor
Removal and installation the heater fan drive motor
Removal and installation the control panel for the heating / ventilation / air conditioning systems
Removal and installation the main heater body
Removal and installation the heater heat exchanger
Removal and installation the heater switch
Checking the proper functioning and maintenance of heating and air conditioning systems
Removal and installation the air conditioning compressor
Removal and installation the air conditioning evaporator
Removal and installation the air conditioning condenser
Removal and installation the air conditioning receiver-dryer
Removal and installation an additional fan
Electrical equipment
Equipment and devices
General information and precautions
On-board electrical equipment specifications
Search for causes of electrical equipment failures
Fuses — General Information
Relay — general information and checking the correct functioning
Removal and installation switches
Replacement of lamps for external lighting and signaling devices
Replacement of interior lighting fixtures
Removal and installation of external lighting/signaling devices
Adjusting the direction of the optical axes of the headlights
Removal and installation the instrument cluster
Removal and installation instrument panel components
Removal and installation the cigarette lighter
Removal and installation horn horns
Removal and installation the wiper arms (leashes)
Removal and installation windshield wiper drive components
Removal and installation windshield washer system components
Checking the correct operation and repairing the rear window heater
Removal and installation the audio system / navigation unit
Removal and installation remote control elements for the audio system
Removal and installation speakers
Removal and installation the radio antenna
Anti-theft and engine immobilization system — general information
Vehicle Speed Sensor (VSS) — General Information
Supplemental Restraint System (SRS)
Removal and installation SRS components
Electrical circuits
Electrical Wiring Diagrams — General Information
Designation of elements depicted in diagrams
Engine control system X14XE and X16XEL
Engine Management System X16SZR
Engine Management System X18XE-1
Engine management system X20XEV
Engine management system X17DTL and X20DTL
Engine Management System Y17DT
Engine Management System Y20DTH
Automatic transmission
Cooling system with K/V (Astra and Zafira petrol)
Cooling system without A/C (Astra and Zafira petrol)
Starting and charging systems (Astra diesel)
Starting and charging systems (except Astra diesel)
ABS and traction control system (TCS) (Astra and Zafira petrol)
ABS and traction control system (TCS) (Astra and Zafira diesel)
Speed sensor (VSS) without ABS (Astra petrol)
Speed sensor (VSS) with ABS (Astra diesel)
Speed sensor (VSS) without ABS (except Astra petrol)
Power steering system (all models)
Tempostat (Astra petrol)
Tempostat (Astra diesel)
Tempostat (Zafira petrol)
Tempostat (Zafira diesel)
Headlights (all models)
Direction indicators (Astra diesel)
Direction indicators (except Astra diesel)
Reversing lights (Zafira diesel)
Reversing lights (Astra diesel)
Reversing lights (Astra and Zafira petrol)
Brake lights (Astra diesel)
Brake lights (Astra petrol)
Brake lights (Zafira diesel)
Brake lights (Zafira petrol)
Number plate light (Astra petrol)
Number plate light (except Astra petrol)
Fog lights, rear lights (all models)
Klaxon (Zafira petrol and diesel)
Horn (Astra petrol and diesel)
Airbags (SRS) (all models)
Rear window heating (all models)
Windscreen washers and cleaners (Astra petrol)
Windscreen washers and wipers (except Astra petrol)
Exterior mirrors (Astra petrol)
Exterior mirrors (except Astra petrol)
Window lifters (Astra petrol)
Window lifters (except Astra petrol)
Interior lighting (Astra petrol and diesel)
Interior lighting (Zafira petrol and diesel)
Cigarette lighter (all models)
Glove compartment lighting (all models)
Three-function display (Astra petrol and diesel)
Three-function display (Zafira petrol and diesel)
Multifunctional display (Astra and Zafira petrol)
Multifunctional display (Astra and Zafira diesel)
Multitimer (Astra diesel)
Multitimer (except Astra diesel)
Heating system (Astra petrol)
Heating system (except Astra petrol)
Additional heater (except Astra petrol)
Air conditioning system (Astra petrol and diesel)
Air conditioning system (Zafira petrol and diesel)
Audio system (all models)
Single lock (all models)
Instrument panel (Astra and Zafira petrol)
Instrument panel (Astra and Zafira diesel)
Astra H (2004-2009)
General information
Introduction to the guide
Introduction to the Opel Astra H manual
Opel Astra and Zafira cars — summary
Vehicle Identification Numbers
Purchase of spare parts
Identification of spare parts
Jacking up a car
Towing a car
Starting the engine from an auxiliary power source
Automotive chemicals, oils and lubricants
List of abbreviations used
Troubleshooting
Introduction to Troubleshooting
Engine malfunctions
Engine electrical equipment faults
Starter malfunctions
Lubrication system malfunctions
Cooling system malfunctions
Clutch faults
Malfunctions of manual transmission (MT)
Automatic transmission (AT) faults
Bridge faults
Brake system malfunctions
Suspension and steering faults
Windscreen wiper blade malfunctions
Tyre faults
Power supply system malfunctions
Heater malfunctions
User manual
Specifications
The first 1000 km
Keys
Doors
Hood
Fuel tank filler neck
Main storage compartment
Upper hatch
Single lock
Elements of security systems. General information
Seat belts
Transportation of children
Adjustment and transformation of seats
Supplemental Restraint System (SRS)
Risk of Carbon Monoxide (CO) Poisoning
Instrument panel and center console
Control and measuring instruments
Service indication
Control lamps and indicator lights
Tachometer dial field
Central field of the instrument cluster
Speedometer dial field
Sound indicators
Airbags
Anti-theft system
Switches and controls located on the steering column and steering wheel
Controls located on the instrument panel to the left of the steering column
Controls located on the console section of the instrument panel
Controls located on the center console
Controls located on the overhead console
Controls located on door assemblies
Cigarette lighter, ashtrays
Power take-off socket
Storage compartments and pockets
Interior rear view mirror
Sun visors
Folding tables
Luggage compartment equipment
Seats
Three-function information display (TID)
Multi-information display (BID)
Graphical Information Display (GID)
Control System (Check Control)
Heating, Ventilation and Air Conditioning (HVAC) Systems: General Information
Air flow distribution elements
HVAC control panel
HVAC system with manual adjustment
HVAC system with automatic temperature control function (climate control)
Selecting the air flow intensity level of automatic mode
Selecting the direction of air flow distribution
Activation/deactivation of air conditioner
Switching the automatic air circulation control system on and off
Infotainment system. General information
Anti-theft system
Information display
General controls for the infotainment system
Radio receiver
CD/MP3 player
Remote controls for the audio system
Twin Audio System
Telephone and radio station
Preparing for a car trip
Requirements for the physical condition of the driver
Starting the engine
Features of driving cars equipped with a manual transmission (MT)
Features of driving cars equipped with automatic transmission (AT): general information
Automatic transmission mode shift control
Features of AT control with Active Select system
Features of driving cars equipped with the Easytronic robotic gearbox
Special driving modes
Sport driving mode (SPORT)
Winter driving mode
Interactive Dynamic Driving System (IDS+)
Speed control system (Tempostat)
Automatic ground clearance control
Braking
Tire pressure monitoring
Tire Pressure Monitoring Systems (DDS)
Features of operation of vehicles equipped with a catalytic converter
Features of driving a car equipped with power steering
Additional tips for drivers
Tips for Economical Driving
Towing a trailer: general information
Traction device
Basic characteristics of driving with a trailer
Trailer Stability Assist (TSA)
Recommendations for driving a car with a trailer
Towing a car
Jacking up and changing a wheel
Maintenance
Specifications. Recommended Lubricants and Fluids
Schedule of scheduled maintenance (TO) for Opel Astra/Zafira vehicles
Active warning system for scheduled maintenance due dates
Maintenance work
Additional maintenance work
Maintenance under severe operating conditions
Maintenance. General information
General information about settings and adjustments
Checking fluid levels
Engine oil
Engine coolant
Windshield/Headlight Washer Fluid
Battery electrolyte
Hydraulic fluid for brake and clutch systems
Power steering fluid
Manual transmission oil
ATF oil
Wheels and tires — general information
Wheels and tires — check
Wheels and Tires — Wheel Rotation
Engine oil change
Replacing the oil filter
Filling with fresh engine oil
Measuring engine oil temperature
Checking the condition and replacing the multi-rib drive belt of the units
Draining sediment, removing air from the filter (diesel models)
Checking the condition and replacing the hoses located in the engine compartment
Checking the condition of the cooling system components
Battery — General Information
Maintenance and charging of the battery
Checking the condition and replacing the windshield wipers
Inspection of suspension and steering components, checking the condition of the drive shaft protective covers
Checking the brake system
Checking electrical equipment
Monitoring the condition of the anti-corrosion coating of the car body and underbody
Lubrication of locks, hinges and stops
Replacing the air cleaner filter element
Replacing the cabin filter
Replacing the fuel filter element — diesel models
Checking idle speed and exhaust gas composition
Replacing spark plugs (petrol models)
Spark Plug Condition Map
Checking the condition of the timing belt, guide and tension rollers
Power unit
Engine repair
Specifications
General information
Engine cover
Checking the compression pressure in the cylinders
Engine condition diagnostics using a vacuum gauge
Some preparatory operations
Bringing the piston of the first cylinder to the top dead center (TDC) position at the end of the compression stroke
Removal and installation a multi-ribbed accessory drive belt
Removal and installation the timing belt/chain (adjusting the valve timing)
Checking and adjusting the timing valves
Removal and installation of camshafts and valve lifters, checking the condition of components
Removal and installation the cylinder head
Removal and installation the oil pan
Removal and installation the oil pump
Removal and installation the engine oil level sensor
Removal, checking condition and installing flywheel/drive disk
Replacing crankshaft seals
Replacing camshaft seals
Checking the condition and replacing the powertrain suspension supports
Removal the engine
Cooling and heating
Specifications
General information
Antifreeze — General Information and Precautions
Draining and filling the system with coolant
Disconnecting and replacing cooling system hoses
Cooling system maintenance, flushing
Removal and installation the cooling system fan
Removal and installation the cooling system radiator
Removal and installation the water pump
Removal, installation and checking of the thermostat operation
Removal and installation the outside temperature sensor
Removal and installation the heating/ ventilation/ air conditioning (HVAC)control panel
Removal and installation air duct deflectors
Removal and installation the HVAC fan drive motor
Removal and installation the resistive assembly of the heater fan drive motor
Removal and installation an additional electric heater (diesel models)
Removal and installation the air circulation flap drive electric motor
Removal and installation the electric motor of the distribution flap drive
Removal and installation the circulation flap housing (Astra models with air conditioning)
Removal and installation the heater heat exchanger
Power and exhaust system
Specifications
Power supply system. General information and safety precautions
Relieving pressure in the fuel system of gasoline engines
Checking the condition and replacing fuel lines and their fittings
Removal air from the fuel system of a diesel engine
Removal dirt and water from the fuel system of a diesel engine
Removal and installation air intake tract components
Removal and installation the gas pedal
Removal and installation the fuel pump
Removal and installation the fuel level sensor
Removal and installation the fuel filter mounting clamp (diesel models)
Removal and installation glow plugs (diesel engines)
Removal and installation the fuel tank
Gasoline Engine Management System. General Information and Precautions
The operating principle of fuel injection systems
Removal and installation of fuel injectors
Diesel Engine Control System. General Information
Removal and installation fuel injectors
Removal and installation of fuel injection pump
Turbocharger and Intercooler — General Information
Particulate filter (engines with a working volume of 1.9 l)
Exhaust system. General information
Emission Control Systems — General Information
Ignition system
Engine Electrical System Specifications
Engine Electrical System. General Information and Precautions
Troubleshooting — General Information and Preliminary Checks
On-board diagnostic system OBD
Using an Oscilloscope to Monitor Control System Signals
Launch and charge system
Removal and installation ECM
Spark Plugs, Coils and Ignition Module — General Information
Ignition Timing Angle — General Information
Removal and installation glow plugs
Battery — disconnecting, removing and installing, purchasing a new battery
Checking the condition and replacing battery wires
Generator — General Information, Checking, Removal and Installation
Removal and installation the voltage regulator
Starter — general information, removal and installation
Transmission
Mechanical gearbox
Manual Transmission and Clutch Specifications
Clutch. General information
Removal and installation the clutch master cylinder
Removal and installation the clutch slave cylinder assembly with release bearing
Bleeding air from the hydraulic circuit of the clutch release drive
Removal and installation the clutch pedal
Removal, inspection and installation of clutch components
Removal and installation the Easytronic clutch control module
Manual transmission (MT). General information
Adjusting the gear shift drive
Removal and installation gear shift drive components
Transmission oil change
Removal and installation of manual transmission
Removal and installation the gearshift control module (Easytronic)
Automatic gearbox
4-speed automatic transmission specifications
General information
Adjusting the gear selection mechanism
Removal and installation the gear selection cable
Checking the condition of the working fluid
Removal and installation of AT
Drive shafts
Specifications
General information
Removal and installation drive shafts
Removal and installation the intermediate shaft
Checking the condition and replacing constant velocity joints (CV joints)
Replacing CV joint boots
Chassis
Brake system
Brake system specifications
General information
Electronic braking control systems
Bleeding the brake system
Checking the condition and replacing brake lines and hoses
Replacing the front disc brake pads
Replacing the rear wheel disc brake pads
Removal, installation and inspection of the brake disc
Removal and installation calipers/pad guides for disc brake mechanisms
Removal and installation of the master brake cylinder (MBC)
Removal and installation the foot brake pedal
Checking the condition, removing and installing the brake booster assembly
Adjusting the parking brake drive
Removal and installation the parking brake lever
Removal and installation parking brake cables
Removal and installation the brake light switch sensor
Removal and installation the parking brake arming indicator light switch sensor
Car suspension
Specifications
General information
Front suspension. Removing and installing the shock absorber strut
Disassembling the shock absorber strut/removing and installing the shock absorber/front suspension spring
Removal and installation the front suspension hub nut
Removal and installation the front subframe
Removal, condition check and installation of rear suspension shock absorbers
Removal and installation rear suspension coil springs
Removal and installation the rear hub assembly
Steering
Removal and installation the driver's front airbag module
Removal and installation the steering wheel
Removal and installation the steering column switch contact block
Removal and installation tie rod ends
Removal and installation steering gear boots
Wheel alignment angles — general information
Body
Interior
Caring for Vinyl Trim Elements
Caring for upholstery and carpeting
Removal and installation sun visors
Removal and installation the ceiling handle/glasses case
Removal and installation interior rear view mirror
Removal and installation steering column covers
Removal and installation lower decorative instrument panel covers
Removal and installation the main storage compartment
Removal and installation the decorative strip of the instrument panel
Removal and installation the door seal
Removal and installation the center console
Removal and installation the gearshift/selector lever base cover
Removal and installation the ashtray
Removal and installation the console section trim of the instrument panel
Removal and installation the instrument panel trim section under the steering column
Removal and installation the side decorative panel of the central console (Zafira models)
Removal and installation of interior trim elements — Hatchback models
Removal and installation of interior trim elements — Station wagon models
Removal and installation of interior trim elements — Astra GTC
Removal and installation of interior trim elements — Zafira models
Removal and installation the front seat
Removal and installation the rear seat
Exterior
Specifications
Exterior Equipment and Body Parts. General Information
Minor damage to windshield caused by stone impact
Removal and installation of body trims (moldings)
Removal and installation the fairing grille
Removal and installation the rear bulkhead cover of the engine compartment (Zafira models)
Removal and installation of wheel arch protection (lockers)
Removal and installation the front bumper/bumper trim
Removal and installation the rear bumper/bumper trim
Removal and installation the decorative radiator grille
Removal and installation front fenders
Removal and installation fixed glass of the A-pillar (Zafira models)
Removal, installation and adjustment of the hood
Removal and installation the hood latch release cable
Removal, installation and adjustment of the tailgate
Removal and installation the rear door trim
Removal and installation the tailgate lock
Removal, installation and adjustment of side doors
Removal and installation side door locks
Removal and installation external side door handles
Removal and installation the base of the outer door handle
Removal and installation side door trim
Removal and installation the rear door window lift handle
Removal and installation the front door window regulator
Removal and installation the rear door mechanical window lifter
Removal and installation the glass of the door rearview mirror
Removal and installation the door rearview mirror
Removal and installation the door rearview mirror cover
Electrical equipment
Equipment and devices
Specifications
General information
Search for causes of electrical equipment failures
Fuses — General Information
Relays — general information and checking the correct functioning
Removal and installation the horn
Removal and installation parking assistance system sensors
Removal and installation windshield washer nozzles
Removal and installation the washer fluid reservoir/pump
Removal and installation the wiper arms (leashes)
Removal and installation the windshield wiper drive electric motor
Removal and installation the rear window wiper motor
Removal and installation the rain sensor
Replacing headlight bulbs
Removal and installation the electric motor for adjusting the headlight position (halogen headlights, Astra models)
Removal and installation of the headlight unit
Removal and installation fog lights
Replacing the fog light bulb
Removal and installation turn signal repeaters
Removal and installation rear combination lights/replacing bulbs
Removal and installation the high-level brake light bulb
Removal and installation the license plate light, replacing the bulb
Removal and installation of the assembly of individual directional front seat lamps
Replacing interior lighting bulbs
Removal and installation the instrument cluster
Removal and installation the information display
Removal and installation the exterior lighting/instrument lighting switch panel
Electrical circuits
Symbols used in electrical equipment diagrams
List of electrical components
Engine Management System — Multec-S-1 for Z16XEP Engine
Engine Management System — Multec-S-2 for Z16XEP engine
Fuel pump, fuel filter heating system
Engine cooling system
Coolant temperature sensor
Front and rear windscreen wipers. Rain sensor. Headlight washers
Outside rear view mirrors (L/R)
Electrical diagram of window lifters
Brake light switch. Reverse light switch
Rear window defroster. A/C compressor
Towing hitch. Sound signal
Headlights (except xenon). Fog lights
Rear combination lights. Number plate light
Interior lighting 1. Main storage compartment lighting
Interior lighting 2. Power take-off socket. Cigarette lighter
Heating and air conditioning system
Astra J (2009-2015, petrol)
General information
Vehicle device
Description and characteristics of the car
Vehicle Passport Data
Car keys
Instrument panel
Instrument cluster
On-board computer
Ventilation, heating and air conditioning system device
Automatic dual-zone climate control unit
Side door locks
Side door window lifters
Tailgate (trunk lid)
Trunk — structure and contents
Seat belts
Adjusting the position of the front seats
Rear seat — folding
Using child seats
Adjusting the position of the steering wheel
Rear view mirrors
Interior lighting
Sun visors
Interior storage compartments and electrical outlet
Opening and closing the hood
Removal the antenna
Roof rack
User manual
Gearbox control
Safety regulations
Useful tips for operation
Traffic safety recommendations
Running in a car
Operation of the vehicle during the warranty period
Preparing the car for departure
Filling up a car with petrol
Using a jack
Towing a car
Faults en route
General techniques for starting an engine
Malfunctions in the starting system
Checking the ignition system
Checking the engine fuel system
Fuel injection system faults
Idle speed is gone
Engine misfires
Engine diagnostics by the appearance of spark plugs
The car moves in jerks
The car accelerates poorly
The engine stalled while driving
Oil pressure warning light
Checking the lubrication system
Coolant temperature gauge
Checking the cooling system
Low battery warning light
Checking electrical equipment
Starting the engine from external power sources
Electrical equipment faults
Extraneous knocking noises in the engine
Extraneous knocks in the suspension and transmission
Vibration and shock on the steering wheel
Signals for urgent brake check
Bleeding the brake system
Checking the brake system
Actions in case of a puncture of a tire
Wheel replacement
Maintenance
Maintenance schedule
Safety rules for maintenance
Checking wheels and tires
Checking the level and adding oil to the lubrication system
Checking the level and adding coolant
Checking and topping up brake fluid in the brake and clutch reservoir
Checking the level and adding fluid to the washer reservoir
Checking external lighting fixtures
Power unit
Engine repair
Engine design features
Possible engine malfunctions
Design Features of Turbocharged Engines
Checking the compression in the cylinders
Adjusting valve clearances
Removal and installation mudguards and engine crankcase protection
Replacing the left support of the powertrain suspension
Replacing the right powertrain suspension support
Replacing the front support of the powertrain suspension
Replacing the rear support of the powertrain suspension
Setting the piston of the first cylinder to the TDC position
Replacement of auxiliary drive belt
Replacing the timing belt
Removal, defect detection and installation of the flywheel
Replacing the cylinder head cover gasket
Replacing the cylinder head gasket
Replacing valve stem seals
Replacing the intake manifold gasket
Replacing crankshaft seals
Replacing the oil pan seal
Replacing camshaft seals
Replacing the oil level indicator guide seal
General information about the cylinder head
Removal, inspection and installation of camshafts
Lapping valves
Removal and installation the engine
Disassembling the engine
Engine parts defect detection
Engine assembly
Cooling and lubrication system
Features of the lubrication system design
Changing engine oil and oil filter
Removal and installation the oil pump
Removal and installation the oil filter housing
Design features of the cooling system
Possible malfunctions of the cooling system
Checking the cooling system hoses and connections
Replacing the coolant
Removal and installation the electric fan of the radiator of the cooling system
Replacing the cooling system radiator
Removal and installation the expansion tank
Replacing the water pump
Removal and installation the thermostat
Engine power system
Features of the design of the engine power supply system
Checking the pressure in the fuel system
Reducing pressure in the fuel system
Replacing the air filter element
Removal and installation the air filter, air duct and muffler
Removal, repair and installation of the fuel pump
Replacing the fuel tank and its filler pipe
Removal and installation the fuel rail
Removal, inspection and installation of injectors
Removal and installation the throttle assembly
Removal and installation the throttle pedal
Exhaust system
Features of the fuel vapor recovery system
Removal and installation the fuel vapor recovery system canister
Removal, checking and installation the purge valve of the adsorber
Design features of the exhaust system
Replacing the exhaust system suspension cushions
Replacing the main and additional mufflers
Replacing the inlet pipe
Removal and installation the catalytic converter, replacing its gasket
Removal and installation of thermal screens
Transmission
Clutch
Clutch design features
Possible clutch malfunctions
Checking the Clutch Release Pedal Travel
Bleeding the clutch release hydraulic drive
Replacing the working fluid in the clutch release hydraulic drive
Removal and installation the clutch
Replacing the clutch release drive slave cylinder with bearing
Replacing the clutch release master cylinder
Replacing the clutch release hydraulic line
Removal and installation the clutch pedal
Car gearbox
Design features of a manual gearbox
Possible malfunctions of a manual transmission
Features of the design of an automatic transmission
Checking the level, topping up and replacing oil in the gearbox
Replacing gearbox seals
Removal and installation the gearbox
Disassembly and assembly of a manual gearbox
Repair of secondary shaft of manual transmission
Repair of synchronizer of manual transmission
Repair of differential of manual transmission
Replacing gearbox control cables
Removal and installation the gearbox control lever linkage
Adjusting the gearbox control drive
Drive shafts
Features of the front wheel drive design
Possible faults of front wheel drives
Removal and installation front wheel drives
Replacing constant velocity joints of front wheel drives
Chassis
Front suspension
Features of the front suspension design
Checking the technical condition of the front suspension parts on the car
Removal and installation the front suspension shock absorber
Repair of the front suspension shock absorber
Replacing the upper support of the front suspension shock absorber strut
Replacing the ball joint of the front suspension shock absorber
Replacing the front suspension arm
Replacing the front suspension stabilizer bar components
Removal and installation the steering knuckle
Replacing the front wheel hub
Removal and installation the front suspension subframe
Checking and adjusting wheel alignment angles
Rear suspension
Features of the rear suspension design
Replacing the rear shock absorber
Replacing the rear suspension spring
Replacing the rear wheel hub
Removal and installation the rear suspension beam
Removal and installation the Watt mechanism
Steering
Features of the steering design
Inspection and testing of the steering system on the vehicle
Checking the free play (play) of the steering wheel
Removal and installation the steering wheel
Removal and installation the steering column cover
Removal and installation the steering column
Replacing the outer tie rod end
Replacing the steering rod and its protective cover
Replacing the steering gear
Brake system
Features of the brake system
Checking the brake pedal position
Checking the tightness of the hydraulic brake system
Checking the operation of the brake booster
Checking the degree of wear of brake pads and discs
Checking the parking brake
Bleeding the hydraulic brake system
Replacing brake fluid
Replacing the brake master cylinder reservoir
Replacing the master brake cylinder
Replacing the brake booster
General information about replacing brake hydraulic hoses and tubes
Replacing brake hoses
Replacing brake pipes
Removal and installation the brake pedal
Replacing the brake pads of the front wheel brake mechanism
Replacing the front wheel brake caliper
Replacing the brake disc of the front wheel brake mechanism
Replacing the brake pads of the rear wheel brake mechanism
Replacing the rear wheel brake caliper
Replacing the brake disc of the rear wheel brake mechanism
Adjusting the parking brake drive
Replacing the rear parking brake cables
Removal and installation the parking brake lever
Wheels and tires
Wheel rim markings
Checking the radial and lateral runout of the disc
Features of tire design
Classification of tires
Tire markings
Tips for choosing tires
Tubeless tire repair
Tips for using wheels
Wheel storage
Body
Exterior
Features of the body design
Removal and installation the radiator grille
Removal and installation mudguards
Removal and installation the front bumper
Removal and installation the rear bumper
Removal and installation the front wing
Removal and installation the air intake box grille
Removal and installation the hood
Removal, installation and adjusting the hood lock
Removal and installation the outside mirror
Removal and installation the battery mounting shelf
Control body dimensions
Interior
Removal and installation the front seat
Removal and installation the rear seat
Removal and installation the floor tunnel lining
Removal and installation the interior mirror
Features of the instrument panel design
Removal and installation storage boxes
Replacing handrails in the cabin
Replacing sun visors
Doors and windows
Removal and installation the front door trim
Front door glass replacement
Replacing the front door window regulator
Replacing the outside handle and front door lock switch
Replacing the inner handle of the front door lock drive
Replacing the front door lock
Replacing the front door opening limiter
Removal and installation the front door
Removal and installation the rear door trim
Rear door glass replacement
Replacing the rear door window regulator
Replacing the outer rear door handle
Replacing the inner handle of the rear door lock actuator
Replacing the rear door lock
Replacing the rear door opening limiter
Removal and installation the rear door
Replacing the tailgate stops
Removal and installation the rear door trim
Removal and installation the outer trim of the tailgate
Replacing the tailgate lock
Removal and installation the tailgate
Removal and installation the fuel tank filler pipe hatch cover
Removal and installation the fuel tank filler pipe hatch lock
Replacement of fixed body glazing
Body Care
Car body wash
Polishing of paintwork
Engine wash
Anti-corrosion protection of the body
Preparation and anti-corrosion treatment of hidden cavities of the body
Body sealing
Care of interior trim panels made of polymer materials
Caring for upholstery and carpets
Lubrication of body fittings
Cleaning drainage holes
Heating and air conditioning
General information about heating, ventilation and air conditioning systems
Features of the heating system
Features of the air conditioning system
Features of the ventilation system
Safety precautions for repair and maintenance of air conditioning systems
Removal refrigerant from the air conditioning system
Replacing the sealing rings
Features of the air conditioner compressor device
Removal and installation the air conditioning compressor
Replacing the condenser
Replacing the pressure sensor
Replacing the outside temperature sensor
Replacing the ambient air pollution sensor
Removal and installation the heating and ventilation system control unit
Replacing the cabin air filter
Security systems
Design features of the passive safety system (SRS)
Removal and installation the driver's airbag and its contact ring
Removal and installation seat belts
Electronic control unit of additional passive safety system
Removal and installation the shock sensor
Removal and installation the front passenger airbag switch
Design features of the anti-lock braking system (ABS)
Removal and installation of the ABS electronic unit
Replacing wheel speed sensors
Electrical equipment
Equipment and devices
Features of the design of electrical equipment
Diagnostics of faults of on-board electrical equipment
Location of fuses and fusible links and their replacement
Removal and installation the trunk mounting block
Design and testing of the ignition switch (lock)
Replacing the ignition switch (lock) contact group
Replacing the ignition switch (lock) cylinder
Removal and installation the ignition switch (lock)
Replacement and maintenance of spark plugs
Design features of the engine management system
Removal and installation the ignition module
Removal and installation of the electronic engine control unit
Checking and replacing engine management system sensors
Removal and installation windshield wiper blades
Removal and installation windshield wiper arms
Removal and installation the windshield wiper linkage and gear motor
Replacement of the rear window wiper motor
Removal and installation the windshield washer
Replacement of the electric window control unit and switches
Replacing the front door window lift motor
Replacing the rear door window lift motor
Replacing the joystick for controlling the outside mirrors
Removal and installation the electric motor of the radiator fan of the cooling system
Electric heating of the rear window glass
Features of the instrument cluster design
Removal and installation the instrument cluster
Replacement of the control unit for external lighting and backlight brightness
Removal and installation the central display
Removal and installation a car radio
Removal and installation speakers
Removal and installation control units on the steering wheel
Removal and installation the immobilizer
Removal and installation the socket block and USB connector
Replacing the oil pressure warning light sensor
Replacing the fuel level indicator sensor
Replacing the Low Oil Level Warning Light Sensor
Checking and replacing the reverse light switch
Replacing the Parking Brake Indicator Lamp Switch
Lighting and signaling
Construction of lighting, light and sound signaling
Checking and adjusting headlights
Replacing lamps
Removal and installation the electrical equipment control unit
Headlight replacement
Replacing the side turn signal light
Replacing the rear light located on the tailgate
Replacing the rear light located on the wing
Replacing an additional brake light
Replacing license plate lights
Replacement of interior lighting lamps
Replacement of the trunk light
Replacing the fog light and turn signal unit
Replacing the glove compartment light
Replacing steering column switches
Removal and installation the horn
Power devices
Features of the battery design
Battery maintenance
Removal and installation the battery
Charging the battery
Design Features of the Generator
Removal and installation the generator
Replacing the generator pulley
Generator repair
Features of the starter design
Removal and installation the starter
Starter repair
Electrical circuits
Windscreen wiper wiring diagram
Windscreen washer wiring diagram
Engine Management System Sensors
Fuel injectors and ignition module
Starter and battery
Starter wiring diagram
Engine control unit
Fuel pump
Variable valve timing system
Power supply to the engine control unit
Oxygen concentration sensors and fuel vapor recovery system
Pressure and temperature sensors
Direction indicators and hazard warning lights
Side lights
High and low beam headlights (halogen)
High and low beam headlights (xenon)
Brake light wiring diagram
Reversing lights and number plate lights



Corsa B (1993-2000)
General information
Introduction to guide
Introduction to the Operation and Repair Manual
Opel Corsa B, Tigra and Combo cars — summary
Vehicle Identification Numbers
Purchase of spare parts
Service technology, tools and workplace equipment
Jacking and towing
Starting the engine from an auxiliary power source
Checking the vehicle's readiness for operation
Automotive chemicals, oils and lubricants
Troubleshooting
User manual
Specifications and technical characteristics of cars
Description of the instrument panel
Information display
Additional electronic devices
Vehicle access and protection
Car interior lighting
Elements of vehicle safety systems
Car interior equipment
Heating, ventilation and air conditioning systems
Vehicle Operation Techniques
Maintenance
Vehicle Maintenance Specifications
Schedule of current maintenance
General information about technical monitoring
General information about settings and adjustments
Checking fluid levels
Checking the condition of the tires and their inflation pressure, rotating the wheels
Changing engine oil and oil filter
Checking the condition and replacing the auxiliary drive belt
Removal sediment from a diesel engine fuel filter
Checking the condition and replacing the hoses located in the engine compartment
Checking the status of components
Checking, servicing and charging
Checking the condition and replacing the brushes
Checking the exhaust system
Checking the brake system
Checking electrical equipment
Monitoring the condition of the anti-corrosion coating of the car body and underbody
Checking and adjusting idle speed and maximum speed
Replacing the filter element
Checking and servicing air conditioning and ventilation
Replacing the fuel filter
Checking the composition of exhaust gases
Lubrication of locks, hinges and stops
Inspection of suspension components
Checking and adjusting valve clearances on a diesel engine
Replacing spark plugs
Checking the clutch pedal adjustment
Replacing brake fluid
Automatic Transmission Fluid Replacement (ATF)
Power unit
SOHC gasoline engines
Specifications of all engines
General information about all engines
Checking the compression pressure in the cylinders and engine oil parameters
Engine condition diagnostics using a vacuum gauge
Bringing the piston of the first cylinder to the position of the top dead center of the compression stroke (TDC)
Removal and installation the timing cover
Removal and installation the crankshaft pulley
Removal and installation the timing belt cover
Removal and installation the timing belt
Removal and installation timing gear wheels
Replacing the camshaft seal
Removal, condition check and installation of the camshaft with the timing mechanism housing
Removal, inspection and installation of valves
Removal and installation the cylinder head
Removal and installation the oil pan
Removal, maintenance and installation of the oil pump
Removal, checking condition and installing flywheel/drive disk
Replacing crankshaft seals
DOHC gasoline engines
Bringing the piston of the first cylinder to the position of the top dead center of the compression stroke (TDC)
Removal and installation the timing cover
Removal and installation the timing belt (1.4 and 1.6 l engines)
Removal and installation of gear wheels of crankshaft and camshafts and intermediate rollers (engines 1.4 and 1.6 l)
Removal and installation camshafts
Removal and installation the cylinder head
Removal and installation the oil pan
Removal, maintenance and installation of the oil pump
Replacing camshaft seals
Removal, checking condition and installing flywheel/drive disk
Replacing crankshaft seals
Removal and installation the crankshaft pulley
Diesel engines
Bringing the piston of the first cylinder to the position of the top dead center of the end of the compression stroke (TDC)
Removal and installation the timing belt
Removal and installation the crankshaft pulley
Removal and installation the timing belt cover
Replacing the camshaft seal
Removal and installation the camshaft
Removal and installation the cylinder head
Removal and installation the oil pan
Removal, maintenance and installation of the oil pump
Removal, checking the condition and installing the flywheel or drive disk
Replacing crankshaft seals
Checking the condition and replacing the powertrain suspension supports
Engine repair
General information about engine overhaul
Removal the power unit from the car — methods and precautions
Removal, disconnecting and installing the engine
Alternative options for engine repair schemes
Engine disassembly sequence
Disassembling the cylinder head
Cleaning and checking the condition of the cylinder head
Cylinder head assembly
Removal connecting rod and piston assemblies
Removal the crankshaft
Cleaning and checking the condition of the cylinder block
Honing of cylinder mirrors
Checking the condition of the connecting rod and piston group components
Checking the condition of the crankshaft
Checking the condition of the main and connecting rod bearings of the crankshaft
Engine assembly procedure
Installing piston rings
Installing the crankshaft and checking the main bearing clearances
Installation of connecting rod and piston assemblies and checking the size of working clearances in the connecting rod bearings of the crankshaft
Test run and running-in of the engine after major repairs
Cooling system
Engine Cooling System Specifications
General information and precautions
Antifreeze — general information
Disconnecting and replacing cooling system hoses
Maintenance of the cooling system (emptying, flushing and filling)
Removal, installation and checking of the thermostat operation
Removal and installation the cooling system radiator
Checking the proper functioning, removing and installing the cooling system fan
Checking the proper functioning of the coolant temperature sensor (ECT)
Checking the condition of the water pump
Removal and installation the water pump
Supply system
Power and exhaust system specifications
General information and precautions
Relieving pressure in the fuel system of gasoline engines
Checking the condition and replacing fuel lines and their fittings
Removal air from the fuel system of a diesel engine
Removal contaminants from the fuel system of a diesel engine
Removal and installation air intake tract components
Replacing and adjusting the throttle cable
Removal and installation the accelerator pedal
Checking and replacing the fuel pump — gasoline models
Replacing the fuel level sensor
Removal and installation the fuel tank
Removal and installation the throttle body — petrol models
Injection system (gasoline)
General information and precautions
The operating principle of fuel injection systems
Checking the proper functioning of the fuel injection system
Checking and replacing the engine temperature sensor
Injection system (diesel)
General information about the fuel injection system of a diesel engine
Checking and adjusting maximum engine speed
Checking and adjusting fuel injection timing settings
Checking the temperature sensitive element
Removal and installation injectors
Fuel filter heating element
Exhaust systems
Exhaust system — general information
Exhaust system — removal and installation
Instructions for replacing the factory installed exhaust system
Catalytic converter
Removal and installation the additional air supply pump (X14XE and X16XE engines)
Control system (gasoline)
Engine Electrical System Specifications
General information and precautions
Electronic ignition (and injection) control system for gasoline engines
Checking the proper functioning of the ignition system
Troubleshooting — General Information and Preliminary Checks
On-Board Diagnostic System OBD — General Information
Using an Oscilloscope to Monitor the Operating Parameters of a Control System
Checking the ignition coil (engine C14NZ)
Removal and installation the ignition distributor (engine C14NZ)
Removal and installation the DIS ignition control unit
Checking and basic adjustment of ignition timing (C14NZ engine)
Octane correction
Preheat system (diesel)
General information about the preheating system
Checking the proper functioning of the preheating system
Removal, checking and installation glow plugs
Checking the glow plug relay
Charge and launch system
General information and precautions
Battery — general information, checking the condition, replacement, storage and commissioning
Checking the condition and replacing battery wires
Checking the proper functioning and condition of the charging system components
Removal and installation the generator
Replacing generator brushes
Checking the proper functioning of the components of the starting system
Removal and installation the starter
Checking the condition and repairing the starter
Transmission
Mechanical gearbox
Manual Transmission Specifications
General information about manual transmission
Adjusting the gear shift drive
Removal and installation of manual transmission
Manual transmission repair — general information
Automatic gearbox
Automatic Transmission Specifications
General information about automatic transmission
Adjusting the gear selection mechanism
Removal and installation the gear selection cable
Removal and installation the AT selector lever assembly
Removal and installation of automatic transmission
Major repairs of AT — general information
Clutch and drive shafts
Clutch and Drive Shaft Specifications
General information about clutches and drive shafts
Design of the clutch and its drive components
Removal and installation the clutch
Removal, checking and installation the clutch release bearing
Replacing the clutch cable
Checking the condition of clutch components
Drive shafts — general information
Removal and installation drive shafts
Checking the condition and replacing constant velocity joints (CV joints)
Replacement of protective covers of CV joints
Chassis
Brake system
Brake system specifications
General information about the brake system
Anti-lock Brake System (ABS) — General Information and Error Codes
Bleeding the brake system
Checking the condition and replacing brake lines and hoses
Replacing the front disc brake pads
Removal and installation brake shoes
Replacing brake linings of drum brakes
Checking the condition, removing and installing the brake disc
Removal, inspection and installation of the brake drum
Removal, repair and installation of front wheel disc brake calipers
Removal, maintenance and installation of wheel cylinders of drum brake mechanisms of rear wheels
Checking the proper functioning and tightness of the brake booster
Replacing and checking the brake booster servo vacuum pump (diesel models)
Adjusting the parking brake drive
Removal and installation parking brake cables
Replacing the brake light switch sensor
Pressure regulator valve in the hydraulic circuits of the rear wheel brake mechanisms
Front suspension
Suspension and steering specifications
Suspension and steering design
Removal and installation the shock absorber strut
Disassembly, inspection and assembly of the shock absorber strut
Removal and installation the transverse suspension arm
Removal and installation the anti-roll bar
Rear suspension
Removal and installation the rear shock absorber
Removal and installation the rear suspension spring (Corsa and Tigra models)
Removal and installation the anti-roll bar (Corsa and Tigra models)
Removal and installation the wheel bearing
Adjusting the clearance in the wheel bearing
Steering
Removal and installation the steering wheel
Removal and installation the steering rod
Removal and installation the steering rod end
Removal and installation the power steering fluid reservoir
Bleeding the hydraulic system of the power steering
Removal and installation the power steering pump
Wheel alignment angles
Body
Ventilation and heating
Removal and installation the cabin air filter
Removal and installation the fan speed switch
Removal and installation air duct deflectors
Removal and installation the heating control unit
Removal and installation heater flap drive rods
Removal and installation the heater fan
Removal and installation an additional resistor
Checking the proper functioning and maintenance of heating and air conditioning systems
Exterior
Body specifications
General information and precautions
Car body and underbody components care
Repair of minor damage to body panels
Repair of seriously damaged body panels
Maintenance of car hinges and locks
Replacement of windshield and other fixed glass
Removal and installation the bumper trim and support beam
Removal and installation the decorative radiator grille (models from 03.1997)
Removal and installation the wheel arch liner
Removal and installation the windshield fairing panel
Removal and installation the hood
Replacing hood hinges
Removal and installation the front wing
Replacing the rear wheel arch lining (Corsa and Combo models)
Removal and installation the outside mirror and its drive electric motor
Removal and installation the exterior mirror housing
Interior
Caring for Vinyl Trim Elements
Caring for upholstery and carpeting
Seat belt tensioner
Safety precautions when handling the emergency seat belt pretensioner and side airbag
Removal and installation the front seat
Removal and installation the rear seat
Removal and installation the center console
Removal and installation the side trim of the front passenger footwell
Removal and installation the glove box
Removal and installation the interior mirror and installing its mounting plate
Removal and installation the instrument panel
Doors and windows
Removal and installation door trim
Removal and installation front door glass
Removal and installation rear door glass (Corsa model)
Removal and installation the window regulator
Removal and installation the outer door handle
Removal and installation the front door lock cylinder
Removal and installation the door lock
Protection against freezing of locks and seals
Removal, installation and adjustment of the door
Removal and installation the tailgate (Corsa and Tigra models)
Removal and installation the tailgate lock (Corsa and Tigra models)
Removal, installation, disassembly and assembly of the outer handle and cylinder of the rear door lock (Corsa model)
Sliding roof panel
Electrical equipment
Equipment and devices
On-board electrical equipment specifications
General information and precautions
Search for causes of electrical equipment failures
Fuses — General Information
Relay — general information and checking the correct functioning
Removal and installation the electric motor of the single lock
Removal and installation the switch and electric motor for adjusting the range of the light (Corsa and Combo models)
Removal and installation the seat heating switch
Removal and installation the horn
Anti-theft device and alarm
Removal and installation the instrument cluster
Removal and installation of measuring instruments and indicators
Removal and installation indicator lamps and printed circuit board of the instrument cluster
Replacing the backlight lamp of the heating control unit panel
Removal and installation the steering column switch
Removal and installation rear fog light (fog light) and seat heating switches
Removal and installation the external and internal lighting switch
Removal and installation the hazard warning switch
Removal and installation the ignition lock cylinder and its contact element
Installing a radio receiver
Removal and installation speakers
Installing the antenna
Removal and installation the windshield wiper
Removal and installation the front windshield wiper motor
Removal and installation the rear wiper motor
Removal and installation the windshield washer reservoir and pump
Checking the K/L for low brake fluid level
Checking the correct operation and repairing the rear window heater
Lamps and lighting
Adjusting the light range
Replacing headlight bulbs
Replacement of incandescent lamps for outdoor lighting devices
Replacing bulbs in headlights, parking lights and front turn signals on Tigra
Replacement of incandescent lamps for interior, luggage compartment and glove compartment lighting
Removal and installation headlights
Headlight adjustment
Removal and installation the rear combination light
Removal and installation fog lights
Electrical circuits
Electrical Wiring Diagrams — General Information
Lighting: external and internal lighting
Lighting: rear fog light and brake light
Windscreen and rear window wipers, headlight lens washers
Electrical equipment: Heated rear window
Lighting: Salon
Cooling and heating
X12XE Engine
X14XE and X16XE engines
X17D and X15D engines
Electrical equipment: Display, cigarette lighter, sound signal
Radio installation: Speakers and antenna
Single lock: Control unit and its actuators
Electrical equipment: Window lifter
Electrical equipment: Outside mirror
Electrical equipment: Heated seats, sliding roof panel, power steering



Corsa C (2000-2006, petrol)
User manual
Car access
Vehicle identification data
Filling capacities of units and systems. Recommended operating materials
Refueling a car
Car keys
Controlling door locks using the key in the driver's door lock
Sliding doors (Combo)
Rear door (Limousine, Combo)
Centralized trunk locking
Swing doors (Combo)
Anti-theft alarm device
Hood — opening and closing
Window lift control
Electric retractable roof
Electric retractable roof (Limousine)
Electric retractable sliding roof (Combo)
Governing bodies
Light and sound alarms
Vehicle dashboard
Information display
Steering column switches
Hazard warning light
Sound signal
Windscreen wiper control
Turning on the glass and headlight washing device
Rear window wiper and washer control
Infotainment system control
Active head restraints
Parking pilot
Maintenance intervals for «ECO Service-Flex»
Cigarette lighter — location
Socket for additional accessories
Ashtrays — location and opening
Front storage compartment
Glasses compartment
Holder for small items
Sun visors
Exterior rear view mirrors
Automatically dimming interior mirror
Lighting control
Seat control
Seat adjustment
Seat headrest control
Boot space expansion (Corsa)
Folding the rear seat back
Raising the rear seats
Removal the luggage compartment cover
Trunk expansion (Combo)
Folding the front passenger seat back
Closing the trunk lid (Combo)
Removal and installation the trunk cover
Fencing grille (Combo)
Mounting behind rear seats
Mounting behind the front seats
Luggage net (Combo)
Bag hooks
Storage compartment under the front passenger seat
Storage compartment above the front seats (Combo)
Seat belts
Opel Full Size Airbag System
Opel Child Safety System
Heating and air conditioning
Heating and ventilation system with additional air conditioning
General description of climate control
Air Conditioning Control
Heated seats
Power-on indicators in keys
Climate control management
Air intake openings
Driving and maintenance
Starting a gasoline engine
Starting a diesel engine
Parking brake
Car parking
Manual transmission
Easytronic gearbox
Driving a car with an automatic transmission
Tips for the driver
Starting the engine using an auxiliary jumper cable
Towing another vehicle
Spare wheel (Corsa)
Jack and car tool (Corsa)
Wheel replacement
Electrical equipment
Maintenance and inspection system
Engines 1.0 and 1.2 l
Engine repair
Engine number
Checking oil pressure (Z10XE, Z10XEP)
Checking engine compression (Z10XE, Z10XEP)
Checking the valve timing (Z10XE, Z10XEP, without air conditioning)
Compression pressure test (Z10XE, Z10XEP, with air conditioning)
Checking fuel pressure (Z10XE, Z10XEP, with air conditioning)
Adjustment of valve timing by acting on the camshaft Z10XEP, Z12XE, Z14XEP (from the end of 2004 to 2005)
Adjustment of valve timing (Z10XE, Z10XEP, without air conditioning)
Replacing the poly V-belt (Z10XE, Z10XEP, with air conditioning)
Cylinder head
Removal and installation of the timing case (Z10XE, Z10XEP)
Engine repair (Z10XE, Z10XEP, without air conditioning)
Cylinder block, crank mechanism and piston group
Cooling and lubrication system
Filling the cooling system filling and bleeding air (Z10XE, Z10XEP)
Replacing the coolant temperature sensor (Z10XE, Z10XEP, without air conditioning)
Removal and installation of the coolant pump (Z10XE, Z10XEP, with air conditioning)
Removal and installation the thermostat with coolant pipe (Z10XE, Z10XEP, without air conditioning)
Radiator replacement (Z10XE, Z10XEP, with air conditioning)
Removal and installation the oil filter housing (Z10XE, Z10XEP, without air conditioning)
Engine oil change (Z10XE, Z10XEP)
Removal and installation the oil pan (Z10XE, Z10XEP, without air conditioning)
Replacing the oil pressure switch (Z10XE, Z10XEP)
Injection system
Replacing fuel injectors (one or all) (Z10XE, Z10XEP, without air conditioning)
Replacing the fuel filter (petrol engines)
Removal and installation an electric fuel pump
Replacing the exhaust manifold seal (Z10XE, Z10XEP, without air conditioning)
Engines 1.4, 1.6 and 1.8 l
Engine repair
Technical characteristics of gasoline engines
Test values for engines
Checking engine pressure loss (1.4-1.6L engines)
Checking engine pressure loss (1.8L engine)
Checking engine compression
Checking engine tightness (CO content in the cooling system)
Measuring oil consumption
Removal and installation the flywheel (1.4L engine)
Replacing the rear crankshaft oil seal
Replacing valve stem seals (installed cylinder head)
Checking the axial free play of the crankshaft
Removal and installation the cylinder head (1.4-1.6 l engine)
Checking the clearance in the connecting rod bearing
Replacing the connecting rod bearing
Replacing piston rings
Replacing the piston with the connecting rod
Cooling and lubrication system
Filling and bleeding the cooling system
Checking the tightness of the cooling system
Removal and installation the coolant pump
Intercooler Replacement — Removal and Installation
Replacing the oil pump (1.4L engine)
Injection system
General information about the fuel injection system
Removal and installation fuel injectors
Replacing the high pressure fuel line
Fuel pump module
Replacing the dosage module — removal and installation
Replacing the fuel pressure regulator — removal and installation
Replacing the fuel return damper housing
Replacing the fuel level sensor — removal and installation
Fuel tank
Replacing the fuel tank filler tube
Fuel vapor recovery system
Replacing the front ventilation tube
Removal and installation the activated carbon container
Removal and installation the mass air flow sensor
Exhaust system (Z14XEP, Z14XEL, Z16XEP)
Exhaust system (Z18XE)
Transmission
Clutch
General information about the clutch
Possible clutch malfunctions
Bleeding the hydraulic clutch drive (gearboxes — F13 / F17+ / F23)
Removal, checking and installation the thrust plate and clutch driven disc (without SAC)
Replacing the clutch pedal
Mechanical gearbox
Possible malfunctions of a manual transmission
Gears and gear shift lever
Checking and repairing a manual transmission
Checking the transmission oil level (F13 gearbox)
Removal and installation the gearbox (F13)
Automatic gearbox
General information about automatic transmission
Torque Converter — General Information
Main gear — general information
Adjusting the Automatic Transmission Shift Selector Cable
Automatic transmission designation (AF 13-II)
Checking the condition of the transmission oil (AF13-II)
Checking oil pressure (AF13-II)
Checking the gearshift lever position switch (AF13-II)
Unlocking the gearshift lever lock if it malfunctions
Adjusting the gear shift lever position switch (AF13-II)
Adjusting the gear shift cable system (AF13-II)
Replacing the gear shift cable system (AF13-II)
Replacing the gear shift lever locking device switch
Replacing the wiring harness in the gear shift lever assembly (AF13-II)
Replacing the electronic gearshift control unit
Replacing the gear shift indicator bulb in the gear shift console (AF 13-II)
Drive shafts
General information about drive shafts
Possible wheel drive faults
Measuring radial and lateral runout of wheel bearings
Measuring the tilt clearance of a bearing block
Removal and installation of the wheel shaft — removal and installation
Replacing the inner constant velocity joint
Replacing the outer constant velocity joint
Disassembling the outer constant velocity joint
Chassis
Wheels and tires
Wheel and tire repair
Condition of tires
Tire replacement
Puncture-resistant tires (RunFlat tires)
Identification of rims and tires
Wheel suspension
Possible suspension and wheel faults
General information about the suspension
Chassis adjustment values
Removal and installation the front axle stabilizer
Removal and installation the front steering knuckle
Removal and installation the front control arm of the independent suspension
Replacing all rubber bearings of the front stabilizer
Removal and installation the front shock absorber strut with shock absorber
Disassembly and assembly of the shock absorber strut
Checking the angular clearance of the rear wheel bearing assembly
Removal and installation the rear axle
Removal and installation the rear stabilizer
Removal and installation the rear shock absorber
Steering
Possible steering malfunctions
Operating principle of EPS
Steering column cover
Steering gear / steering rods
Checking the steering wheel play
Checking the steering wheel effort
Bleeding the power steering system
Checking the tie rod ends and seals
Testing constant velocity joints
Checking the tightness of the power steering
Checking the power steering fluid level
Troubleshooting in operating conditions
Brake system
General information about the braking system
Front brake mechanisms
Rear brakes
Brake booster
Master brake cylinder
Checking and adjusting the brake system components
Checking the brake fluid level in the hydraulic reservoir of the service brake system
Bleeding air from the hydraulic drive of the service brake system
Brake hoses
Adjusting the parking brake system
Removal and installation front brake hoses
Replacing brake system tubes — removal and installation
Removal and installation the front brake pad lining
Removal and installation the front wheel brake protective cover
Replacing the front brake disc
Removal and installation the rear wheel brake shield
Removal and installation rear wheel brake pads
General information about the anti-lock braking system
Repair instructions for ABS 5.3, ABS 5.3 / PBS, ABS 8.0, ABS 8.0 PZS
Instructions for repairing the PBS (traction control system)
Removal and installation / replacement of the ABS hydraulic unit (ABS 8.0, ABS 8.0 PZS)
Body
Exterior
Features of the car body design
Removal and installation the front bumper
Removal and installation the front beam holder (impact limiter)
Wing replacement — removal and installation
Removal and installation the protective sheathing inside the wing
Removal and installation the rear bumper — removal and installation
Removal and installation the entrance molding
Removal and installation the front protective strip
Removal and installation the water repellent
Replacing the additional roof frame seal
Removal and installation the hood — removing and installing
Doors and windows
Central and door locks
Removal and installation the front door lock
Removal and installation the outer front door handle
Replacing the front door window glass guide
Removal and installation the front door interior trim
Remove and install the front/rear door window regulator gap strip inside
Removal and installation the front door lock bracket
Removal and installation the front door seal
Removal and installation the rear door — removal and installation
Removal and installation the rear door interior trim
Removal and installation the rear door seal
Removal and installation the rear hatch
Removal and installation the rear hatch lock
Removal and installation the outer handle of the rear hatch
Removal and installation the rear tailgate air spring
Removal and installation the tailgate seal
Removal and installation the rear hatch interior trim
Removal and installation the glass seal in the rear hatch
Replacing the control element of the outside rearview mirror, adjustable from the inside
Removal and installation or replacement of windshield
Electrical equipment
Equipment and devices
General information about the electrical system
Rechargeable battery
Generator — General Information
Removal and installation of the generator (engine Z18XE, with air conditioning)
Replacing the Generator Drive Pulley — Removal and Installation
Generator Regulator Replacement (Z18XE Engine, with Air Conditioning)
Checking the generator
Starter replacement (Z10XE, Z10XEP, without air conditioning)
Removal and installation of the starter (Z14XE, Z16YNG, with air conditioning)
Windshield Wiper Arm Replacement
Removal and installation the window lift switch
Removal and installation the rear wiper motor
Replacing both wiper arm bearings
Lighting system
Checking and adjusting headlights, exterior lighting, interior light, headlight switch
Adjusting fog lights — removal and installation
Removal and installation of headlights — removal and installation
Removal and installation rear fog lights
Replacing the high beam bulb
Replacing the low beam bulb
Replacing the xenon headlight bulb
Replacing the turn signal bulb (xenon headlight)
Removal and installation the xenon lamp starter
Replacing the high beam/parking light bulb (xenon headlight)
Replacing a Bulb / Trunk or Luggage Compartment Light
Removal and installation of license plate lighting / bulb
Removal and installation the parking brake indicator light switch
Replacing the front interior light / bulbs
Removal and installation rear interior light/bulb
Removal and installation the cigarette lighter/bulb
Electrical circuits
Wire Color Codes
Scheme #1: Z10XEP engine, Motronic 7.6.1 (part 1)
Scheme #2: Z10XEP engine, Motronic 7.6.1 (part 2)
Scheme #3: Z12XEP engine, Motronic 7.6.1 (part 1)
Scheme #4: Z12XEP engine, Motronic 7.6.1 (part 2)
Scheme #5: Z14XEP engine, Motronic 7.6.1 (part 1)
Scheme #6: Z14XEP engine, Motronic 7.6.1 (part 2)
Scheme #7: Fuel pump, Motronic 7.6.1
Diagram #8: Z14XE engine, Multec S (F) (part 1)
Diagram #9: Z14XE engine, Multec S (F) (part 2)
Diagram #10: Fuel pump, Multec S (F)
Diagram #11: Z18XE engine, Simtec 71 (part 1)
Diagram #12: Z18XE engine, Simtec 71 (part 2)
Scheme #13: Fuel pump, Simtec 71
Diagram #14: Engine cooling system (Z10XEP without air conditioning and ECO)
Diagram #15: Engine cooling system (Z10XEP / Z12XEP / Z14XEP with air conditioning)
Diagram #16: Engine cooling system (Z14 XE / Z18XE with air conditioning)
Scheme #17: Starting and charging system
Scheme #18: Voltage distribution
Schematic #19: Body Control Module — Power Supply (Diagnostic Connector)
Scheme No. 20: Manual transmission with automatic clutch (Easytronic)
Scheme #21: Electric power steering, anti-theft alarm system
Diagram #22: Anti-lock braking system and traction control (ABS 8)
Scheme #23: Power windows and outside rearview mirror
Scheme #24: Central door lock control (hatchback)
Scheme #25: Brake light switch, rear lights (hatchback), clutch switch
Scheme #26: Air Conditioner
Scheme No. 27: Headlights (except xenon headlights)
Scheme #28: Headlights (xenon headlights)



Corsa C (2000-2006)
General information
Introduction to guide
Opel Corsa C and Meriva cars — summary
Vehicle Identification Numbers
Purchase of spare parts
Jacking up a car
Towing a car
Starting the engine from an auxiliary power source
Automotive chemicals, oils and lubricants
List of abbreviations used
Troubleshooting
Troubleshooting — General Information
Engine fault detection
Troubleshooting engine electrical equipment
Troubleshooting the starter
Troubleshooting the engine fuel system
Troubleshooting the engine lubrication system
Troubleshooting the engine cooling system
Identifying heater faults
Troubleshooting Clutch Problems
Troubleshooting Manual Transmission
Troubleshooting Automatic Transmissions
Detecting brake system faults
Troubleshooting suspension and steering
Windscreen wiper blade defects
Chassis, tire defects
Vehicle device
Technical characteristics of the car
Running in the car for the first 1000 km
Car keys
Doors — opening and closing
Hood — opening and closing
Fuel tank filler neck
Main storage compartment
Upper hatch
Single lock
Control from the driver's door lock
Remote control control
Unlocking and locking doors in emergency mode
Replacing the remote control battery
Anti-theft system
General information about the security system
Seat belts
Transportation of children
Adjustment and transformation of seats
Supplemental Restraint System (SRS)
Risk of Carbon Monoxide (CO) Poisoning
Instrument panel and center console
Instrument cluster, control lamps and indicator lights
Switches and controls on the steering column and steering wheel
Controls on the instrument panel to the left of the steering column
Controls on the console section of the instrument panel
Controls on the center console
Overhead console controls
Controls for the lifting and sliding hatch drive
Controls on door assemblies
Cigarette lighter, ashtrays
Power take-off socket
Storage boxes
Interior rear view mirror
Sun visors
Luggage compartment equipment
Information display
Ventilation, heating and air conditioning (HVAC) systems
Infotainment system
Telephone and radio station
User manual
Starting the engine and starting the movement
Driving cars with manual transmission (MT)
Driving cars with automatic transmission (AT)
Control of cars with Easytronic robotic gearbox
Special driving modes
Braking a car
Tire pressure monitoring
Operation of vehicles with a catalytic converter
Features of driving a car with power steering
Additional tips for drivers
Tips for Economical Driving
Towing a trailer
Maintenance
Specifications for maintenance
Schedule of scheduled maintenance (TO)
General information about maintenance
General information about settings and adjustments
Checking Fluid Levels — General Information
Engine oil — check
Engine Coolant — Check
Windshield and rear window/headlight washer fluid
Brake system and clutch drive fluid
Manual transmission oil — check
Automatic transmission fluid (ATF) — check
Wheels and tires — general information and designation
Wheels and tires — checking condition and pressure
Wheel rotation
Changing engine oil and oil filter
Checking the condition and replacing the multi-rib drive belt of the units
Draining sediment, removing air from the filter (diesel models)
Checking and replacing hoses located in the engine compartment
Checking the condition of the cooling system components
Checking, servicing and charging the battery
Checking the condition and replacing the windshield wipers
Checking the condition of shock absorbers
Checking the condition of the suspension and steering components
Checking the condition of wheel bearings
Checking the condition of the protective boots of the drive shafts
Checking the brake system
Checking electrical equipment
Control of anti-corrosion coating of the car body and underbody
Lubrication of locks, hinges and stops
Replacing the air cleaner filter element
Replacing the cabin filter
Replacing the fuel filter
Checking idle speed and exhaust gas composition
Replacing spark plugs, checking high-voltage wiring
Checking the condition of the timing belt and rollers
Power unit
Engine repair
Specifications for engine repair
General information about engines
List of works performed without removing the engine from the car
Engine cover
Checking the compression pressure in the cylinders
Engine condition diagnostics using a vacuum gauge
Removal and installation the multi-rib belt cover and engine crankcase protection
Removal the right engine mount
Removal and installation the crankshaft pulley
Removal and installation camshaft sprockets/wheels
Bringing the piston of the first cylinder to the top dead center (TDC) position
Removal and installation the accessory drive belt
Removal and installation the timing belt/chain
Checking and adjusting the timing valves (engines Y17DT(L)/Z17DTH)
Removal and installation of camshafts and valve lifters, checking of timing components
Removal and installation the cylinder head
Removal and installation the oil pan
Removal and installation the oil pump
Measuring engine oil pressure
Removal, checking condition and installing flywheel/drive disk
Replacing crankshaft seals
Replacing camshaft seals
Checking the condition and replacing the powertrain suspension supports
Removal the engine
Cooling system
Cooling and Heating System Specifications
Engine cooling system — design description
Antifreeze — General Information and Precautions
Draining and filling the system with coolant
Disconnecting and replacing cooling system hoses
Cooling system maintenance, flushing and leak testing
Removal and installation the cooling system fan
Removal and installation the cooling system radiator
Removal and installation the water pump
Removal, installation and checking the thermostat
Power and exhaust system
Fuel and exhaust system specifications
General information and safety precautions
Relieving pressure in the fuel system of gasoline engines
Checking and replacing fuel lines and their fittings
Removal air from the fuel system of a diesel engine
Removal dirt and water from the fuel system of a diesel engine
Removal and installation air intake tract components
Removal and installation the gas pedal
Removal and installation the fuel pump/fuel level sensor
Removal and installation the fuel filter mounting clamp (diesel)
Removal and installation the fuel tank
Turbocharger and Intercooler — General Information
Exhaust system — general information
Removal and installation of the exhaust system
Removal and installation lambda probes (petrol models)
Emission control systems
Control system
General information and precautions
Operating principle of petrol engine injection systems/Opel-Twinport system
Removal and installation of fuel injectors (petrol)
Diesel Engine Control System
The principle of operation of fuel injection systems of diesel engines
Removal and installation of the fuel distribution line of the Z13DT engine
Removal and installation of fuel injectors (diesel)
Removal and installation of fuel injection pump (diesel)
Engine electrical equipment
Engine Electrical Specifications
General information and precautions
Troubleshooting the ignition system
On-board diagnostic system OBD
Using an Oscilloscope to Monitor Control System Signals
Removal and installation of spark plugs, ignition modules and high-voltage wires
Ignition Timing Angle — General Information
Removal, installation and inspection of glow plugs (diesel)
Battery — Shutdown
Purchasing a new battery
Removal and installation the battery
Checking the condition and replacing the battery cables
Generator — General Information
Checking the generator voltage
Removal and installation the generator
Removal and installation the voltage regulator
Checking and replacing generator brushes
Starter — General Information
Removal and installation the starter
Checking the starter traction relay
Checking the condition and repairing the starter
Transmission
Clutch
Clutch and Gearbox Specifications
General information about manual transmission
Clutch design and operating principle
Removal and installation the clutch master cylinder
Removal and installation the clutch cylinder with release bearing
Bleeding air from the clutch hydraulic circuit
Removal and installation the clutch pedal
Removal, inspection and installation of clutch components
Features of removal and installation of the Easytronic clutch system
Removal and installation the Easytronic clutch control module
Mechanical gearbox
Manual transmission — general information
Adjusting the gear shift drive
Removal and installation gear shift drive components
Transmission oil change
Removal and installation the gearshift control module (Easytronic)
Removal and installation of manual transmission
Automatic gearbox
Automatic transmission specifications
General information about automatic transmission
Adjusting the gear shift drive
Removal and installation gear shift drive components
Checking the condition and replacing the working fluid AT
Removal and installation of automatic transmission
Drive shafts
Drive shaft specifications
General information about drive shafts
Removal and installation the hub nut
Removal and installation drive shafts
Right drive shaft with intermediate shaft (diesel)
Checking the condition of constant velocity joints (CV joints)
Replacement of double compensation CV joint
Features of replacing a tripod type CV joint (Z10XE engines)
Replacing CV joint boots
Torsional vibration damper (right drive shaft)
Chassis
Brake system
Brake system specifications
General information and precautions
Electronic braking control systems
Bleeding the brake system
Checking the condition and replacing brake lines and hoses
Replacing the front disc brake pads
Replacing the rear wheel disc brake pads
Front brake calipers and guide pads
Calipers and guide pads of rear brake mechanisms
Removal, installation and inspection of the brake disc
Brake drum, replacement of shoes of drum brake mechanisms
Wheel brake cylinder (drum brakes)
Removal and installation of the master brake cylinder (MBC)
Checking, removing and installing the brake booster assembly
Removal and installation the foot brake pedal assembly
Removal and installation the parking brake lever
Removal and installation sections of the parking brake cable
Adjusting the parking brake drive
Removal and installation the brake light switch sensor
Wheel suspension
Suspension and steering specifications
General information about car suspension
Removal and installation the front shock absorber strut
Disassembly, removal and installation of the front shock absorber
Removal and installation the steering knuckle
Removal and installation the front wheel hub assembly
Removal and installation the front transverse arm
Removal and installation the front subframe
Removal, checking and installation rear suspension shock absorbers
Removal and installation rear suspension coil springs
Removal and installation the rear hub assembly and wheel bearing
Wheel alignment angles — general information
Steering
Safety precautions when working with the steering system
Removal and installation the driver's airbag module
Removal and installation the steering wheel
Removal and installation tie rod ends
Removal and installation steering gear boots
Body
Exterior
Car body specifications
General information about the car body
Minor damage to windshield caused by stone impact
Removal and installation the lower spoiler (Corsa Eco models)
Removal and installation the engine compartment bulkhead cover (Meriva)
Removal and installation of side (door) trims (moldings)
Removal and installation the fairing grille
Removal and installation the front bumper and bumper cover
Removal and installation the rear bumper and bumper cover
Removal and installation of wheel arch protection (lockers)
Removal and installation front fenders
Removal and installation the wheel arch molding (Corsa)
Removal and installation lower outer threshold trims
Removal, installation and adjustment of the hood
Interior
Caring for Vinyl Trim Elements
Caring for upholstery and carpeting
Removal and installation sun visors
Removal and installation the ceiling handle and glasses case
Removal and installation interior rear view mirror
Removal and installation the main storage compartment
Removal and installation the gearshift lever boot (models with manual transmission)
Removal and installation the center console
Side trim panels for the console section of the instrument panel
Lower decorative cover of the instrument panel under the steering column
Instrument panel decorative strip (Meriva models)
Removal and installation interior door sill trim
Removal and installation the A-pillar trim
Removal and installation the B-pillar trim
Removal and installation rear side trim (3-door Hatchback)
Removal and installation C and D pillar trim
Lower instrument panel trim panels (Meriva models)
Removal and installation the rear door sill trim
Removal and installation luggage compartment side trim
Removal and installation the front seat belt (Corsa C)
Upper seat belt anchor height adjuster (Corsa C)
Removal and installation the rear seat belt (Corsa C)
Removal and installation rear seat belt buckles (Corsa C)
Removal and installation the front seat
Removal and installation the rear seat
Rear bench seat backrest support bracket (Corsa C)
Doors and windows
Removal, installation and adjustment of the tailgate (Corsa C/Meriva)
Removal and installation the rear door trim
Removal and installation the tailgate lock
Removal, installation and adjustment of side doors
Removal and installation side door locks
Removal and installation external side door handles
Removal and installation the lock cylinder
Removal and installation the inner door handle
Removal and installation the window lift handle
Removal and installation side door trim
Removal and installation triangular trims on the front doors
Removal and installation the door rearview mirror
Removal and installation the glass of the door rearview mirror
Removal and installation the door rearview mirror cover
Removal and installation the front door window regulator
Removal and installation the rear door window regulator
Removal and installation door seal
Heating and air conditioning
Interior heating, ventilation and air conditioning (HVAC) systems
Removal and installation air duct deflectors (Corsa C)
Removal and installation air duct deflectors (Meriva)
Complete removal and installation of HVAC control panel
Removal and installation the HVAC control panel switch assembly
Removal and installation the HVAC fan drive motor
Removal and installation the heater fan drive motor
Removal and installation the air distribution flap assembly (Corsa)
Removal and installation an additional heater (diesel models)
Removal and installation the heater heat exchanger
Electrical equipment
Equipment and devices
Fuses and relays — location and designation
General information about on-board electrical equipment
Search for causes of electrical equipment failures
Fuses — General Information
Removal and installation the underhood fuse box (Corsa C)
Relays — general information and checking the correct functioning
Removal and installation the horn
Removal and installation windshield washer nozzles
Removal and installation the wiper arms (leashes)
Removal and installation the windshield wiper motor
Removal and installation the rear window wiper motor
Removal and installation the reservoir and washer fluid supply pump
Removal and installation the instrument cluster
Removal and installation steering column switch levers
Removal and installation the information display
Exterior lighting switch panel, instrument lighting
Removal and installation the hazard warning switch
Removal and installation the cigarette lighter panel (Corsa models)
Power window and door mirror adjustment switches
Removal and installation door contact switches
Removal and installation the bonnet contact switch (Corsa models)
Removal and installation the infotainment system assembly
Removal and installation speakers
Removal and installation the external antenna (Corsa C models)
Lamps and lighting
Power characteristics of on-board lighting lamps
Replacing headlight bulbs
Removal and installation of the headlight unit
Removal and installation fog lights
Replacing the fog light bulb
Removal and installation turn signal repeaters
Removal and installation rear combination lights and replacing bulbs
Removal and installation a fog light
Removal and installation the high-level brake light bulb
Removal and installation the license plate light, replacing the lamp
Replacing interior lighting bulbs
Electrical circuits
Symbols used in electrical equipment diagrams
Z10XE Engine Management System
Z12XE Engine Management System
Z14XE Engine Management System
Engine Management System Z16SE
Engine Management System Z18XE
Engine Management System Z13DT
Cooling system of engines Z10XEP/Z12XE/Z14XEP/Z16SE/Z18XE
Heating system, fuel pump, rear window heating
Easytronic robotic gearbox
Automatic transmission
Anti-lock braking system (ABS), multi-function display
Anti-lock brake system (ABS) with traction control (TC)
Anti-theft alarm system, electric power steering
Door mirrors, electric windows
Single lock
Interior lighting, interior mirror, door switches, cigarette lighter, horn
Glass cleaners and washers, headlight washers
Radio (audio system)
Electric heated seats
Direction indicator switch, hazard warning switch...
Halogen headlights
Tail lights, brake light switch, clutch switch
License plate light, fog lights, fog lamps



Insignia A (2008-2017)
General information
Repair on the road
Fuses
Device for removing fuses
Engine compartment fuse box
Fuse box in the dashboard
Fuse box in the luggage compartment
Automotive tool
Replacing windshield wiper blades
Replacing lamps
Low beam/daytime running lights
High beam lamps
Front direction indicators
Side lights
Xenon lamps and fog lamps
Tail light bulbs
License plate lights
Interior lighting
Tire repair kit
Wheel replacement
Side direction indicators and instrument panel lighting
Spare wheel
Tires with the specified direction of rotation
Starting the engine from an external power source
Towing a car
Towing another vehicle
Daily checks
Checks on the car before driving
Starting the engine
Start of movement
While moving
Determining engine faults by the condition of spark plugs
Diagnostics and cleaning of fuel injectors
Table of causes of malfunctions in the car
Types of tire tread wear
Operation and maintenance
Introduction to the operation and repair manual Insignia A
Vehicle identification data
Engine parameters
Traction and dynamic characteristics
Fuel consumption — CO₂ emissions
Weight characteristics of the car
Dimensions of the car
Filling tanks
Dashboard
Outdoor lighting
Adjusting the position of the steering wheel
Steering wheel controls
Sound signal
Windscreen wiper/washer
Windshield and headlight washer
Rear window wiper/washer
Outside temperature
Watch
Plug sockets
Cigarette lighter
Ashtrays
Speedometer
Odometer
Tachometer
Fuel level indicator
Engine coolant temperature indicator
Maintenance display
Information displays
Control indicators on the instrument panel
Informational messages
Warning beeps
Road Sign Detection System
On-board computer
Saving individual settings
Outdoor lighting
Automatic lighting control
Lighting when driving in countries with left-hand traffic
Adaptive Front Lighting System
Lighting in the area of the sign «Caution, children!»
Lighting in the city
Lighting on a country road
Highway Lighting
Lighting in adverse weather conditions
Dynamic cornering lighting
Side lights
Additional lighting when reversing
Automatic switching of high beam
Automatic dynamic headlight range adjustment
Malfunction in the adaptive front lighting system
Emergency light signaling
Turn signals and lane change signals
Front fog lights
Rear fog lights
Parking light
Reversing lights
Fogging of headlights
Interior lighting
Features of the lighting system
Storage boxes
Luggage compartment
Luggage compartment cover
Cargo management system
Luggage net
Roof mounted luggage rack
Information on permitted loads
Warning triangle
Travel first aid kit
Car storage
Commissioning
Disposal of a vehicle that has reached the end of its service life
Car exterior care
Salon care
Vehicle check
Vehicle maintenance
Recommended working fluids, lubricants and spare parts
Coolant and antifreeze
Brake and clutch fluids
Safety and tool
Occupational safety during repairs
Precautions to prevent poisoning by vapors or gases
Precautions to prevent the collapse of the vehicle or its components
Precautions to prevent burns
Precautions to prevent electric shock
Precautions when working with toxic substances and materials
Precautions when working with Supplemental Restraint System (SRS) components
Environmental protection
Basic set of necessary tools
Flat feeler gauges
Micrometers
Calipers
Dial type indicator
Bore gauge
Power unit
Petrol engines 1.6 l
General information
Checking the compression in the cylinders
Checking the tension of the accessory drive belt
Replacing the accessory drive belt
Cylinder head cover
Gas distribution mechanism drive device
Checking the timing belt of the gas distribution mechanism
Replacing or adjusting the timing belt
Cylinder head structure
Replacing the cylinder head
Disassembling the cylinder head
Cleaning and checking the technical condition of the cylinder head
Construction of the cylinder block and crank mechanism
Replacing the crankshaft pulley
Replacing pistons with connecting rods
Visual inspection and cleaning of the connecting rod and piston group
Measuring pistons and connecting rods
Removal and installation the crankshaft
Checking the axial play of the crankshaft
Checking the radial runout of the crankshaft
Checking the clearance in the crankshaft main bearings
Cylinder Block Cleaning Procedure
Checking the technical condition of the cylinder block
Removal and installation a turbocharger
Specification
Special tools and accessories
Operating materials
Tightening torques for threaded connections
Petrol engines 2.0 l
General information
Checking the compression in the cylinders
Replacing the accessory drive belt
Replacing the drive belt tensioner for ancillary equipment
Removal the cylinder head cover
Installing the cylinder head cover
Gas distribution mechanism drive
Replacing the primary drive chain (camshaft drive chain)
Adjusting the primary drive chain (camshaft drive chain)
Replacing the secondary drive chain (drive chain of the water pump and balance shafts)
Cylinder head structure
Replacing the cylinder head
Construction of the cylinder block and crank mechanism
Disassembly and assembly of the cylinder head
Cleaning and checking the technical condition of the cylinder head
Replacing the crankshaft pulley
Replacing pistons with connecting rods
Cleaning and checking the technical condition of the connecting rod and piston group
Removal and installation the crankshaft
Cleaning and checking the technical condition of the crankshaft
Cleaning and checking the technical condition of the cylinder block
Replacing the turbocharger
Cleaning and checking the technical condition of the turbocharger
Specification
Special tools and accessories
Operating materials
Tightening torques for threaded connections
Engine Thread Recovery Map
Diesel engines 2.0 l
General information
Checking engine compression
Replacing the alternator drive belt, air conditioning compressor and power steering pump
Gas distribution mechanism drive belt
Replacing the timing belt
Cylinder head structure
Replacing the camshaft housing
Replacing the cylinder head
Disassembling the cylinder head
Cleaning and checking the technical condition of the cylinder head
Construction of the cylinder block and crank mechanism
Replacing the connecting rod and piston group
Replacing the crankshaft and main bearing shells
Cleaning and checking the technical condition of the connecting rod and piston group
Cleaning and checking the technical condition of the cylinder block
Replacing the turbocharger. Engines LBS/A20DTH, LBX/A20DTJ, LCD/A20DTC
Replacing the turbocharger. Engine LBY/A20DTR
Specification
Special tools and accessories
Operating materials
Tightening torques for threaded connections
Diesel engines 2.8 l
General information
Checking the compression in the cylinders
Replacing the accessory drive belt
Replacing the drive belt idler pulley
Replacing the drive belt tensioner
Cylinder head cover
Replacing the secondary timing chain
Replacing the primary timing chain
Replacing camshafts
Cylinder heads
Disassembly and assembly of the cylinder head
Cleaning and checking the technical condition of the cylinder head
Removal the crankshaft balance pulley
Installing the crankshaft balance pulley
Removal pistons with connecting rods
Cleaning and checking the technical condition of the connecting rod and piston group
Installation of pistons with connecting rods of the group
Removal the crankshaft
Cleaning and checking the technical condition of the crankshaft
Cleaning and checking the technical condition of the cylinder block
Installing the crankshaft
Replacing the turbocharger
Specification
Special tools and accessories
Operating materials
Tightening torques for threaded connections
Engine Thread Recovery Map
Cooling system
General information
Checking the tightness of the cooling system
Checking the opening pressure of the steam valve
Checking the Thermostat
Draining and filling the cooling system
Draining the cooling system
Filling the cooling system — petrol engines 1.6 and 1.8 l
Filling the cooling system — 2.0L petrol engines
Filling the Cooling System — 2.0L Diesel Engines
Filling the cooling system — 2.8L petrol engine
Flushing the cooling system
Specification
Special tools and accessories
Tightening torques for threaded connections
Lubrication system
Lubrication system of gasoline engines
Diesel engine lubrication system
Checking oil pressure — 1.6 and 1.8L petrol engines
Checking Oil Pressure — 2.0L and 2.8L Petrol Engines
Checking Oil Pressure — 2.0L Diesel Engines
Oil filter replacement — 1.6 and 1.8L petrol engines
Oil Filter Replacement — 2.0L Petrol Engines
Oil Filter Replacement — 2.0L Diesel Engines
Oil Filter Replacement — 2.8L Petrol Engine
Oil pan replacement — 1.6 and 1.8L petrol engines
Oil Pan Replacement — 2.0L Petrol Engines
Oil Pan Replacement — 2.0L Diesel Engines
Oil Pan Replacement — 2.8L Petrol Engine
Specification
Special tools and accessories
Operating materials
Tightening torques for threaded connections
Supply system
Fuel system of gasoline engines
Fuel system of diesel engines
Checking the pressure in the fuel system of gasoline engines
Checking the fuel tank for leaks
Removal fuel from the tank
Fuel tank for modifications with petrol engines
Fuel tank for diesel engine modifications
Special tools and accessories
Tightening torques for threaded connections
Engine management
General information
Electronic engine control unit
Tightening torques for threaded connections
Intake and exhaust system
General information
Replacing the air filter
Removal and installation the intake manifold — 1.6 and 1.8 L petrol engines
Removal and installation the intake manifold — 2.0L petrol engines
Removal and installation the intake manifold — 2.0L diesel engines
Removal and installation the intake manifold — 2.8L petrol engine
Exhaust manifold replacement — 1.6 and 1.8 L petrol engines
Exhaust Manifold Replacement — 2.0L Petrol Engines
Exhaust Manifold Replacement — 2.0L Diesel Engines
Exhaust Manifold Replacement — 2.8L Petrol Engine
Replacing the exhaust system
Special tools and accessories
Tightening torques for threaded connections
Engine electrical equipment
Charging system
Engine starting system
Ignition system of gasoline engines
Pre-heating system for diesel engines
Removal and installation the negative battery terminal
Replacing the battery
Generator replacement
Starter Replacement — Petrol Engines
Starter Replacement — Diesel Engines
Replacing ignition coils
Replacing spark plugs
Checking spark plugs
Replacing glow plugs
Replacing the pre-heating control unit
Specification. Charging system
Special tools and accessories
Tightening torques for threaded connections
Transmission
Clutch
General information
Bleeding the clutch hydraulic drive
Replacing the clutch pedal position sensor
Replacing the clutch master cylinder
Replacing the clutch slave cylinder line
Replacing the clutch slave cylinder
Replacing the clutch slave cylinder (LDE/A16XER, 2H0/A18XER engines)
Replacing clutch discs
Specification
Special tools and accessories
Operating materials
Tightening torques for threaded connections
Mechanical gearbox
General information
Calibration of the transmission neutral position sensor
Replacing transmission oil in a manual gearbox M32-6
Replacing transmission oil in a manual gearbox F40-6
Replacing the manual gearbox M32-6
Replacing a manual gearbox F40-6
Gear shift mechanism device
Replacing the gear shift knob
Replacing the gear shift lever
Replacing gear shift cables
Adjusting the gear shift cables
Specification
Special tools and accessories
Tightening torques for threaded connections
Automatic gearbox
General information
Checking the level and condition of transmission oil
Checking the pressure in the main lines
Checking for transmission oil leaks
Transmission oil change
Replacing the valve body
Replacing the gearshift lever on the gearbox
Adjusting the selector lever cable
Specification
Special tools and accessories
Operating materials
Tightening torques for threaded connections
Transfer case
General information
Transfer case replacement
Installing a transfer case
Specification
Special tools and accessories
Operating materials
Tightening torques for threaded connections
Drive shafts
General information
Rear axle
Replacing the drive shaft
Replacing the right drive shaft with the intermediate shaft
Replacing the cardan shaft
Checking the oil level in the rear differential clutch of the propeller shaft
Replacing the working fluid of the cardan shaft differential clutch
Checking the oil level in the rear main gear of the propeller shaft
Replacing the oil in the rear main transmission of the propeller shaft
Replacing the rear differential clutch of the propeller shaft
Replacing the limited slip differential clutch of the propeller shaft
Replacing the rear differential clutch control unit of the propeller shaft
Replacing the oil filter of the rear differential clutch of the propeller shaft
Replacing the rear wheel drive shaft
Special tools and accessories
Operating materials
Tightening torques for threaded connections
Chassis
Wheel suspension
Front suspension
Rear suspension
Electronic suspension control
Measuring wheel alignment angles
Wheel alignment
Camber and angle of longitudinal inclination of the wheel rotation axis
Rear axle turning angle
Replacing the wheel hub
Replacing the front suspension stabilizer bar struts
Replacing the stabilizer bar
Removal and installation the GMA front suspension strut assembly
GMA Lower Control Arm Replacement
GMA Lower Control Arm Bushing Replacement
Replacing the steering knuckle of the GMA suspension
Removal and installation the GNB front suspension strut assembly
Replacing the steering knuckle and front suspension fork GNB
GNB Lower Control Arm Replacement
Replacing the upper ball joint of the front suspension GNB
Disassembly and assembly of the front suspension strut
Shock absorber disposal
Replacing the rear suspension trailing arm
GNC Rear Suspension Spring Replacement
Replacing the GNC suspension adjusting rod
Replacing the GNC suspension trunnion
GNC Stabilizer Bar Replacement
GNC Stabilizer Bar Replacement
GNC Suspension Shock Absorber Replacement
GNC Rear Upper Arm Replacement
GNC Rear Lower Arm Replacement
GNC Suspension Subframe Replacement
GNE Rear Suspension Spring Replacement
GNE Rear Lower Arm Replacement
GNE Rear Suspension Shock Absorber Replacement
Replacing the stabilizer bar of the GNE suspension
Replacing the anti-roll bar of the GNE suspension
Replacing the wheel hub with suspension bearing GNE
Replacing the GNE suspension adjusting rod
GNE Rear Upper Arm Replacement
Replacing the GNE suspension trunnion
GNE Suspension Subframe Replacement
Disposal of GNE rear shock absorber
Replacing the electronic control unit of the GNE suspension
GNE Front Suspension Lower Cortical Acceleration Sensor Replacement
Replacing the upper vertical acceleration sensor of the front suspension GNE
Replacing the rear GNE suspension position sensor
Wheel alignment angles
Special tools and accessories
Tightening torques for threaded connections
Brake system
General information
Vacuum brake booster
Hydraulic brake system
Disc brakes
Anti-lock braking system (ABS)
Anti-slip system
Electronic stability control system
Electronic Brakeforce Distribution System
Emergency Brake Assist System
Slope assist system
Parking brake system
Checking the brake pedal travel
Checking the vacuum in the brake booster system
Checking for external brake fluid leaks
Checking brake lines and hoses
Visual inspection of the performance of the hydraulic brake system components
Bleeding the brake system
Replacing the pedal assembly
Replacing the master brake cylinder
Replacing the brake booster
Replacing the brake system expansion tank
Replacing the front brake line
Replacing brake hoses
Replacing the modulator valve lines
Checking brake pads
Replacing the front brake pads
Checking the hardware for mounting the front brake pads
Replacing the front brake caliper
Replacing the brake caliper bracket
Checking the technical condition of the brake caliper
Replacing the front brake disc
Checking the technical condition of brake discs
Regrinding of brake discs
Checking the rear brake pads
Replacing rear brake pads
Checking the equipment for fastening the rear brake pads
Replacing the rear brake caliper
Replacing the rear brake caliper bracket
Checking the technical condition of the rear brake caliper
Replacing rear brake discs
Checking the technical condition of the rear brake discs
Regrinding of front brake discs
Adjusting the parking brake
Replacing the parking brake lever
Replacing the parking brake lever handle
Replacing the Parking Brake Indicator Switch
Replacing the Parking Brake Switch
Replacing the parking brake cable
Electric parking brake (J71)
Electronic Parking Brake System Control Unit
Centering the steering wheel angle sensor
Calibration of the brake pressure modulator pressure sensor
Calibrating the Yaw Rate Sensor
Replacing the electronic brake control unit
Replacing the front wheel speed sensors
Replacing the rear wheel speed sensors
Replacing the yaw rate sensor
Replacing the wheel angle position sensor
Specification
Service data
Special tools and accessories
Operating materials
Tightening torques for threaded connections
Checking the level and topping up the power steering fluid
Replacing the outer tie rod end
Steering
General information
Power steering system
Steering wheel replacement
Replacing the upper and lower steering column covers
Replacing the steering column switch bracket
Replacing the steering column turn signal switch
Replacing the steering column lock and ignition switch
Replacing the intermediate steering shaft
Steering column replacement
Checking the power steering
Bleeding the power steering system
Replacing the power steering pump (four-cylinder engines)
Replacing the power steering pump (six-cylinder engines)
Replacing the power steering pump pulley
Replacing the power steering expansion tank (four-cylinder engine)
Replacing the power steering expansion tank (six-cylinder engine)
Replacing the Power Steering Pressure Pipe/Hose (Four-Cylinder Engine)
Replacing the power steering pressure pipe/hose (six-cylinder engine)
Replacing the Power Steering Return Hose (Four Cylinder Engine)
Replacing the Power Steering Return Hose (Six-Cylinder Engine)
Replacing the power steering radiator
Replacing the heat shield of the steering gear
Replacing the steering gear
Replacing the steering gear dust boots
Replacing the steering gear pipes
Replacing inner tie rods
Replacing the control unit of the system for changing the force on the steering wheel
Power Steering Pump Specification
Special tools and accessories
Operating materials
Tightening torques for threaded connections
Body
Exterior
General information
Front bumper device
Replacing the front bumper trim
Replacing the front bumper energy accumulator
Replacing the front bumper center support bracket
Replacing the front bumper beam
Replacing the lower beam of the front bumper
Rear bumper device
Replacing the rear bumper trim
Replacing the rear bumper energy accumulator
Replacing the rear bumper beam
Replacing the lower brackets of the rear bumper trim
Front Fender Replacement
Door replacement
Front door adjustment
Rear door adjustment
Replacing the hood
Adjusting the hood
Replacement of the tailgate
Adjusting the tailgate
Trunk lid
Adjusting the trunk lid
Replacing the fuel filler flap
Body dimensions
Interior
Replacing the instrument panel assembly
Windshield Blower Nozzle Replacement
Replacing the upper center trim panel
Replacing the lower center trim panel
Replacing the headlight switch trim
Replacing the dashboard strut
Replacing the front floor console
Replacing the Trim Frame of a Ceiling Reading Lamp
Replacement of the ceiling console
The device of the interior trim panels
Replacing the front and rear door sill trims
Replacing the windshield pillar trim
Replacement of the lower and upper trims of the central body pillar
Replacing the ceiling panel
Replacing the front floor covering
Replacing the rear floor covering
Replacing the interior door trim
Replacing door waterproofing
Replacing the door frame trim
Special tools and accessories
Tightening torques for threaded connections
Passive safety
General information
Passive safety system device
Safety rules for working with seat belt pretensioners
Safety precautions when working with airbags
Replacing the contact disk
Centering the steering airbag contact disc
Deactivation and activation of the additional passive safety system
Steering Wheel Airbag Module Replacement
Replacing the remaining system components
Disposal of passive safety elements
Special tools and accessories
Tightening torques for threaded connections
Cooling «quick check» procedure
Heater and air conditioner
General information
Air conditioning control
Precautionary measures
Checking the refrigerant circuit
Checking for refrigerant leaks
Repair operations
Replacing the passenger cabin air filter
Specification
Special tools and accessories
Operating materials
Tightening torques for threaded connections
Electrical equipment
Electrical circuits
General information about the electrical system
Zoning of vehicle wiring harnesses
Wiring harness routing
Non-standard symbols and designations
Standard symbols and color designations for wires on diagrams
Adaptive Headlights (TT2)
Anti-lock braking system and traction control system
Instrument cluster fuse box
Gearshift lock
Steering column lock
Interior rear view mirror
High speed GMLAN bus
High-speed GMLAN CE Bus
Gas discharge headlamps (TT2)
Hydraulic brakes
High beam headlights (TT4)
Rain sensor (CE1)
Wheel speed sensors
Daytime and low beam headlights (TT4)
Rear parking lights and number plate light
Rear fuse box
Rear windscreen wiper
Ignition switch
Sound signal
Immobilizer
Backlight lamps
Local internet
Low speed GMLAN bus
Washers
Interior lighting
Front lighting
Front windshield wipers
Rear window heating
Fuel filler flap release drive
Rear window curtain drive
Cigarette lighters and sockets for connecting additional equipment
Fog lights
Mass distribution
Trailer connector
Power Distribution: Fuses
Power distribution: positive battery terminal (B+), engine compartment fuse box
Power distribution: positive battery terminal (B+), fuse box, battery
Adjusting the brightness of interior lighting
Headlight regulator (TT4)
AC power outlet
Door opening alarm
Door locking system
Tire pressure monitoring system
All-wheel drive system (F46)
Stabilization system
Body control system
GMLAN medium speed bus
Parking brake
Direction indicators and brake lights
Interior Lighting Control
Headlight control
Outdoor Lighting Control
Reversing light
Electronic suspension control system: sensors and actuators (F45)
Electronic suspension control system: power supply, ground and serial data (F45)
Electric power steering



Kadett D (1979-1984)
General information
Car care
Car body care
Bottom protection and cavity preservation
Bitumen stains on the car body
Traces of insects on the body
Industrial pollution of the body
Car preservation
Care of polymer parts and varnish coatings
Cleaning car windows
Caring for rubber seals
Caring for upholstery
Maintenance
Lifting a car with a jack
Basic and special tool
Functions of engine oil
Viscosity of engine oil
Oil Change — Manual Transmission and Final Drive
Engine oil change
Annual technical inspection
Annual technical inspection of the engine and clutch
Annual inspection of the power supply system
Annual technical inspection of the front suspension and steering
Annual technical inspection of the car body
Annual technical inspection of brakes, tires and wheels
Annual technical inspection of gearbox, drive, steering
Power unit
Gasoline engines
Description and characteristics of gasoline engines
Removal and installation the engine
Removal and installation the timing belt
Checking and adjusting the timing belt tension
Removal and installation the cylinder head (OHC engine)
Replacing the camshaft housing/removing and installing the camshaft (OHC)
Removal and installation valves (OHC engine)
OHV engine cylinder head
Removal and installation the cylinder head (OHV)
Removal and installation valve springs (OHV engine)
Removal and installation valves (OHV engine)
Removal and installation of the timing case (OHV)
Removal and installation the chain tensioner (OHV engine)
Checking the valve timing (OHV engine)
Checking the valve guides
Grinding valves to seats
Replacing the valve stem seals
Adjusting valve clearances
Checking the flatness of the mating surface of the cylinder head
Checking the cylinder block surface for flatness
Checking the compression in the cylinders
Starting the engine from an auxiliary source
Engine malfunctions
Lubrication system
Oil circulation circuit — 1.0/1.2/1.3L engines
Engine oil consumption
Replacing the oil filter
Checking oil pressure
Removal and installation the oil pan
Removal and installation the oil pump (ONS engine)
Measuring engine oil temperature
Removal and installation the front crankshaft oil seal
Removal and installation the oil pressure reducing valve
Engine lubrication system malfunctions
Cooling system
Coolant circulation
Replacing the coolant
Removal and installation the radiator
Removal and installation and checking the thermostat
Removal and installation the coolant pump
Cooling system malfunctions
Power system (gasoline)
Fuel system maintenance
Carburetor — General Information
Carburetor adjustment
Malfunctions in the fuel supply system
Preheating of intake air
Removal and installation the air filter element
Cleaning and replacing the fuel pump filter
Removal and installation the fuel pump
Carburetor malfunctions and how to fix them
Removal and installation of the exhaust system
Replacing the exhaust pipe with a middle muffler
Replacing the rear muffler
Carburetor Solex 35 PDSI
Carburetor Solex 35 PDSI — design description
Removal and installation the carburetor
Removal and installation the upper part of the carburetor
Checking the float valve
Adjusting idle speed and CO content
Idle speed adjustment
Adjusting the CO content in exhaust gases
Checking the idle air cut-off valve
Replacing the accelerator pump membrane
Checking and adjusting the amount of fuel in the accelerator pump
Checking and adjusting the air (starting) damper clearance
Adjusting the air damper thrust
Checking and adjusting the throttle clearance
PDSI Carburetor Specifications
Carburetor Varajet II
Varajet II Carburetor — Design Description
Removal and installation the carburetor
Removal and installation the carburetor cover
Adjusting the throttle clearance
Adjusting the damper of the support flap (secondary chamber air flap)
Idle speed adjustment
Adjusting the carburetor drive
Adjusting CO content
Installing and checking the starting air damper clearance
Checking the opening time of the starting air damper
Adjusting the starter cover
Checking and adjusting the accelerator pump
Checking and setting fast idle speed (for cold engine)
Checking and adjusting the fuel level in the float chamber
Installing a damping valve
Varajet II Carburetor Specifications
Carburetor 1B1
Carburetor 1B1 — design description
Removal and installation the carburetor
Removal and installation the carburetor cover
Removal and adjusting the starter cable
Adjusting the carburetor throttle cable
Checking and adjusting idle speed and CO content
Checking and adjusting CO concentration
Installing and adjusting the starter cover
Checking and adjusting the starting valve clearance
Checking and adjusting the injection quantity
Characteristics of the 1B1 carburetor
Fuel injection (gasoline)
LE-Jetronik fuel injection system — design description
Adjusting the idle speed
Checking and adjusting CO content
Checking the control relay
Checking the performance of the fuel pump
Removal and installation the fuel pump
Replacing the fuel filter
Checking, removing and installing injection valves (injectors)
Checking, adjusting and replacing the throttle position sensor
Checking, removing and adjusting the air flow meter
Checking, removing and installing the temperature sensor
Checking and replacing the additional air valve
Replacing the filter element
Replacing the fuel level sensor
LE-Jetronik fuel injection system faults
Diesel engines
Diesel Engine — General Information
The most important technical characteristics of the engine
How a diesel engine works
Removal and installation the engine
Toothed Belt Drive — Design Description
Removal and installation the timing belt
Checking and adjusting the timing belt tension
Removal and installation the cylinder head
Removal and installation valves
Diesel engine malfunctions and how to fix them
Fuel system (diesel)
Diesel fuel system — general description
Instructions for working on the fuel injection device
Replacing and draining sediment from the fuel filter
Checking and adjusting idle speed
Checking and adjusting the maximum speed
Checking the preheating system
Checking the spark plugs
Removal and installation injectors
Idle speed problems
Loud knocking noises in the engine
Checking and adjusting the moment of start of injection of the high-pressure fuel pump
Cleaning and replacing the air filter element
Malfunction: too high fuel consumption
Removal and installation a vacuum pump
Checking and adjusting valve timing
Removal and installation the electromagnetic shut-off valve
Malfunction: Engine power too low
Transmission
Clutch
Clutch — design description
Removal and installation the clutch
Replacing the release bearing and clutch release lever
Replacing the clutch cable
Clutch adjustment
Clutch malfunctions and how to fix them
Manual gearbox
Gearbox — General Description
F16 Gearbox — Removal
F10 Gearbox — Removal
Gearbox — installation
Gear Shift Lever — Design Description
Removal and installation the gear shift lever
Switching adjustment
Chassis
Front suspension
Front suspension — design description
Removal and installation the shock absorber strut
Removal and installation the front spring
Removal and installation a hydraulic shock absorber
Checking the shock absorber
Removal and installation the drive shaft
Replacing the hinge and hinge housing
Rear suspension
Rear suspension — design description
Removal and installation a hydraulic shock absorber (sedan)
Removal and installation a hydraulic shock absorber (station wagon)
Removal and installation the stabilizer
Removal and installation rear springs (sedan)
Removal and installation rear springs (station wagon)
Adjusting the play of the hub bearings
Replacing the rear wheel hub bearing
Steering
Steering — design description
Removal and installation the steering wheel
Steering gear drive — design description
Checking and adjusting the steering play
Removal and installation of steering rods
Removal and installation the steering rod end
Brake system
Brake system — general information
Checking the condition of the friction linings
Removal and installation brake pads
Piston installation template
Removal and installation the brake disc
Rear brakes — design description
Checking the thickness of friction linings
Rear brake adjustment
Removal and installation the brake drum
Removal and installation rear brake pads (before 8.1983)
Removal and installation rear brake pads (since 8.1983)
Replacing friction linings
Removal and installation the wheel brake cylinder
Repair of the brake wheel cylinder
Checking and adjusting the brake system regulator
Brake fluid expansion tank
Bleeding the brake system
Removal and installation the handbrake cable
Adjusting the handbrake
Checking the brake booster
Brake system malfunctions
Wheels and tires
Wheel alignment angles
Negative toe-in adjustment
Parameter values for adjusting wheel alignment
Wheels and tires — general information
Wheel balancing
Wheel replacement
Tire wear
Anti-skid chains
Tire and wheel sizes
Correct tire pressure (overpressure) in kPa (bar/atm)
Tyre defects
Abnormal tire wear
Running in new tires
Speed Limit Markings
Body
Body elements
General description of the car body
Removal and installation the bumper
Removal and installation the front wing
Removal and installation the radiator grille
Additional installation of protective moldings
Heater — design description
Removal and installation fresh and heated air regulator/replacing rods
Doors and windows
Removal and installation front door trim
Removal and installation rear door trim (sedan)
Removal and installation the window regulator
Removal and installation front door glass
Removal and installation glass in the rear doors
Removal and installation the outer front door handle
Removal and installation the front door lock cylinder
Removal and installation a window lifter with rivets
Electrical equipment
Equipment and devices
On-board electrical equipment — general information
Instructions for installing additional equipment
Maintenance of electrical equipment
Replacing fuses
Fuse box table
On-board electrical equipment instruments — general information
Removal and installation the instrument panel
Checking the voltage stabilizer
Removal and installation light bulbs
Removal and installation of devices
Turn signal switch and windshield wiper switch
Removal and installation the fan motor
Removal and installation the windshield wiper arm
Removal and installation the windshield wiper motor
Removal and installation the windshield wiper
Additional installation of adjustable outside rearview mirror
Windscreen wiper rubber defects
Installing the antenna
Installing a Loudspeaker on the Dashboard
Installing a radio receiver
Lighting system
Replacing headlight bulbs
Replacing the parking light bulb
Replacing front turn signals
Replacing tail light bulbs
Removal and installation headlights
Headlight adjustment
Removal and installation rear lights
Removal and installation interior lighting lamps
Removal and installation the license plate light
Table of incandescent lamps
Power devices
Removal and installation the battery
Checking the battery
Charging the battery
Maintenance free batteries
Battery malfunctions and how to fix them
Generator — design description
Removal and installation the generator
Checking and tensioning the V-belt
Removal and installation the V-belt
Replacing and checking the carbon contacts of the generator/voltage regulator
Removal and installation the starter
Replacing the traction relay
Starter malfunctions and how to fix them
Ignition system
Ignition system — general information
Maintenance of the ignition system
Functions of TSZ-H,TSZ-I systems
Safety precautions when operating an electronic ignition system
Checking the ignition coil
Checking the capacitor
Removal and installation the ignition distributor
Replacing breaker contacts
Checking and adjusting the closed state angle
Adjusting the ignition timing
Spark plugs
Electrical circuits
Working with electrical circuits
Additional Electrical Circuit — Fuel Injection System
Electrical diagram I
Electrical diagram II
Electrical diagram III
Electrical diagram IV



Kadett E (1984-1995)
General information
Vehicle description
Car wheels and tires
Overall dimensions of cars
Mass characteristics of cars
Conventional fuel consumption
Filling tanks and used fuels and lubricants
Fuels and lubricants of domestic production and their foreign analogues
Body checkpoints
Operation and maintenance
Introduction to the Kadett E vehicle operating manual
Vehicle Passport Data
Lifting and towing a car
Designation of some vehicles
General requirements for car repair
Instrument cluster of the Opel «Kadett E» model «GL»
Instrument cluster of the Opel «Kadett E» model «GSi»
Instrument cluster of the Opel «Kadett E» models «GLS» and «OT»
Controls and instrumentation for Opel «Kadett E» cars
Engine hood
Starting the engine
Starting a carburetor engine
Lubrication system of a carburetor engine
Carburetor engine cooling system
Fuel system of a carburetor engine
Ignition system of a carburetor engine
Clutch
Manual transmission
Automatic transmission
Front wheel drive
Steering system
Front suspension
Rear suspension
Brake system
Rechargeable battery
Generator
Fuses and fuses
Electronic control and measuring devices
On-board control system
On-board computer
Ventilation and heating
OHV power unit
Engine design
Main technical characteristics
Cylinder head specifications
Technical characteristics of the cylinder block
Technical characteristics of the crank mechanism
Technical characteristics of the valve timing mechanism
Technical characteristics of the lubrication system
Technical characteristics of the cooling system
Technical characteristics of the power supply system
Technical characteristics of the ignition system
Tightening torques of main threaded connections, kgf.m
Check and repair
Adjusting clearances in the valve drive mechanism
Removal and installation the ignition system distributor
Adjusting the gap between the contacts of the ignition system interrupter
Setting the ignition timing
Fuel pump
Operating principle of the Weber 32 TL carburetor
Main metering system of the Weber 32 TL carburetor
Adjusting the starting clearance of the carburetor throttle valve
Oil filter
Engine work
Removal the cylinder head
Installing the cylinder head
Disassembling the cylinder head
Checking the cylinder head
Grinding of valve seats and valves
Repair of valve guide bushings
Cylinder head assembly
Removal and installation the engine
Disassembling the engine
Engine assembly
Installing the crankshaft
Checking the diametrical clearance between the bearings and the crankshaft journals
Assembly of the connecting rod and piston group
Checking and installing piston rings
Installing pistons with connecting rods into cylinders
Installing the camshaft
Installing the camshaft drive
Replacing the valve timing tappets
Replacing camshaft bearing bushings
Checking the technical condition of the oil pump
Checking oil pressure
Replacing the coolant
Replacing the thermostat
Replacing the water pump
OHC power unit
Engine design
Main technical characteristics
Technical characteristics of the 8-valve cylinder head
Technical characteristics of the 16-valve cylinder head
Technical characteristics of the cylinder block
Technical characteristics of the crank mechanism
Technical characteristics of the valve timing mechanism of 8-valve engines
Technical characteristics of the valve timing mechanism of the 16-valve engine
Technical characteristics of the lubrication system
Technical characteristics of the cooling system
Technical characteristics of the power supply system
Technical characteristics of carburetor engines
Technical characteristics of the fuel injection system «Multec SPI»
Technical characteristics of the fuel injection system «LE-Jetronic»
Technical characteristics of the fuel injection system «LE3-Jetronic»
Technical characteristics of the digital engine management system «Motronic ML 4.1»
Technical characteristics of the fuel injection system
Technical characteristics of the ignition system
Technical characteristics of the digital engine management system «Motronic ML 4.1»
Technical characteristics of the fuel injection system «Motronic M 1.5»
Technical characteristics of the ignition system «Motronic M 1.5»
Technical characteristics of the digital engine management system «Motronic M 2.5»
Technical characteristics of the fuel injection system «Motronic M 2.5»
Technical characteristics of the ignition system «Motronic M 2.5»
Technical characteristics of the ignition system of engines «13N», «13S», «14NV», «16S», «18E»
Engine repair
Adjusting clearances in the drive mechanism
Construction of hydraulic tappets
Operating principle of hydraulic tappets
Checking the technical condition of hydraulic tappets
Removal the cylinder head of 8-valve engines
Installation of cylinder head of 8-valve engines
Disassembly and assembly of cylinder heads of 8-valve engines
Removal and installation the camshaft of 8-valve engines
The device of the gas distribution mechanism of 8-valve engines
Removal and installation the cylinder head of a 16-valve engine
Disassembly and assembly of the cylinder head of a 16-valve engine
The device of the valve timing mechanism of 16-valve engines
Checking the installation of the timing mechanism drive of a 16-valve engine
Replacing the camshaft drive belt of a 16-valve engine
Replacing the front camshaft seals of a 16-valve engine
Removal and installation of a 16-valve engine
Disassembling a 16-valve engine
Assembly of a 16-valve engine
The design of the crank mechanism of a 16-valve engine
Device of the exhaust gas system
Engine mount device
Cross and longitudinal sections of the engine
Ignition system
Contactless ignition system device
The principle of operation of a contactless ignition system
Fully electronic ignition system
Ignition distributor sensor device
Scheme for troubleshooting and troubleshooting contactless ignition system
Cooling and lubrication
Lubrication system
Lubrication system device
Cooling system
Cooling system device
Supply system
Fuel system of carburetor engines
The principle of operation of the Solex 35 PDSI carburetor
Air filter device
Adjustment and check of carburetor Solex 35 PDSI
Automatic starting device for GM Varajet II carburetor
GM Varajet II Carburetor Manual Choke Starter
GM Varajet II Carburetor Idle System
Adjustment and check of the GM Varajet II carburetor
Adjusting the fast idle speed of the GM Varajet II carburetor engine
Checking and adjusting the automatic starting device of the GM Varajet II carburetor
Adjusting the Manual Choke Starter on a GM Varajet II Carburetor
Operating principle of the Pierburg 2E3 carburetor
Checking and adjusting the Pierburg 2E3 carburetor
Carburetor Pierburg 2EZ
Checking and adjusting the GM «Multec SPI» fuel injection system
GM «Multec SPI» fuel injection system
GM Fuel Injection System Self-Diagnostics System «Multec SPI»
Fuel injection «LE-Jetronic»
Features of the device and operating principle
Fuel injection system «LE-Jetronic»
Checking and adjusting the LE-Jetronic system
Checking the additional air supply valve
Checking injection nozzles
Checking the electronic control unit
Test sequence for identifying faults in the LE-Jetronic injection system
Fuel injection «LE3-Jetronic»
Fuel injection system «LE3-Jetronic»
Checking and adjusting the «LE3-Jetronic» system
Test sequence for determining faults in the fuel injection system «LE3-Jetronic»
Motronic ML4.1 system
Distinctive components of the Motronic ML4.1 system from LE-Jetronic
The structure of the system «Motronic ML4.1»
Operating principle
Warnings: Checking and adjusting the fuel injection system
Checking and adjusting engine idle speed
Self-diagnosis system
Ignition system
Motronic M1.5 system
Digital engine management system «Motronic M1.5»
Malfunctions and methods of their elimination
Motronic M2.5 system
Digital engine management system «Motronic M2.5»
Possible malfunctions of the digital engine control system «Motronic M 1.5», their causes and methods of elimination
Fuel injection system
Ignition system
Malfunctions and methods of their elimination
Transmission
Clutch
Design and technical characteristics
Tightening torques of main threaded connections, kgf.m
Removal and installation the clutch
Clutch device
Gearbox F10 and F13
Design and technical characteristics
Tightening torques of main threaded connections, kgf.m
Removal and installation the gearbox
4-speed gearbox device
Disassembling a 4-speed gearbox
Features of disassembling a 5-speed gearbox
5-speed gearbox device
Disassembling the differential
Differential assembly
Assembly of a 4-speed gearbox
Gear shift and differential drive device
Assembly Features of a 5-speed Gearbox
Adjusting the gear shift drive
Removal and installation the gear shift lever
Gearbox F16 and F20
Design and technical characteristics
Tightening torques of main threaded connections, kgf m
Removal and installation the gearbox
Disassembling the gearbox
The device of the 4-speed gearbox type «F16»
Disassembling the differential
Differential assembly
The device of the 5-speed gearbox type «F16»
Gearbox assembly
Adjusting the gear shift drive
Removal and installation the gear shift lever
Gear shift and differential drive device of the F16 gearbox
Gear shift drive device of the F20 type gearbox
Automatic gearbox
Design and technical characteristics
Gearbox specifications
Technical characteristics of transmission oil
Tightening torques of main threaded connections, kgf.m
Design features and operating principle
Torque converter torque converter
Planetary gear
Frictions
Band brake
Freewheel clutch
Output planetary gear
Removal the hydromechanical gearbox
Checking oil pressure
Adjusting the forced reverse shift cable
Removal and installation the drive chain
Checking the band brake
Speedometer drive unit, band brake servo regulator, pressure accumulator and transmission brake
Automatic transmission control mechanism device
Possible malfunctions of the hydromechanical gearbox and their causes
Drive shafts
Design and technical characteristics
Tightening torques of main threaded connections, kgf m
Removal and installation front wheel drive shafts
Replacing the front wheel drive shaft joints
Replacement of protective covers of wheel drive shaft joints
Front wheel drive device
Chassis
Front suspension
Design and technical characteristics
Technical characteristics of the anti-roll bar
Technical characteristics of front wheel hubs
Tightening torques of main threaded connections, kgf.m
Removal and installation a telescopic stand
Front suspension device
Removal and installation front suspension springs
Removal and installation front suspension shock absorbers
Removal and installation the anti-roll bar
Removal and installation suspension arms
Replacing the ball joints of the suspension arms
Replacing the silent blocks of the suspension arms
Checking and adjusting the front wheel alignment angles
Replacing the front wheel hub bearing
Adjusting the clearance in the front wheel hub bearing
Rear suspension
Design and technical characteristics
Tightening torques of main threaded connections, kgf m
Removal and installation rear suspension springs
Removal and installation rear suspension springs
Replacing rear suspension shock absorbers
Replacing rubber shock absorber bushings on cars
Removal and installation the anti-roll bar
Removal and installation the rear suspension beam
Rear suspension device
Adjusting the clearance in the rear wheel hub bearings
Removal and installation of rear wheel hubs on all models of vehicles, except for vehicles with the «20XE» engine
Replacement of rear wheel hub bearings on all models of vehicles, except for vehicles with the «20XE» engine
Removal, installation and repair of rear wheel hubs on vehicles with the «20XE» engine
Rear wheel hub device for cars with the «20 XE» engine
Steering
Mechanical steering specifications
Technical characteristics of power steering
Tightening torques of main threaded connections, kgf.m
Removal and installation of the steering gear of the mechanical steering
Disassembly and assembly of the steering mechanism of mechanical steering
Removal and installation the mechanical steering shaft
Checking the straight-line position of the mechanical steering
Steering device
Removal and installation of the power steering gear
Checking the oil pressure in the power steering system
Replacing the V-belt of the power steering pump drive
Replacing steering gear sealing rings
Brake system
Design and technical characteristics
Technical characteristics of the front wheel brake mechanisms
Technical characteristics of rear wheel drum brakes
Technical characteristics of wheel cylinders
Technical characteristics of rear wheel disc brakes
Technical characteristics of the brake drive
Technical characteristics of the parking brake system
Technical characteristics of the anti-lock braking system
Tightening torques of main threaded connections, kgf.m
Replacing brake pads
Removal and installation brake discs
Removal and installation of the ATE brake mechanism
Disassembly and assembly of the front wheel brake mechanism of the ATE brand
The device of the front wheel brake mechanisms
Removal and installation of the Delco Moraine brake mechanism
Disassembly and assembly of the Delco Moraine brake mechanism
Removal and installation brake drums on vehicles up to model year 1984
Replacing the brake shoes of the rear wheel drum brakes
Removal and installation of the wheel cylinder of the rear wheel drum brake mechanisms
Rear wheel brake mechanism device
Rear wheel drum brake mechanism device
Replacing the brake pads of the rear disc brake mechanisms
Rear wheel disc brake mechanism device
Removal and installation the caliper
Adjusting the parking brake system
Parking brake system device
Removal and installation the brake master cylinder
The structure of the main brake cylinder and the brake booster
Removal and installation the brake booster
Rear brake pressure regulator device for van brake drive
Removal and installation brake pressure regulators on hatchback and sedan vehicles
Replacing the brake pressure regulator on station wagons
Replacing the brake pressure regulator on Delvan and Combo vans
Checking the operation of the brake drive pressure regulator
Removal air from the brake hydraulic drive using a special installation
Bleeding the brake hydraulic system without special installation
The principle of operation of the anti-lock braking system
ABS device
Monitoring the operation of the ABS system
Removal and installation of the ABS hydraulic unit
Removal and installation ABS wheel speed sensors
Electrical equipment
Equipment and devices
Technical characteristics of the battery
Generator specifications
Starter specifications
Technical characteristics of fuses
Tightening torques of main threaded connections, kgf m
Removal and installation the generator
Adjusting the tension of the generator drive V-belt
Adjusting the tension of the auxiliary drive belt of the generator
Disassembly and assembly of the generator
Generator device
Removal and installation the starter
Disassembling and assembling the starter
Starter device
Headlight adjustment
Removal and installation the windshield wiper gear motor
Glass cleaner device
Removal and installation the instrument cluster
Instrument cluster design
Assembly block device
Interior heater
Electrical circuits
Wire color designation
Electrical Equipment Diagram No.1
Electrical Equipment Scheme No.2
Electrical Equipment Diagram #3
Electrical Equipment Diagram No.4
Electrical Equipment Diagram #5
Electrical Equipment Diagram #6
Electrical Equipment Diagram #7
Electrical Equipment Diagram No. 8
Electrical Equipment Diagram #9
Electrical Equipment Diagram #10
Electrical Equipment Diagram #11
Electrical Equipment Diagram #12
Electrical Equipment Diagram #13
Electrical diagram of cars with engine «20XE»



Omega A (1986-1993)
General information
User manual
Car keys
Seat and steering wheel adjustments
Ignition switch
Lighting and sound signalization
Windscreen wipers and washers
Dashboard
Transmission
Starting the engine
Stopping the car
Temperature, fuel and control lamps
Instruments (pointer instrument panel)
Instruments (LCD instrument panel)
Automatic control system
On-board computer
Door control
Trunk lid, tailgate
Interior Elements Management
Structural safety of the body
Lighting fixtures
Windows, retractable sunroof
Heating and ventilation control
Air Conditioning Control
Automatic transmission
Electronically controlled chassis damping
Adjusting the vehicle's landing level
Manual speed control device
Brake system
Wheels and tires
Additional luggage rack on the roof of the body
Traction device
Fuel system of diesel engine
Starting the engine with outside help
Electronic equipment, ignition system
Replacing lamps
Maintenance
Overall dimensions, weight and capacity
Identification numbers
View of the engine compartment (model 1.8 GL Saloon)
Front view from below (model 1.8 GL Saloon)
Bottom rear view (model 1.8 GL Saloon)
Recommended lubricants and fluids
Maintenance Procedures (Gasoline Models)
Maintenance Procedures (Diesel Engines)
Necessary actions for maintenance
Checking engine oil level — every 400 km
Check coolant level — every 400 km
Exhaust quality check — every 400 km
Checking the glow plug indicator light — every 400 km
Engine oil and filter change — every 5000 km
Draining water from the fuel filter — every 5000 km
Engine oil and filter change — every 7500 km
Drain water from the fuel filter — every 7500 km
Checking and adjusting the idle speed — every 10,000 km
Replacement of fuel filter — every 10,000 km
Replacement of air filter element — every 10,000 km
Checking the condition of the auxiliary drive belt — every 10,000 km
Checking systems for leaks — every 10,000 km
Checking and adjusting the idle speed — every 15,000 km
Checking and adjusting the maximum engine speed — every 15,000 km
Checking the condition of the auxiliary drive belt — every 15,000 km
Lubrication of the throttle lever rod — every 15,000 km
Checking the concentration of antifreeze in the coolant — every 15,000 km
Checking the concentration of antifreeze in the coolant — every 10,000 km
Replacement of fuel filter — every 30,000 km
Replace glow plugs — every 100,000 km
Coolant replacement — every 2 years, regardless of mileage
Changes and additions
Introduction
Specifications
Fuel and Exhaust Systems — 2.0 Liter Models
Ignition system — carburetor models 1.8 liters
Automatic transmission
Main gear and drive shafts
Brake system
Body
Electrical system
Troubleshooting
Engine
Cooling system
Fuel and exhaust systems
Clutch
Manual transmission
Automatic transmission
Differential and propeller shaft
Brake system
Suspension and steering
Electrical system
Power unit
Gasoline engines
Petrol Engine Specifications
General description
Technical support
Basic operations possible with the engine in a car
Basic operations requiring engine removal
Engine Removal Method
Engine — removal
Engine disassembly — general description
Engine Auxiliaries — Removal
Engine — complete disassembly
Pallet — removal and installation with engine in car
Engine Mounting Brackets — Replacement
Cylinder head — removal and installation with engine in car
Toothed drive belt — replacement with engine in a car
Engine Components — Inspection and Refurbishment
Cylinder head — overhaul
Engine — assembly
Engine Accessories — Installation
Engine — installation
Engine — preparation for start-up after major repairs
Diesel engines
Diesel Engine Specifications
General description
Compression Test — Description
Basic actions possible with the engine in a car
Basic actions requiring engine removal
Engine Removal Method
Engine — removal
Engine disassembly — general description
Engine Auxiliaries — Removal
Engine — complete disassembly
Pallet — removal and installation with engine in car
Engine Mounting Brackets — Replacement
Cylinder head — removal and installation (engine in a car)
Valve clearances — checking and adjustment
Engine Components — Inspection and Refurbishment
Cylinder head — overhaul
Engine — assembly
Engine Accessories — Installation
Engine — installation
Pre-heating system — description and serviceability check
Engine — preparation for first start after major repair
Cooling system
Cooling system specifications
General description
Routine maintenance
Cooling system — draining fluid
Cooling system — flushing
Cooling system — filling
Antifreeze mixture — general description
Radiator — removal and installation
Radiator — inspection and repair
Thermostat — removal and installation
Thermostat — Test
Thermally Viscous Cooling Fan — Removal and Installation
Water pump — removal and installation
Generator/fan drive belt — replacement and adjustment
Expansion tank — removal and installation
Temperature gauge sensor — removal and installation
Fuel system (gasoline)
Fuel System Specifications
General description of the fuel system
Routine maintenance
Capped Adjustment Screws — General Description
Air Filter and Element — Removal and Installation
Fuel pump (carburetor models) — removal, inspection and installation
Fuel Pump (Fuel Injection Models) — Checking, Removing and Installing
Fuel Filter (Fuel Injection Models) — Replacement
Fuel tank — removal and installation
Fuel level sensor — removal and installation
Diaphragm Damper (Fuel Injected Engines) — Removal and Installation
Accelerator cable — removal, installation and adjustment
Fuel Pedal — Removal and Installation
Carburetor — description
Carburetor — idle speed and mixture adjustment
Carburetor — removal and installation
Carburetor — overhaul
Carburetor Throttle Damper (Automatic Transmission Models) — Adjustment
Carburetor — Adjusting the High Idle Speed
Carburetor Thermo-Time Valve — Check
Intake Manifold Heater Element (Carburetor Models) — Removal, Checking and Installation
Fuel injection system — description
Fuel injection system — precautions
Fuel injection system — idle speed and mixture control
Fuel injection system throttle switch — checking and adjusting
Bosch L3 Jetronic Fuel Injection System Components — Removal and Installation
Bosch Motronic ML4 Fuel Injection System Components — Removal and Installation
Speed control system — general description
Intake manifold — removal and installation
Exhaust manifold — removal and installation
Exhaust system — removal and installation
Fuel system (diesel)
Fuel System Specifications (Diesel)
General description
Glow Plugs — Checking
Fuel system — bleeding
Injectors — removal and installation
Moment of injection start of the high-pressure fuel pump — check
Gas turbine supercharger — general description
Exhaust system — removal and installation
Ignition system
Ignition System Specifications
General description and precautions
Routine maintenance
Breaker distributor cover and distributor runner — removal and installation
Ignition timing angle — check
Octane Cap — Adjustment
Ignition Coil — Testing, Removal and Installation
Inductive pulse sensor — testing, removal and installation
Ignition control unit (models 1.8) — removal and installation
Spark plugs — removal, maintenance and installation
High Voltage Wires — General Description
Troubleshooting — Ignition System
Transmission
Clutch
Clutch specifications
General description
Routine maintenance
Clutch cable — removal and installation
Clutch pedal — removal and installation
Clutch — removal
Clutch — inspection
Release bearing and lever — removal and installation
Clutch — installation
Mechanical gearbox
Manual Transmission Specifications
General description
Checking the oil level in the manual transmission
Manual gearbox — removal and installation
Manual gearbox — disassembly into main blocks
Manual transmission — inspection
Secondary shaft of a manual gearbox — disassembly and assembly
Input shaft of a manual transmission — disassembly and assembly
Rear housing of a manual transmission — disassembly and assembly
Main casing of manual transmission — disassembly and assembly
Manual gearbox — assembly
Manual transmission shift lever — removal, overhaul and installation
Gear Shift Lever Mounting Hanger — Removal and Installation
Gear shift rod for manual transmission — adjustment
Automatic gearbox
Automatic Transmission Specifications
Automatic transmission maintenance
Automatic transmission — removal and installation
Automatic transmission kickdown cable — replacement
Automatic transmission kickdown cable — adjustment
Automatic transmission selector lever rod — adjustment
Automatic transmission selector lever — removal and installation
Inhibitor switch — removal and installation
Cardan shaft
Propeller shaft specifications
General description
Cardan shaft — removal and installation
Central bearing — replacement
Coupling discs — replacement
Final Drive Rear Cover Gasket — Replacement
Drive shafts
Final Drive and Drive Shaft Specifications
General description
Technical support
Final drive mechanism — removal and installation
Final Drive Mechanism Damping Hanger — Replacement
Final Drive Gear Seal — Replacement
Final Drive Differential Bearing Seal — Replacement
Drive shaft — removal and installation
Rubber boots of the drive shaft and outer CV joint — replacement
Chassis
Brake system
Brake system specifications
General description
Technical support
Front Brake Pads — Inspection and Replacement
Rear Brake Pads — Inspection and Replacement
Front Brake Caliper — Removal, Repair and Installation
Rear Brake Caliper — Removal, Repair and Installation
Brake disc — inspection, removal and installation
Handbrake shoes — inspection and replacement
Handbrake cable — removal and installation
Handbrake lever — removal and installation
Master Cylinder — Removal, Adjustment and Installation
Rear Brake Pressure Limiter — Removal and Installation
Hydraulic system — bleeding
Brake pipes and hoses — removal and installation
Vacuum booster — testing
Booster Vacuum Hose and One-Way Valve — Replacement
Vacuum booster — removal and installation
Brake pedal — removal and installation
Anti-lock Braking System (ABS) — Precautions
ABS hydraulic modulator — removal and installation
Electronic ABS control unit — removal and installation
ABS Wheel Speed Sensor — Removal and Installation
ABS Relay — Replacement
Car suspension
Suspension specifications
General description
Technical support
Front suspension strut — removal and installation
Front suspension strut — bulkhead
Lower control arm front suspension — removal and installation
Front lower ball joint — replacement
Front Anti-Roll Bar — Removal and Installation
Front Anti-Roll Bar — Removal and Installation
Steering knuckle — removal and installation
Front Hub and Bearings — Removal and Installation
Front suspension crossmember — removal and installation
Rear shock absorber rod — removal and installation
Rear Trailing Arm — Removal and Installation
Rear Coil Spring — Removal and Installation
Rear Anti-Roll Bar — Removal and Installation
Rear axle (assembled) — removal and installation
Rear suspension crossmember — removal and installation
Rear Suspension Crossmember Installations — Replacement
Rear Hub and Bearing — Removal and Installation
Rear Suspension Leveling System Components — Removal and Installation
Steering
Steering Specifications
General description
Steering wheel — removal and installation
Steering column — removal and installation
Steering column (without height adjustment) — bulkhead
Steering column (with height adjustment) — bulkhead
Steering gear — removal and installation
Steering gear — adjustment on site
Steering rods — removal and installation
Steering idler gear — removal and installation
Power Steering Pump — Removal and Installation
Wheel installation — checking and adjustment
Wheels and tires — care and maintenance
Body
Exterior
Body specifications
General description of the body
Technical support
Body and subframe — maintenance
Repair of minor body damage
Body repair — serious damage
Hood — removal and installation
Trunk lid — removal and installation
Rear door — removal and installation
Rear Door Trim Panel — Removal and Installation
Radiator grille — removal and installation
External door handle — removal and installation
Front Door Lock Cylinder — Removal and Installation
Door lock — removal and installation
Door — removal and installation
Windshield and rear door window/rear window — removal and installation
Front door window — removal and installation
Rear Door Window — Removal and Installation
Outside door mirror — removal and installation
Rear side window — removal and installation
Fixed Rear Door Window — Removal and Installation
Bumpers — removal and installation
Luke — General Information
Interior
Upholstery and carpets — maintenance
Door trim panel — removal and installation
Door speaker — removal and installation
Inner door handle — removal and installation
Headrest guides — removal and installation
Seat belts — removal and installation
Seats — removal and installation
Instrument panel — removal and installation
Center console — removal and installation
Heater instrument panel — removal and installation
Heater radiator — removal and installation
Heater — removal and installation
Heater Fan Motor — Removal and Installation
Central air/heating deflectors — removal, installation and adjustment
Side air and heating deflectors — removal and installation
Air Conditioning System — Description and Warnings
Air Conditioning System Parts — Removal and Installation
Electrical equipment
Power devices
Electrical System Specifications
General description
Technical support
Electrical System — Precautions
Battery — Removal and Installation
Battery — charging
Generator — Testing in a Car
Generator — removal and installation
Generator brushes and voltage regulator — removal and installation
Starter — General Description
Starter — Checking in a Car
Starter — removal and installation
Starter overhaul — general description
Starter Solenoid Relay — Removal and Installation (Starter Removal)
Starter brushes — inspection and removal
Starter — disassembly and assembly
Lighting and appliances
Fuses and relays — general description
Steering Column Combination Switches — Removal and Installation
Panel switches — removal and installation
Interior Light Switch — Removal and Installation
Watch — removal and installation
Cigarette lighter illumination — removal and installation
Heater Control Switch — Removal and Installation
Ignition switch — removal and installation
Instrument panel — removal and installation
Speedometer Drive Cable — Replacement
Sound signal — removal and installation
Lamps — replacement
Front Turn Signal Lamp — Removal and Installation
Headlight — removal and installation
Headlight — beam adjustment
Windscreen wiper blades and arms — removal and installation
Windscreen wiper motor and linkage — removal and installation
Windshield Washer Pump — Removal and Installation
Rear Door Wiper Motor — Removal and Installation
Rear Door Washer Pump — Removal and Installation
Central locking system — general description
On-board computer — general description
Heated Seats — General Description
Control system — general description
Radio equipment — noise reduction (elimination of interference)
Electrical circuits
Electrical Wiring Diagrams — General Description
Conventional symbols on electrical circuits
Electrical connection diagrams for 1987-1988 models
Electrical connection diagrams for 1989-1990 models
Electrical connection diagrams for 1991-1992 models
Electrical connection diagrams for models produced since 1993



Omega B (1993-1999)
General information
User manual
Instrument panel design
Control lamps and switches
Vehicle controls
Instrument cluster
Instrument cluster control indicators
Opening the car
Rear view mirrors
Ignition/Starter Switch
Manual transmission
Automatic transmission
Starting the engine
Releasing the handbrake
Car parking
Multifunctional display
Electronic air conditioning system
Fuses — location and replacement
Replacement of lighting lamps
Lubricants and fluids
Location of components in the engine compartment
Tips for the car owner
Buying a used car
We identify re-punched numbers
Buying an old car, or a mysterious set of numbers and letters
Preparing your car for winter
Tips for Diesel Car Owners
Diesel Engine Maintenance
Diagnostics of diesel engine faults with Bosch fuel equipment
Buying a used diesel engine
Maintenance of diesel engines
Maintenance (gasoline)
Technical specifications
Routine maintenance
After 8000 km or every 6 months
After 16,000 km or every 12 months
After 32,000 km or every 2 years
After 64,000 km or every 4 years
After 112,000 km or every 7 years
Every 2 years regardless of mileage
Maintenance (diesel)
Technical specifications
Routine maintenance
After 7500 km or 6 months
After 15,000 km or 12 months
After 30,000 km or 2 years
Every 2 years regardless of mileage
Power unit
Petrol engine SOHC 2.0 l
Technical specifications
Compression check
Top dead center (TDC) of piston No. 1
Camshaft cover
Crankshaft pulley
Timing Belt Covers
Gas distribution belt
Timing Belt Tensioner and Sprockets
Camshaft oil seal
Camshaft housing and camshaft
Pushers and hydraulic lifters
Cylinder head
Oil pan
Oil pump
Flywheel — removal, inspection and installation
Crankshaft seals — replacement
Engine and gearbox mounts
Petrol engine DOHC 2.0 l
Technical specifications
Compression check
Top dead center (TDC) of piston No. 1
Camshaft cover
Crankshaft pulley
Timing Belt Covers
Gas distribution belt
Belt tensioner, sprockets and idler pulleys
Camshaft oil seals
Camshafts and tappets
Cylinder head
Oil pan
Oil pump
Crankshaft balancing system (engines since 1998)
Flywheel — removal, inspection and installation
Crankshaft seals — replacement
Engine and gearbox mounts
Petrol engines 2.5 and 3.0 l
Technical specifications
Compression check
Top dead center (TDC) of piston No. 1
Camshaft covers
Crankshaft pulley
Timing Belt Covers
Gas distribution belt
Belt tensioner, sprockets and idler pulleys
Camshaft Seals — Replacement
Camshafts and tappets
Cylinder head
Oil pan
Oil pump
Oil radiator
Flywheel and drive disk
Crankshaft oil seals
Engine and gearbox mounts
Repair of gasoline engines
Technical specifications
Compression check
Engine overhaul
Engine diagnostics using a vacuum gauge
Checking the compression in the engine cylinders
Engine Overhaul — Alternatives
Engine accessories
Dismantling the power unit — methods and safety precautions
Removal and installation the engine
Engine overhaul
Cylinder head and valves
Pistons and connecting rods
Crankshaft
Cylinder block
Main and connecting rod bearings
Piston rings
First engine start after overhaul
Diesel engine 2.0 l
Technical specifications
Repair operations on the engine installed in the vehicle
Checking the compression pressure
Top dead center (TDC) of piston No. 1
Valve timing mechanism
Cylinder head cover
Crankshaft pulley
Chain cover — removal and installation
Chain tensioners — removal and installation
Chains and sprockets
Camshafts and tappets
Cylinder head
Oil pan — removal and installation
Oil pump — removal, inspection and installation
Oil radiator — removal and installation
Crankshaft sealing rings
Flywheel — removal, inspection and installation
Powertrain suspension — check
Diesel engine repair 2.0 l
Overhaul of a 2.0 liter diesel engine
Technical specifications
Cylinder head
Pistons and connecting rods — removal, inspection and installation
Crankshaft — removal, inspection and installation
Engine Cylinder Block — Cleaning
Main and connecting rod bearings
Sequence of engine assembly during major repairs
Piston rings — installation
Main bearing working clearances
Working clearances of connecting rod bearings
Starting the engine after major repairs
Diesel engine 2.5 l
Removal and installation the engine
Cylinder head — removal and installation
Camshaft — removal and installation
Compression check
Multi-ribbed V-belt
Oil pan and gasket
Cooling system of a 2.5 liter diesel engine
Radiator — removal and installation
Viscous coupling fan / fan clutch
Cooling pump — removal and installation
Air blower pipe — removal and installation
Cooling and heating
Technical specifications
Radiator — removal and installation
Cooling Fan — Removal and Installation
Thermostat — removal and installation
Coolant pump
Expansion tank — removal and installation
Temperature indicator sensor
Elements of heating and ventilation systems
Heater Radiator — Removal and Installation
Blower Motor and Series Resistor
Air conditioning system — precautions
Elements of the air conditioning system
Elements of the electronic climate control system
Power system (petrol)
Technical specifications
Unleaded petrol
Fuel injection systems
Air filter and air ducts
Accelerator cable — removal and installation
Accelerator pedal — removal and installation
Releasing pressure from the fuel injection system
Fuel pump — removal and installation
Fuel level sensor — removal and installation
Fuel tank — removal and installation
Throttle body
Fuel injection system (2.0 liter engine)
Fuel injection system (2.5 and 3.0 liter engines)
Intake manifold — removal and installation
Exhaust manifold — removal and installation
Multi-flow air supply system
Exhaust gas system
Emission reduction
Emission Control Systems
Technical specifications
Testing of emission control systems
Elements of the exhaust emission control system
Fuel vapor collection system components
Exhaust gas recirculation system components
Elements of the additional air supply system
Catalytic converter
Fuel system (diesel 2.0 l)
General information and precautions
Technical specifications
Air filter and air intake ducts
Accelerator pedal — removal and installation
Filling and bleeding the fuel system
Fuel level sensor — removal and installation
Fuel tank — removal and installation
Checking and adjusting maximum speed
Electrical components of the injection system
High pressure fuel pump
Fuel injection timing
Fuel injectors — removal and installation
Turbocharger — removal and installation
Intake manifold — removal and installation
Exhaust manifold — removal and installation
Fuel system (diesel 2.5 l)
How a diesel engine works
Turbocharger — general information
Exhaust Gas Recirculation System (EGR System)
Preheating device for diesel engines
Pre-glow system / glow plugs
Pre-glow system relay
Removal air from the fuel system
High pressure fuel pump (HPFP)
Injectors — checking, removal and installation
Checking/adjusting the start of injection pump delivery
Intake manifold — removal and installation
Main faults of diesel injection system
Exhaust system of diesel engines
Launch system
Engine Starting System — General Information
Technical specifications
Finding the source of a fault in an electrical system
Battery — removal and installation
Battery charging system
Connecting an auxiliary battery
Generator drive belt
Generator — removal and installation
Engine starting system
Starter — removal and installation
Low Oil Pressure Warning Light Switch
Oil level sensor — removal and installation
Ignition system
General information and verification
Technical specifications
Ignition Distribution Module
Ignition timing angle
Transmission
Clutch
Technical specifications
Hydraulic clutch release drive system
Master cylinder — removal and installation
Slave cylinder — removal and installation
Clutch pedal — removal and installation
Clutch discs — removal and installation
Main faults, their causes and methods of elimination
Mechanical gearbox
Technical specifications
Transmission oil
Gear shift mechanism — adjustment
Gear shift lever
Seals — replacement
Reverse Light Switch
Manual gearbox — removal and installation
Automatic gearbox
Unlocking the gear shift lever
Technical specifications
Transmission fluid — replacement
Gear shift mechanism
Gear shift lever
Seals — replacement
Transmission Fluid Radiator
Electrical components of the transmission control system
Automatic transmission — removal and installation
Drive shafts
Technical specifications
Main gear
Damper bushings of the main transmission
Main Gear Rear Cover Gasket
Main gear pinion seal
Axle shaft bearing seals
Half shaft — removal and installation
Axle shaft boots and outer CV joint
Cardan shaft — removal and installation
Chassis
Brake system
Technical specifications
Front brake linings
Rear brake linings
Front brake caliper
Rear brake caliper
Brake disc — removal and installation
Handbrake brake pads
Handbrake cable — removal and installation
Handbrake lever — removal and installation
Master Brake Cylinder — Removal and Installation
Brake fluid reservoir and fluid level sensor
Bleeding the brake system
Hydraulic tubes and hoses
Vacuum hose and brake booster valve
Vacuum booster — removal and installation
Brake pedal — removal and installation
Anti-lock brakes/traction control
Wheel suspension
Suspension and steering specifications
Front suspension strut
Front wheel alignment
Lower control arm of the front suspension
Ball joint of the lower arm of the front suspension
Front suspension anti-roll bar
Anti-roll bar connecting links
Steering knuckle — removal and installation
Front wheel hub and bearings
Front suspension cross member
Rear suspension shock absorber
Rear suspension arm — removal and installation
Rear suspension springs — removal and installation
Rear suspension anti-roll bar
Rear suspension cross rods
Rear suspension height adjustment system
Rear suspension — removal and installation
Rear suspension cross member
Rear suspension crossmember mounts
Rear wheel hub and bearings
Steering
Steering wheel — removal and installation
Steering column — removal and installation
Steering column lock / ignition lock
Steering gear — removal and installation
Steering rods — removal and installation
Steering knuckle — removal and installation
Power steering system pump
Wheel alignment and steering angles
Body
Exterior
Technical specifications
Maintenance and repair
Repair of minor body damage
Repair of significant body damage
Hinges and locks
Windscreen and fixed glass
Bumpers — removal and installation
Radiator grille — removal and installation
Bonnet and support pillars — removal and installation
Hood Lock Cable — Removal and Installation
Bonnet Lock Spring — Removal and Installation
External rear view mirrors
External body elements
Interior
Seats — removal and installation
Elements of seat belts
Interior trim panels
Center console — removal and installation
Glove compartment — removal and installation
Instrument panel — removal and installation
Doors and windows
Doors — removal and installation
Interior door trim panel
Door handles and locks
Window lifters and glass — removal and installation
Rear side window (station wagon models)
Fuel tank flap lock and lock cable
Trunk lid and support pillars
Trunk lid lock elements
Rear door and support pillars
Rear door lock components
Elements of the central locking system
Electric window lift components
Windscreen and fixed glass
Upper hatch elements
Electrical equipment
Equipment and devices
General information and precautions
Technical specifications
Finding the source of a fault in an electrical system
Fuses and relays
Switches — removal and installation
External lighting bulbs
Interior Light Bulbs
External lighting fixtures
Headlight adjustment
Instrument cluster — removal and installation
Instrument cluster elements
Clock / Multifunctional display
Lighter — removal and installation
Xenon headlight adjustment system
Horns of the sound signal
Windscreen wiper arms — removal and installation
Engine, windscreen wiper connection mechanism
Rear window wiper motor
Windscreen/Rearscreen/Headlamp washers
Radio / Cassette / CD player
Speakers — removal and installation
Radio antenna — removal and installation
Anti-theft alarm system and engine immobilizer
Air bag system
Elements of the airbag system
Cruise control system components
Wiring diagrams (early)
Explanations for electrical circuits
Chain index 100-1199 (early models)
Keys to early model schematics
Electrical circuit diagrams 100-199
Electrical circuit diagrams 200-299
Electrical circuit diagrams 300-399
Electrical circuit diagrams 400-499
Electrical circuit diagrams 500-599
Electrical circuit diagrams 600-699
Electrical circuit diagrams 700-799
Wiring diagrams (late)
Chain index 100-1699 (late models)
Keys to late model schematics
Electrical circuit diagrams 100-199
Electrical circuit diagrams 200-299
Electrical circuit diagrams 300-399
Electrical circuit diagrams 400-499
Electrical circuit diagrams 500-599
Electrical circuit diagrams 600-699
Electrical circuit diagrams 700-799
Electrical circuit diagrams 800-899
Electrical circuit diagrams 900-999



Omega B2 (1999-2003)
General information
User manual
Signal lights and button designations
Key numbers and codes
Unlocking doors
Seat adjustment
Headrests — height and tilt adjustment, locking
Steering wheel height adjustment
Adjust the seat position according to your height
Adjusting the interior rearview mirror
Electrically adjustable exterior rear view mirrors
Ignition switch and key positions in it
Heated rear window and outside rearview mirrors
Cleaning fogged or iced glass
Controls and monitoring devices on the instrument panel
Lighting and light signaling switch
Windscreen wiper switch under the steering wheel
Windshield and headlight washers
Rear window wiper and washer
Gear shifting. Cars with manual transmission
Gear shifting. Cars with automatic transmission
Starting the engine. Cars with gasoline engines
Starting the engine. Diesel vehicles
Stopping and parking a car
Instrument panel
Front seat occupant recognition system
Tachometer and speedometer
Coolant temperature gauge
Fuel reserve indicator
Information display
Electronic air conditioning system
Interior air conditioning. Deflectors
Air recirculation mode in the cabin
General information about the air conditioning system
Location and purpose of fuses
Checking the level and filling the engine oil
Fuel filter. Cars with a diesel engine
Fluid tanks in the engine compartment
Security alarm
Maintenance
Car care
Starting the engine using an auxiliary battery
Towing a car
Jacking up a car
Maintenance plan
Maintenance — works
Fuel Filter — Condensate Removal/Replacement
V-belt — check
Timing belt of the gas distribution mechanism-check
Coolant — Check
Coolant — Checking Concentration
Exhaust system — visual leak check
Replacement Air Filter Element — Replacement
Spark plugs — removal, inspection and installation
Gearbox and final drive
Brakes. Tires. Wheels
Brake fluid — checking the level
Brake fluid — replacement
Wheels and tires
Front axle and steering
Body. Interior equipment
Troubleshooting
Identifying and troubleshooting engine faults
Identifying and troubleshooting engine lubrication system faults
Identifying and troubleshooting engine cooling system faults
Identifying and troubleshooting gasoline injection system faults
Identifying and troubleshooting diesel engine fuel system faults
Identifying and troubleshooting brake system faults
Identifying and troubleshooting clutch problems
Identifying and troubleshooting battery problems
List of starter faults and their elimination
Identifying and troubleshooting generator faults
Identifying and troubleshooting windshield wiper problems
Power unit
Petrol 4-cylinder
Petrol 4-cylinder engine specifications
General description of the engine
Compression Test — Description
Setting the piston of cylinder No. 1 to top dead center (TDC)
Camshaft Cover — Removal and Installation
Crankshaft pulley — removal and installation
Timing Belt Covers — Removal and Installation
Toothed drive belt — removal and installation
Timing Belt Sprockets, Tensioner and Idler Pulleys — Removal and Installation
Camshaft Seals — Replacement
Camshafts and hydraulic tappets — removal, inspection and installation
Cylinder head — removal and installation
Pallet — removal and installation
Oil pump — removal, overhaul and installation
Crankshaft balancer unit — removal, installation and adjustment
Flywheel/Drive Disc — Removal, Inspection and Installation
Crankshaft seals — replacement
Engine/Transmission Mounts — Inspection and Replacement
Petrol 6-cylinder
Petrol 6-cylinder engine specifications
General description of the engine
Compression Test — Description
Setting the piston of cylinder No. 1 to top dead center (TDC)
Valve covers — removal and installation
Crankshaft pulley — removal and installation
Timing Belt Covers — Removal and Installation
Toothed drive belt — removal and installation
Sprockets, tensioner and timing belt guide pulleys — removal and installation
Camshaft Seals — Replacement
Camshafts and hydraulic tappets — removal, inspection and installation
Cylinder head — removal and installation
Pallet — removal and installation
Oil pump — removal, overhaul and installation
Engine Oil Cooler — Removal and Installation
Flywheel/Drive Disc — Removal, Inspection and Installation
Crankshaft seals — replacement
Engine/Transmission Mounts — Inspection and Replacement
Engine overhaul
General description
Engine overhaul — general description
Engine Removal — Methods and Precautions
Engine — removal and installation
Engine overhaul — disassembly sequence
Cylinder head — dismantling
Cylinder head and valves — cleaning and inspection
Cylinder head — assembly
Piston/Connecting Rod Assembly — Removal
Crankshaft — removal
Cylinder block — cleaning and inspection
Piston/Connecting Rod Assembly — Inspection
Crankshaft — inspection
Main and connecting rod bearings — inspection
Engine — Assembly Sequence
Piston rings — installation
Crankshaft — installation and checking of main bearing clearance
Piston/Connecting Rod Assemblies — Installing and Checking Connecting Rod Bearing Clearance
Engine — preparation for starting after overhaul
Diesel engines 2.0 l
2.0 litre diesel engine specifications
Engine — removal and installation
Cylinder Head Cover — Removal and Installation
TDC of piston of cylinder No. 1 — installation
Cylinder head — removal and installation
Cylinder head — overhaul
Camshaft — Removal and Installation
Vacuum pump — removal and installation
Timing Gear Housing — Removal and Installation
Oil pump — removal and installation
Crankshaft — removal and installation
Crankshaft — checks
Connecting rod and piston group — removal and installation
Flywheel — removal and installation
Rear Crankshaft Oil Seal — Removal and Installation
Torsional vibration damping unit — removal and installation
V-ribbed auxiliary drive belt — removal and installation
Oil pan — removal and installation
Compression — check
Diesel engines 2.5 l
2.5 liter diesel engine specifications
Engine — removal and installation
Cylinder Head Cover — Removal and Installation
TDC of piston of cylinder No. 1 — installation
Cylinder head — removal and installation
Cylinder head — overhaul
Vacuum pump — removal and installation
Crankshaft — removal and installation
Connecting rod and piston group — removal and installation
Flywheel — removal and installation
Front Crankshaft Oil Seal — Replacement
Rear Crankshaft Oil Seal — Replacement
V-ribbed auxiliary drive belt — removal and installation
Oil pan — removal and installation
Oil pump — removal and installation
Compression — check
Cooling and heating
General information and device
Coolant — draining, filling and checking concentration
Thermostat — removal and installation
Radiator — removal and installation
Radiator Fan Thermal Switch — Check
Radiator Fan Motor — Removal and Installation
Viscous coupling — removal and installation
Water pump — removal and installation
Heating and air conditioning system
Heater Switch Block — Removal and Installation
Additional fan resistors — removal and installation
Air distribution flap actuator diaphragm valve — removal and installation
Electric motor of the interior blower — removal and installation
Air conditioner
Injection system (gasoline)
General information about the fuel injection system
Fuel injectors — checking, removal and installation
Lambda probe — removal and installation
Fuel system (diesel)
How a diesel engine works
Preheater unit — checking, removing and installing glow plugs
Preheater Block Relay — Removal and Installation
Fuel Shut-Off Valve — Checking, Removing and Installing
High pressure fuel lines and injectors — removal and installation
Start of injection pump supply — checking and adjustment
Intake manifold — removal and installation
Fuel system
General description of the fuel system
Fuel pump — removal and installation
Fuel level sensor — removal and installation
Accelerator cable — removal, installation and adjustment
Air filter — removal and installation
Intake Air Storage Chamber — Removal and Installation
Intake manifold — removal and installation
Exhaust system
General information
Exhaust system — removal and installation
Rear muffler — replacement
Catalyst
Ignition system
Ignition System Specifications
Ignition system — general description
Ignition system — check
Ignition module — removal and installation
Ignition timing angle — checking and adjustment
Transmission
Clutch
Clutch specifications
General description of the clutch
Clutch hydraulic system — bleeding
Master Cylinder — Removal and Installation
Clutch release cylinder — removal and installation
Clutch pedal — removal and installation
Clutch assembly — removal, inspection and installation
Mechanical gearbox
Manual Transmission Specifications
General description of mechanical transmission
Transmission oil — draining, filling the block and measuring the level
Gear shift rod — adjustment
Gear shift rod — removal and installation
Seals — replacement
Reverse Light Switch — Checking Serviceability, Removal and Installation
Transmission — removal and installation
Transmission Overhaul — General Description
Automatic gearbox
Automatic Transmission Specifications
General description of automatic transmission
Transmission fluid — draining and filling the block
Driving mode switching rod — adjustment
Shift Rod — Removal and Installation
Assembly of the drive mode selection lever — removal and installation
Seals — replacement
Transmission Fluid Cooler — General Description
Electrical components of the transmission control system — removal and installation
Automatic transmission — removal and installation
Automatic Transmission Overhaul — General Description
Main gear and shafts
Final Drive and Drive Shaft Specifications
General description of the main transmission and drive shafts
Main gear unit — removal and installation
Main gear unit — filling and checking oil level
Damper bushings of the main transmission block — replacement
Final Drive Unit Rear Cover Gasket — Replacement
Main gear seal — replacement
Differential Bearing Seal — Replacement
Drive shaft — removal and installation
Rubber protective boots of the drive shaft and its outer CV joint — replacement
Cardan shaft — removal and installation
Central bearing of the propeller shaft — replacement
Cardan shaft elastic joints — replacement
Chassis
Brake system
Brake system specifications
General description of the braking system
Front Brake Pads — Checking, Removing and Installing
Rear Brake Pads — Checking and Replacing
Front Brake Caliper — Removal, Overhaul and Installation
Rear wheel brake caliper — removal, overhaul and installation
Brake disc — inspection, removal and installation
Parking brake shoes — inspection, removal and installation
Parking brake lever and cables — removal and installation
Master Brake Cylinder — Removal and Installation
Expansion tank and brake fluid level sensor — removal and installation
Brake system — bleeding
Brake hoses — removal and installation
Brake booster — inspection, removal and installation
Vacuum Booster Hose and Its One-Way Valve — Replacement
Brake pedal — removal and installation
ABS and Traction Control — General Description
ABS and Traction Control System — Removal and Installation of Components
Car suspension
Suspension specifications
General description of the suspension
Front suspension strut — removal and installation
Front wheel alignment — adjustment
Lower suspension arm — removal and installation
Front lower ball joint — replacement
Front Anti-Roll Bar — Removal and Installation
Front anti-roll bar vertical link — removal and installation
Steering knuckle — removal and installation
Front Wheel Hub and Bearings — Removal and Installation
Engine subframe — removal and installation
Rear shock absorber — removal and installation
Rear Trailing Arm — Removal and Installation
Rear leaf spring — removal and installation
Rear Anti-Roll Bar — Removal and Installation
Rear Suspension Reactive Rod — Removal and Installation
Rear Ride Control System — Component Removal and Installation
Rear suspension assembly — removal and installation
Rear suspension crossmember — removal and installation
Rear Crossmember Fasteners — Replacement
Rear Wheel Hub and Bearing — Removal and Installation
Steering
Steering Specifications
Steering wheel — removal and installation
Steering column — removal and installation
Ignition/Steering Column Lock — Removal and Installation
Steering gear — removal and installation
Steering rods — removal and installation
Pendulum arm — removal and installation
Power steering pump — removal and installation
Wheel alignment angles — checking and adjusting
Body
Body elements
General description of the body
Front bumper — removal and installation
Front bumper trim — removal and installation
Front crossmember — removal and installation
Rear bumper — removal and installation
Fairing — removal and installation
Front fenders — removal and installation
Hood — removal and installation
Door — removal, installation and adjustment
Door trim — removal and installation
Door glass — removal, installation and adjustment
Door handles — removal and installation
Door lock — removal and installation
Center console — removal and installation
Rear Tailgate — Removal and Installation
Electrical equipment
Equipment and devices
Checking the light bulbs
Checking Electric Motors
Light bulb and motor switches — checking
Sensor switches — checking
Relay — check
Turn signal flasher — check
Windscreen wiper motor — check
Rear Window Defogger — Check
Stop light — check
Central locking — device
Battery — Removal and Installation
Generator — device
Starter — removal and installation
Lighting fixtures — replacing lamps
Instrument cluster — removal and installation
Instrument cluster indicator lights — replacement
Electrical circuits
Reading electrical diagrams
Scheme 1. Cars with Y22DTH engine
Scheme 2. Cars with Y25DT engine
Scheme 3. Cars with Y25DT engine (supplement to scheme 2)
Scheme 4. Cars with Z22XE engine
Scheme 5. Cars with Z22XE engine (supplement to scheme 4)
Scheme 6. Cars with Y26SE/Y32SE engine
Diagram 7. Cars with Y26SE/Y32SE engine (supplement to diagram 6)
Scheme 8. Cooling and ventilation system. Cars with Y22DTH engine
Scheme 9. Cooling system. Cars with Y25DT engine
Scheme 10. Cooling and ventilation system. Cars with engine Y26SE/Y32SE
Scheme 11. Cooling system. Cars with Z22XE engine
Scheme 12. Cars with Y25DT engine and automatic transmission
Scheme 13. Cars with automatic transmission and automatic transmission switch
Diagram 14. Anti-lock braking system (ABS)
Scheme 15. ABS and ESP
Scheme 16. Cars with ABS and traction control system
Scheme 17. Climate control
Scheme 18. Airbags
Scheme 19. Central lock
Scheme 20. Window lifters
Scheme 21. Instrument panel
Scheme 22. Towing hitch, reversing lights, fog lights...
Scheme 23. Parking lights, brake lights, direction indicators
Scheme 24. Horn, windshield wiper (without rain sensor), headlight washer



Vectra A (1988-1995, petrol)
General information
User manual
Your car key
Steering wheel height adjustment
Seat adjustment
Seat belt
Adjusting the rear view mirrors
Ignition switch
Description of the dashboard
Control lamps in the instrument cluster
Manual transmission
Automatic transmission
Pre-departure checks
Starting the engines
Putting the vehicle in the parking lot
Description of devices
Control lamps
Liquid crystal display
Power-up control check
On-board computer
Passenger safety
Safety accessories
Use of seat belts
External lighting
Interior lighting
Windows doors
Sliding sunroof
Heating and ventilation system
Air conditioner device and control
Automatic transmission control
Maintenance
Dimensions and weight of the car
Lubricants and fluids
Service Specifications
Vehicle identification
Weekly checks
Engine oil level
Coolant level
Windscreen washer fluid level
Brake fluid level
Power Steering Fluid Level
View of the engine compartment of the 1989 1.6 L model (16 SV engine)
Engine compartment view of a 1991 Cavalier 3L (C16 NZ engine)
Engine compartment view of the 1989 2.0 SRi model (20 SEH engine)
Engine bay view of a 1990 2000 GSI (20 XEJ engine)
Maintenance schedule
General description of maintenance
Intensive service
Engine oil and filter — replacement
Hoses — checking the condition and tightness of their fastenings
Steering and suspension — check
Checking the drive shaft protective cover
Checking the transmission fluid level
Inspection and cleaning of the radiator
Adjusting the idle speed and mixture
Throttle linkage maintenance
Checking the exhaust system
Checking the electrical wiring
Ignition timing angle
Replacing brake fluid
Checking brake pads
Checking the handbrake linkage
Checking the Power Steering Fluid
Checking the Power Steering Pump Drive Belt
Checking the rear suspension level control system
Body check
Checking locks and hinges
Checking the alternator V-belt
Headlight alignment
Battery in door lock key — replacement
Road test
Replacing the coolant
Air Filter Element — Replacement
Checking the intake air temperature control (carbureted models only)
Replacing the fuel filter
Replacing the spark plug (SOHC engines)
Breaker distributor cover and high voltage wires check
Checking the clutch cable
Checking manual transmission fluid
Checking the automatic transmission
Replacing the toothed drive belt
Replacing the spark plug (DOHC engines)
Transmission fluid replacement
Power unit
SOHC engine
Single Overhead Cam Engine Specifications
General Description of SOHC Engine
Crankcase ventilation system — description and maintenance
Compression Test — Description
Basic operations performed without removing the engine from the vehicle
Basic operations requiring engine removal
Engine Removal Method
Engine — removal and installation (transmission remains in the car)
Engine and transmission — removal, separation, connection and installation
Engine and Transmission Mounting Brackets — Replacement
Disassembling and assembling the engine — general description
Toothed drive belt and sprockets (without automatic tensioning mechanism) — removal, installation and adjustment
Toothed drive belt and tensioner (1.4 and 1.6L models, except C16NZ2) — removal, installation and adjustment
Timing Belt Cover Opening, 1.4L and 1.6L Models — General Description
Toothed drive belt and tensioner mechanism (C16NZ2, 1.8 and 2.0 l) — removal, installation and adjustment
Front camshaft oil seal — removal and installation
Rear camshaft oil seal — removal and installation
Camshaft housing and camshaft — general description
Camshaft housing and camshaft — disassembly, inspection and assembly
Camshafts, repair dimensions for models C16NZ2, 1.8 and 2.0 liters — general description
Cylinder head — removal and installation (engine in a car)
Cylinder head — removal and installation (engine removed)
Cylinder head — disassembly and assembly
Cylinder head — inspection and restoration
Hydraulic valve lifters — inspection
Flywheel — removal, inspection and installation
Drive Disc (Automatic Transmission) — Removal and Installation
Front Crankshaft Oil Seal — Replacement
Rear Crankshaft Oil Seal — Replacement
Pallet — removal and installation
Oil pump — removal and installation
Oil pump — disassembly, inspection and assembly
Pistons and connecting rods — removal and installation
Pistons and connecting rods — inspection and maintenance
Crankshaft and bearings — removal and installation
Crankshaft and bearings — inspection
Cylinder Block and Channels — Inspection and Maintenance
Inspection and Maintenance — General Description
Preparing for launch after major repairs
Engine fault detection
DOHC engine
General characteristics of the DOHC engine
Engine — removal and installation
DOHC Engine Specifications
Engine/Transmission Mounts — Replacement
Toothed drive belt, sprockets, tensioner pulley and idler pulley — removal, installation and adjustment
Toothed drive belt with automatic regulator — removal, installation and adjustment
Front camshaft oil seal — removal and installation
Camshafts — removal, inspection and installation
Cylinder head — removal and installation (engine in a car)
Cylinder head — removal and installation (engine removed from vehicle)
Cylinder head — disassembly and assembly
Valve lifters — general characteristics
Front Crankshaft Oil Seal — Replacement
Pallet — removal and installation
Oil pump — removal and installation
Oil radiator — removal and installation
Cooling and ventilation
Cooling and ventilation system specifications
General description of the cooling and ventilation system
Cooling system — draining liquid
Cooling system — flushing
Cooling system — filling
Coolant — General Information
Radiator (manual transmission) — removal and installation
Radiator (automatic transmission) — removal and installation
Radiator — inspection and cleaning
Thermostat — removal and installation
Thermostat — checking operation
Coolant pump — removal and installation
Fan — removal and installation
Expansion tank and coolant level sensor — removal and installation
Temperature gauge sensor — removal and installation
Fan Switch — Removal and Installation
Heater Control Panel — Removal and Installation
Heater — removal and installation
Heater Blower Motor — Removal and Installation
Panel deflectors — removal and installation
Troubleshooting the cooling system
Fuel system (carburetor)
Carburetor fuel system specifications
General description of the carburetor fuel system
Fuel system — precautions
Air filter — removal and installation
Inlet Air Temperature Control — Description and Testing
Fuel pump — check
Fuel pump — removal and installation
Fuel tank — removal, inspection and installation
Fuel level sensor unit — removal and installation
Fuel vapor separator (1.6 and 1.8 liter models) — removal and installation
Gas pedal — removal and installation
Throttle Cable — Removal, Installation and Adjustment
Carburetor — General Description
Carburetor — removal, overhaul and installation
Idle speed and mixture — adjustment
Needle and float — removal, inspection and installation
Secondary Throttle Valve Vacuum Diaphragm — Checking, Removing and Installing
Economizer valve diaphragm — removal and installation
Accelerator pump — checking, removal and installation
Automatic air damper unit — removal, installation and adjustment
Automatic Air Damper Pull-Down Vacuum Blocks — Removal, Installation and Adjustment
Carburetor filter — removal and installation
Throttle Damper (Automatic Transmission Models) — Adjustment
Throttle Position Sensor (Automatic Transmission Models) — Removal and Installation
Idle Speed Increase Valve
Idle Air Cutoff Valve (1.8L Models) — Description and Testing
Intake manifold — removal and installation
Fuel system (injector)
Fuel injection system specifications
General description of the injection fuel system
Fuel injection system — precautions
System Check — General Description
Air filter — removal and installation
Air Block — Removal and Installation
Air Temperature Control — Description and Testing
Air Temperature Sensor (Late Models) — Removal and Installation
Fuel System Depressurization — General Description
Fuel filter (models with fuel pump) — removal and installation
Fuel filter (models with fuel pump) — removal and installation
Fuel transfer pump-check
Fuel pump — removal and installation
Fuel pump — removal and installation
Fuel Pump Relay — Replacement
Fuel tank filler pipe — removal and installation
Fuel tank — removal and installation
Fuel tank sensor — removal and installation
Fuel Flow Arrester — Removal and Installation
Throttle cable — removal, installation and adjustment
Idle mixture — checking and adjustment
Fuel pressure regulator — removal and installation
Idle Speed Regulator — Removal and Installation
Throttle Position Sensor — Removal and Installation
Throttle Potentiometer — Removal and Installation
Air Flow Meter (if equipped) — Removal and Installation
Air mass meter (if equipped) — removal and installation
Air Mass Flow Meter Tape — Removal and Installation
Fuel injectors (except Multec system) — removal and installation
Fuel injector (Multec system) — removal and installation
Fuel injector (Multec system) — check
Throttle body (except Multec system) — removal and installation
Throttle Body (Multec System) — Removal and Installation
Idle Air Control Stepper Motor — Removal and Installation
Throttle Potentiometer — Removal and Installation
Electronic Control Unit (ECU) — Removal and Installation
Knock Sensor and Module (X16 SZ Models) — Removal and Installation
Knock sensor (Simtec system) — removal and installation
Intake Manifold (SOHC Non-Multec) — Removal and Installation
Intake Manifold (SOHC Engine with Multec) — Removal and Installation
Intake Manifold (DOHC Models) — Removal and Installation
Exhaust converter
Exhaust Neutralizer Specifications
Emission Control Systems — General Description
Exhaust Gas Recirculation (EGR) System — General Description
EGR Valve (Models with Multec System) — Testing, Removal and Installation
Exhaust Gas Recirculation Valve (Simtec System) — Checking, Removing and Installing
Exhaust Gas Recirculation Unit (X16 SZ Models) — Removal and Installation
Assembly of the toxicity neutralization system pump (Simtec system) — removal and installation
Emission Control System Shut-Off Valve — Removal, Inspection and Installation
Emission Control System Shut-Off Valve — Removal and Installation
Emission Control System Tube and One-Way Valve — Removal and Installation
Catalytic Converter — Description and Precautions
Carbon filter — removal and installation
Oxygen Sensor (Catalytic Converter Models) — Removal and Installation
Exhaust manifold — removal and installation
Exhaust system — inspection, removal and installation
Detecting faults in fuel and exhaust systems
Transmission
Clutch
Clutch specifications
General description of the clutch
Clutch cable — removal and installation
Clutch cable — adjustment
Clutch pedal — removal and installation
Clutch (engine and transmission are located in the engine compartment) — removal, inspection and installation
Clutch (transmission removed) — removal and installation
Release bearing and lever — removal and installation
Troubleshooting Clutch Problems
Mechanical gearbox
Manual Transmission Specifications
General description of mechanical transmission
Gear Selector Rod — Adjustment
Gear Shift Lever Housing Assembly — Removal and Installation
Gear Selector Rod — Removal and Installation
Gear Shift Lever — Removal and Installation
Gear Shift Lever Boot — Removal and Installation
Differential Bearing Seals — Removal and Installation
Input shaft seal (clutch) — removal and installation
Transmission — removal and installation (engine remains in the car)
Transmission Overhaul — General Description
Differential bulkhead — general description
Speedometer drive — removal and installation
Reverse Light Switch — Removal and Installation
Troubleshooting a Manual Transmission
Automatic gearbox
Automatic Transmission Specifications
General description of automatic transmission
Transmission fluid — replacement
Downshift mechanism — adjustment
Downshift mechanism — removal and installation
Starter interlock — removal and installation
Gear Shift Cable — Adjustment
Gear Shift Cable — Removal and Installation
Driving mode selection lever — removal and installation
Central control panel — removal and installation
Submode switches — removal and installation
Electronic Control Unit (ECU) — Removal and Installation
Driving Mode Selector Panel Illumination Lamp — Replacement
Auxiliary Transmission Fluid Cooler Hoses and Tubes — General Specifications
Differential seals — replacement
Transmission Fluid Temperature Sensor — Removal and Installation
Input/Output Shaft Speed Sensors — Removal and Installation
Transmission — removal and installation
Troubleshooting Automatic Transmissions
Drive shafts
Drive shaft specifications
General description of drive shafts
Drive shaft — removal and installation
Intermediate shaft — removal, overhaul and installation
Drive shaft CV joint — replacement
Protective cover of CV joint — replacement
Troubleshooting drive shafts
Chassis
Brake system
Brake system specifications
General description of the braking system
Anti-lock braking system (ABS) — general description
Brake hydraulic system — bleeding
Front brake pads — inspection, removal and installation
Rear Disc Brake Pads — Inspection, Removal and Installation
Rear brake shoes (drum brakes) — inspection, removal and installation
Handbrake pads (rear disc brakes) — inspection, removal and installation
Front Brake Caliper — Removal, Overhaul and Installation
Rear Disc Brake Caliper — Removal, Overhaul and Installation
Brake disc — inspection, removal and installation
Brake drum — removal, inspection and installation
Rear Wheel Cylinder (Drum Brakes) — Removal, Overhaul and Installation
Rear Brake Shield — Removal and Installation
Front Brake Disc Guard — Removal and Installation
Master Cylinder — Removal and Installation
Master Cylinder (Non ABS Models) — Overhaul
Master Cylinder (ABS Models) — General Description
Vacuum booster — description and testing of operation
Vacuum booster — removal and installation
ABS hydraulic modulator — removal and installation
ABS Sensor Mounted on Wheel — Removal and Installation
ABS control unit — removal and installation
ABS Relay (ABS-2E System Only) — Removal and Installation
Pressure Regulating Valves — Removal and Installation
Brake pipes and hoses — general description, removal and installation
Handbrake — adjustment
Handbrake cable — removal and installation
Handbrake lever — removal and installation
Detecting brake system faults
Car suspension
Suspension specifications
General description of the suspension
Front Wheel Bearing — Replacement
Engine subframe — removal and installation
Front suspension strut — removal, overhaul and installation
Lower control arm front suspension — removal and installation
Front Lower Arm Bushings — Replacement
Ball joint of the lower arm of the front suspension — removal and installation
Front Anti-Roll Bar — Removal and Installation
Front Anti-Roll Bar Bushings — Replacement
Rear Wheel Bearing (SOHC Models) — Adjustment
Rear Wheel Bearing (SOHC Models, Pre-Mid 1993) — Replacement
Hub and rear wheel bearings (since mid-1993) — removal and installation
Rear Wheel Hub (SOHC Models) — Removal and Installation
Rear shock absorber — removal and installation
Rear shock absorber rubber pads — replacement
Rear suspension coil spring (single overhead camshaft (SOHC) models). — removal and installation
Rear suspension longitudinal arm assembly (single overhead camshaft (SOHC) models) — removal and installation
Rear Anti-Roll Bar (SOHC Models) — Removal and Installation
Rear Trailing Arm Bushings (SOHC Models) — Replacement
Rear Suspension Pivot Pin (SOHC Models) — Removal and Installation
Rear Suspension Rigidity Control System — Adjustment
Rear Ride Control Components — Removal and Installation
Rear Wheel Bearing (DOHC Models) — Replacement
Rear Wheel Hub (DOHC Models) — Removal and Installation
Rear Suspension Coil Spring (DOHC Models) — Removal and Installation
Rear Suspension Assembly — Removal and Installation (DOHC Models)
Rear Suspension Tail Arm (DOHC Models) — Removal and Installation
Rear Suspension Crossmember (DOHC Models) — Removal and Installation
Rear Anti-Roll Bar (DOHC Models) — Removal and Installation
Troubleshooting suspension and steering
Steering
Steering Specifications
Steering wheel — removal and installation
Steering wheel — centering
Flexible coupling of the steering gear shaft — replacement
Steering column — removal and installation
Steering column — bulkhead
Steering damper — removal and installation
Steering Gear Guards — Replacement
Steering gear assembly (without power steering) — removal, overhaul and installation
Steering gear assembly (with power steering) — removal, overhaul and installation
Power steering hydraulic line — bleeding
Power Steering Pump — Removal and Installation
Power Steering Hydraulic Reservoir — Removal and Installation
Power Steering Fluid Cooling Pipes (Where Used) — Removal and Installation
Tie Rod End — Removal and Installation
Steering rod — removal and installation
Front Wheel Alignment Angles — General Characteristics
Body
Body elements
Body specifications
General description of the body
External mirror — removal, adjustment and installation
Interior Trim Components — Removal and Installation
Seats (without belt tensioner) — removal and installation
Front seats (with belt tensioner) — removal and installation
Electrical equipment
Power devices
Power Equipment Specifications
Electrical system — general description
Ignition system — general description
Electrical System — Precautions
Checking the ignition system — general description
Battery — Checking and Charging
Battery — Removal and Installation
Generator — description
Generator — removal and installation
Generator — check
Generator brushes — removal, inspection and installation
Generator Drive Belt — Removal, Installation and Adjustment
Starter — General Description
Starter — check
Starter — removal and installation
Starter — overhaul
Ignition coil — removal, inspection and installation
Breaker Cover and Distributor Runner — Removal and Installation
Distributor (models with one overhead camshaft) — removal and installation
Distributor (models with two overhead camshafts) — removal and installation
Distributor — disassembly, inspection and assembly
Ignition timing — checking and adjustment
Ignition timing — adjustment for use with unleaded petrol
Electronic modules — removal and installation
MSTS-i Components — Removal and Installation
Motronic System Components — Removal and Installation
DIS module — removal and installation
Camshaft phase sensor (engine C20 XE) — removal and installation
Troubleshooting the electrical system
Equipment and devices
Electrical System Specifications
General description and precautions
Electrical Troubleshooting — General Description
Fuses and Relays — General Description
Ignition switch — removal and installation
Light/Turn Signal Switch — Removal and Installation
Windscreen Washer/Wiper Switch — Removal and Installation
Dashboard Switches — Removal and Installation
Electric outside mirror adjuster — removal and installation
Electric sunroof switch — removal and installation
Car interior light switch that turns on when doors are opened — removal and installation
Luggage compartment light switch — removal and installation
Brake light switch — removal and installation
Handbrake indicator light switch — removal and installation
Oil Pressure Warning Light Switch — Removal and Installation
Cigarette lighter illumination — removal and installation
Watch — removal and installation
Heated Front Seats — General Description
Instrument panel — removal and installation
Instrument cluster components — removal and installation
On-board computer components — removal and installation
Control system components — removal and installation
Horn(s) — Removal and Installation
Interior Light — Removal and Installation
Car Interior Lights — Replacement
Headlight unit — removal and installation
Headlight Angle Adjustment Motor — Removal and Installation
Headlights — adjustment
Headlight dimming system — general characteristics, removal and installation
Front turn signal light — removal and installation
Side repeater light — removal and installation
Front fog light — removal, installation and adjustment
Rear Light Assembly — Removal and Installation
License Plate Light — Removal and Installation
External Incandescent Light Bulbs — Replacement
Windscreen wiper blades — replacement
Windscreen wiper arms — removal and installation
Washer Jets — Removal and Installation
Windscreen wiper motor and linkage — removal and installation
Rear Up Door Wiper Motor — Removal and Installation
Headlight wiper motor — removal and installation
Washer reservoir — removal and installation
Washer pump — removal and installation
Headlight Washer Fluid One-Way Valve — Removal and Installation
Power Window Components — Removal and Installation
Electric window lifter control tool-programming
Central door locking components — removal and installation
Antenna — removal and installation
Electrically controlled antenna — removal and installation
Loudspeakers — Removal and Installation
Radio — removal and installation
Sunroof Motor — Removal and Installation
Speedometer Drive Cable — Removal and Installation
Anti-theft alarm — general characteristics
Anti-theft alarm components — removal and installation
Air cushion — general characteristics
Air bag unit, driver side — removal and installation
Steering wheel (with air cushion) — removal and installation
Air bag connection block — removal and installation
Air bag unit, passenger side — removal and installation
Bracket, passenger air bag unit — removal and installation
Airbag control unit — removal and installation
Electrical circuits
Electrical Wiring Diagrams — General Characteristics
Explanation of abbreviations used in electrical wiring diagrams
Electrical Wiring Diagram for Models Since 1989
Wiring diagram key for 1989 and later models
Electrical Wiring Diagram for Models Since 1991
Wiring diagram key for 1991 and later models
Electrical Wiring Diagram for Models Since 1992
Wiring diagram key for 1992 and later models



Vectra A (1988-1995)
Power unit
Engine repair
Engine specifications
Removal and installation the engine
Removal and installation the timing belt
Checking and adjusting the timing belt tension
Installing the timing belt tensioner
Removal and installation a vacuum pump
Removal and installation the cylinder head
Checking the cylinder head and cylinder block for straightness
Replacing the camshaft housing. Removing and installing the camshaft
Checking and adjusting valve timing
Cleaning the oil separator of the camshaft housing cover
Checking and adjusting valve clearances
Removal and installation valves
Replacing valve stem seals
Valve grinding
Lapping valves
Checking the valve guide clearance
Checking the valve guides
Compression check
Removal, installation and tensioning the V-belt
Removal, checking, installing and tensioning the poly V-belt
Visual search for oil leaks
Checking the V-belt
Towing a car
Engine malfunctions
Ignition system
General information
Safety precautions when working with electronic ignition systems
Checking the ignition coil
Operation of the variable ignition system
Removal and installation the ignition distributor
Checking and adjusting ignition timing
Adaptation of the ignition system to the octane number of the fuel used
Spark plugs
Removal, checking and installation spark plugs
Ignition System Error Codes
Ignition system malfunctions
Lubrication system
General information
Operation of the lubrication system
Measuring oil temperature
Measuring oil pressure
Removal and installation the oil pan
Removal and installation the oil pump
Removal and installation the safety valve
Maintenance of the lubrication system
Cooling system
Operation of the cooling system
Replacing the coolant
Removal, checking and installation the thermostat
Checking the cooling system
Removal and installation the radiator
Removal and installation the coolant pump
Removal and installation the fan motor
Cooling liquid
Visual leak detection
Checking the coolant level
Checking the density of the coolant
Injection system
Technical data of fuel injection systems
Motronic injection system
Safety precautions when working with injection systems
Multec injection system
Diagnostics of faults in fuel injection systems
Fuel injection system fault codes
Checking, removing and installing the coolant temperature sensor
Checking, adjusting and replacing the throttle position sensor (Motronic system)
Removal and installation the lambda probe
Removal and installation the activated carbon filter
Checking the fuel pump relay
Checking the performance of the fuel pump
Removal and installation the fuel pump
Replacing the fuel level sensor (all engines)
Replacing the air filter
Checking fuel hoses
Replacing the fuel filter
Fuel injection system malfunctions
Fuel system (carburetor)
General information
Rules for working with the fuel system
Safety precautions when working with the Ecotronic carburetor
Malfunctions in the fuel supply system
Carburetor 2EE
Carburetor calibration data
Removal and installation the carburetor
Removal and installation the carburetor cover
Adjusting the accelerator cable
Checking idle speed and adjusting CO content in exhaust gases
Removal and installation the fuel filter
Air damper control device
Throttle starting device
Removal and installation the throttle valve starter filter
The device of the carburetor 2E3
Calibration data of the 2E3 carburetor
Removal and installation the 2E3 carburetor
Removal and installation the carburetor cover 2E3
Checking and adjusting the idle speed of the 2E3 carburetor and the CO content in the exhaust gases
Removal, installation and adjusting the accelerator cable of the 2E3 carburetor
Removal and installation the fuel filter of the 2E3 carburetor
Removal, installation and testing of the starting device of the 2E3 carburetor
Checking and adjusting the accelerator pump of the 2E3 carburetor
Checking and adjusting the fast idle speed of the 2E3 carburetor
Checking, removing and installing the intake manifold heating device of the 2E3 carburetor
Checking the air thermostat of the 2E3 carburetor
Removal and installation the air filter of the carburetor 2E3
Removal and installation the fuel pump
Ecotronic system fault codes
Checking the carburetor
Replacing the air filter
Carburetor malfunctions
Fuel system (diesel)
How a diesel engine works
Checking glow plugs
Checking the preheating system
Removal air from the fuel system
Checking and adjusting idle speed
Removal and installation injectors
Checking fuel injection advance
Fuel filter heating
Maintenance of the fuel system of diesel engines
Replacing the air filter element
Draining water from the fuel filter and replacing it
Malfunctions of the fuel system of diesel engines
Exhaust system
General information and structure
Removal and installation of the exhaust system
Replacing the hinge flange gasket
Cars with a catalytic converter
Checking the exhaust gas recirculation valve
Visual inspection of the exhaust system
Transmission
Clutch
General information and structure
Removal, installation, checking of the clutch
Removal and installation the clutch release bearing
Replacing the clutch cable
Checking and adjusting the free travel of the clutch pedal
Clutch faults
Car gearbox
Removal and installation the gearbox
Visual detection of oil leaks
Checking the gearbox oil level
Drive adjustment
Automatic transmission. General information
Checking the oil level and changing the oil in the automatic transmission
Automatic transmission oil change
Adjusting the automatic transmission gear selector lever rod
Automatic transmission fault codes
Chassis
Front suspension
Front suspension and axle shafts. Design and general information
Removal and installation the front pillar
Removal and installation the shock absorber and front spring
Checking the shock absorber
Removal and installation axle shafts
Replacement of axle joint and joint boot
Removal and installation front wheel hub bearings
Removal and installation the front suspension beam
Front Suspension Maintenance
Rear suspension
Rear suspension. Design and general information
Removal and installation rear shock absorbers
Removal and installation rear springs
Checking and adjusting the play of wheel hub bearings
Removal and installation rear wheel hub bearings
Removal and installation the stabilizer
All-wheel drive vehicles
Bleeding air from the hydraulic system
Checking the level and adding oil to the transfer case
Checking the level and replacing the oil in the main gear
Checking axle shaft covers
Steering
General information and structure
Removal and installation the steering wheel
Removal and installation of steering rods
Removal and installation tie rod ends
Removal and installation the power steering reservoir
Removal and installation the power steering pump
Bleeding the hydraulic system (front-wheel drive vehicles)
Checking the condition of the steering rod end seals
Checking the steering play
Checking the oil level in the power steering reservoir
Checking, replacing and adjusting the tension of the V-belt
Wheel alignment angles
Measuring wheel alignment angles
Wheel alignment
Brake system
General information
Removal and installation front disc brake pads
Brake calipers with pin-mounted pads
Removal and installation rear disc brake pads
Making a brake piston template
Checking the thickness of brake discs
Removal and installation front brake discs
Removal and installation rear brake discs (all-wheel drive vehicles)
Removal and installation brake calipers
Removal and installation rear brake drums
Removal and installation brake shoes for drum brakes
Replacing brake linings of drum brakes
Removal and installation rear wheel brake cylinders
Brake fluid
Bleeding the brake system
Replacement of brake hoses and pipes
Replacing the front brake hose
Checking the brake booster
Brake force regulators
Checking, removing and installing the brake light switch
Removal and installation the parking brake lever
Removal and installation parking brake pads
Adjusting the parking brake
Removal and installation the parking brake cable
Anti-lock braking system (ABS)
Checking ABS
Checking the brake fluid level
Checking the thickness of brake pads
External inspection of brake pipes
Replacing brake fluid
Technical characteristics of the brake system
Brake system malfunctions
Wheels and tires
Wheel and tire sizes
Wheel rim designation
Tyre designation
Speed class designation
Date of tire manufacture
Wheel replacement
Tire running-in
Wheel balancing
Anti-skid chains
Abnormal tire wear
Eliminating steering vibrations
Installing wheels on a car
Wheel balancing on a car
Spare wheel
Checking tire pressure
Checking the tire profile
Checking tire valves
Tyre defects
Body
Exterior
General information
Removal and installation the front bumper
Removal and installation the rear bumper
Removal and installation the hood
Removal and installation front fenders
Additional installation of trunk lid trim
Removal and installation moldings
Removal and installation the trunk lid/fifth door lock
Removal and installation the trunk lid/fifth door lock cylinder
Removal and installation mirror glass
Removal and installation the outside mirror
Removal and installation the mirror drive motor
Interior
Removal and installation door trim
Removal and installation the pocket on the front door
Removal and installation armrests
Removal and installation of door glass
Removal and installation of window lifters
Removal and installation the door handle
Removal and installation the door lock cylinder
Removal and installation the door lock
Adjusting the electric drives of the central lock
Removal and installation the parking brake lever and center console
Removal and installation the interior mirror
Electrical equipment
Electrical circuits
Maintenance free batteries
Charging the battery
Self-discharge of the battery
Designations on electrical diagrams
Scheme 1. Battery, starter, generator, heater, fan, ignition, instruments
Scheme 2. Central fuel injection system
Scheme 3. Fuel injection system Multec and Motronic
Scheme 4. Fuel filter heating, trip computer, automatic transmission
Scheme 5. Light switches, headlights, side lights, interior lighting
Scheme 6. Windscreen wipers, windscreen washers, heated seats, horn
Scheme 7. Instruments, control unit, external mirrors, radio
Scheme 8. Central lock, alarm, immobilizer, window lifts
Scheme 9. Air conditioner, radiator fan
Scheme 10. Fuel injection system Motronic M2.8
Scheme 11. ABS, traction control system, sunroof
Scheme 12. Simtec 56 fuel injection system



Vectra B (1995-2002, petrol)
General information
Maintenance
View of the engine compartment with an eight-valve 1.6-liter engine
View of the engine compartment with a 1.6-liter sixteen-valve engine
View of the engine compartment with a sixteen-valve 1.8/2.0 liter engine
Maintenance intervals
Operating principle of maintenance
Maintenance plan for hobbyists
Car care center
Using a jack
Always support your car
Rented workshop
Oil tasks
Checking the engine oil level
Oil consumption
Too much oil consumption
Oil quality
Oil viscosity
The right engine oil for Vectra
All about oil change
Changing engine oil and oil filter
Checking the oil level in a manual transmission
Checking the ATF level in an automatic transmission
Checking the fluid level in the servo control
Gas supply systems
Lubrication of door hinges
What else needs to be lubricated?
Technical characteristics of the car
Help with malfunctions
Does the starter turn the engine?
Are the spark plugs sparking?
Is fuel entering the Multec central injection system?
Is fuel entering the four-point injection system?
First, an external examination
The source of the fault is electrical equipment
The source of the fault is ignition
The source of the fault is the fuel supply
Power unit
Engine repair
A look at the engine bay
Individual nodes
Eight-valve engine
16-valve engine
Lubrication system
Engine ventilation
Visual inspection of the engine
Running in a new engine
Engine life
Nominal and maximum engine speed
Limiting the number of revolutions
Measuring compression pressure
Help with pressure problems
Engine scrolling
Working with a toothed belt
Checking the condition of the timing belt
Replacing the timing belt
Checking the timing belt tension
Cylinder head work
Hydraulic tappets
Help with cylinder head gasket problems
Bearing damage
Engine damage
Exhaust system
Service life of the exhaust system
Exhaust system components
Checking the suspension and condition of the exhaust system
Replacing the exhaust system
Ensuring clean exhaust
What does the engine emit?
Reducing toxicity of exhaust gases
Lambda probe function
Operating a vehicle with a catalytic converter
Exhaust Gas Recirculation (AGR)
Secondary air boost
Cooling system
This is how cooling occurs
Checking the coolant level
Checking the concentration of antifreeze
Checking the cooling system for leaks
Radiator
Cooling system locking cap
Thermostat
Help with thermostat problems
Water pump
Radiator fan
Help with cooling system problems
Fuel system
Regular gasoline or super gasoline?
Fuel consumption
This way you will save in economy mode
Fuel tank — general information
What is the purpose of fuel tank ventilation?
Fuel quantity indicator sensor
Fuel lines
Checking the fuel system for leaks
Electric fuel pump
Removal the fuel pump
Replacing the fuel filter
Removal the air filter insert
Blowing out the air filter insert
Replacing the air filter
Preheating of intake air
Help with air filter problems
Intake manifold heating
Throttle body heating
Multec injection system
General information about the Multec injection system
The most important components of the Multec injection system
Functioning of the Multec injection system
Self-help
Malfunctions and self-diagnosis
Emergency mode function of the Multec injection system
Checking nodes
Throttle cable
Exhaust Gas Test (AU)
Should I perform an idle speed adjustment?
Help with Multec central injection system faults
Four point injection
Two injection versions
Injection system components
Functioning
Adjustment using a lambda probe
Self-help
Visual inspection
Malfunctions and self-diagnosis
Emergency mode function of the injection system
Checking structural units
Dismantling of individual units
Throttle cable
Exhaust Gas Test (AU)
Should I perform an idle speed adjustment?
Help with malfunctions
Transmission
Clutch
Clutch operation
Clutch control
Checking the clutch
Checking the clutch hydraulics
Driving with faulty clutch hydraulics
Clutch removal
Clutch release bearing
Help with clutch problems
Gearbox and drive
Functioning of a manual transmission
Help with manual transmission problems
Automatic transmission
Gear shift evaluation
Help with automatic transmission problems
Main gear
Drive shafts
Checking the drive shaft seals
Troubleshooting Drive Shafts
Chassis
Wheel suspension
Front wheel suspension
Wheel adjustment
Shock absorber struts
Shock absorbers
Rear axle
Measuring wheel alignment
Help with suspension and steering problems
Checking the wheel bearing clearance
Checking shock absorbers
Help with shock absorber problems
Disassembling the front wheel suspension
Work on the rear axle
Steering
Steering system
Checking the dust caps and clearance of the tie rod ends
Checking the axle joint dust caps
Checking the dust caps of the front stabilizer joints
Checking the steering gear cuffs
Checking the steering clearance
Checking the operation of the servo control
Checking the servo control for leaks
Poly V-belt
Checking the oil level
Do-it-yourself work on the chassis and steering
Work on the steering
Steering gear
Filling and bleeding the servo system
Help with servo control malfunctions
Safety instructions
Brake system
Airbag system
Do-it-yourself work on the brake system
This is how the braking system works
Checking the brakes
Brake fluid
Checking the brake fluid level
Checking the brake system for leaks and damage
Replacing brake fluid
Disc brakes
Checking the brake pedal travel
Measuring Front Disc Brake Pads
Checking the condition of the brake discs
Replacing the front brake pads
Rear disc brakes
Measuring rear disc brake pads
Drum brakes
Measuring drum brake shoes
Handbrake
Checking the handbrake
Checking the handbrake pads on vehicles with rear disc brakes
Hydraulics and controls
Work on the hydraulic brake system
Master brake cylinder
Brake booster
Checking the brake booster
Bleeding the brake system
Help with brake problems
ABS can't do everything!
What does ABS do?
Functions of individual nodes
Malfunction of the anti-lock system
Traction Control System
Wheels and tires
What tires should I install?
Tyre designation
Rims — description and care
Checking tire pressure
Checking the condition of the tires
Help with tire problems
Wheel replacement
Wheel mounting position
Checking the tightness of wheel bolts
Unbalanced wheels
Anti-skid chains
Body
Exterior
Dismantled parts
Front of the car
Bumpers
Engine hood
Wings
Doors
Dismantling doors
External view mirrors
Rear lid/trunk lid
Sliding roof
Glasses
Preservation of the car body
Checking the anti-corrosion coating
Cleaning the water drainage holes
Checking the varnish
Interior
Instrument disk
Middle console
Seats
Seat belts
Seat belt tensioner
Interior upholstery
Ceiling
Electrical equipment
Fuses and electronics
Hidden powers
Electrical measurements
Basic concepts of electronics
Precautions when handling electronic components
Help for orientation in the electrical equipment of the car
Wires
Box with fuses
Fuses
Plug-in wire connections
Fuse box table
Checking the acid level in the battery
Power devices
This is how a battery works
The right battery choice
How long does the battery reserve last?
Non-maintainable batteries
Battery life
Removal the battery
Checking the battery charge
Charging the battery
Starting an engine with a dead battery
Pushing the car
Towing a car
Three-phase current generator
Generator charging control
Generator voltage regulator
Self-help with generator and regulator
Poly V-belt of the generator
Checking the condition of the alternator poly V-belt
Correct length of alternator poly V-belt
Help with battery and generator problems
Starter design
Help with starter problems
Ignition system
What provides ignition
When does ignition occur?
Ignition system
This is how the ignition spark is created
Ignition coils in a distributorless ignition system
The brain of the ignition system
Knock control
Inductive pulse sensor
Camshaft Position Sensor
Precautions when handling ignition
Work on the ignition system
Troubleshooting Ignition
Checking the ignition timing
High voltage unit
Replacing spark plugs
Buying new spark plugs
Lighting and signaling
Bright nights
Checking lighting equipment
Spare lamps
Replacing headlight bulbs
Removal the headlight
Fog lights
Checking headlight adjustment
Adjusting the light range
Front direction indicators
Side direction indicators
Rear lights
License plate light
Other lights
Dashboard lights
Checking direction indicators and hazard warning lights
Help with signaling equipment malfunctions
Checking the brake lights
Brake light switch
Help with brake light malfunctions
Checking the sound signal
Help with horn malfunctions
Light signal
Equipment and devices
Checking control instruments and bulbs
Disassembling the instrument panel
Speedometer
Tachometer
Coolant temperature indicator
Fuel tank level indicator
Control lights in the instrument panel
Battery charge indicator light
Oil pressure warning light
Check Engine Light
Direction indicator light
High beam indicator light
Brake warning light
Fog light indicator light
Rear fog light indicator light
ABS warning light
Airbag control light
TC control light
Trailer direction indicator light
Fuel tank quantity indicator light
Sport driving program indicator light
Emergency warning light
Information display
Multi-information display
On-board computer
Signals for the on-board computer
Control system
Switches
Lever switches
Key switches
Light switch
Rotary switches
Ignition switch
Checking switches
Relays and control units
Cigarette lighter
Heated rear window
Checking windshield wipers and washers
Filling with water for washing the glass
Windscreen wiper motor
Help with malfunctions
Water pump
Rear windshield wiper motor
Headlight washer system
Radio receiver
Electrically adjustable mirror
Electric power windows
Central lock
Blocking the car from leaving
Replacing the battery of the radio remote control
Anti-theft alarm system
Heating and ventilation
Warm wind
Checking heating and ventilation
Replacing the dust filter
Air blower
Air conditioning system
Help with heating and ventilation problems
Electrical circuits
Structure of electrical circuits
Battery, starter, generator, fuses...
Engine X25 XE Motronic M 2.8, secondary air pump (SLP), fuel pump...
High beam / low beam, parking light / tail light, multi-timer...
X18 XE engine, X20 XEV Simtec 56-S, X16 SZR Multec (F) engine
Engine X16 XEL Multec-S (F), automatic transmission
Instrument cluster, triple information display (TID)...
Rear window, outside view mirror, fog lights, trailer socket...
Central locking and anti-theft system fuse...
Anti-lock braking system and Traction Control, vehicle departure prevention system, FI speed control...
Electronic climate control, sliding roof
Windscreen wiper, windscreen washer, brake light, control system...
Door switch, lights, glove box, cigarette lighter, air conditioning...
Engine 16 LZ2, X16 SZR, X18 XEV, 28 NEJ, X28 XEV, module C, fan, radiator...
Radio, CD changer, telephone



Vectra B (1995-2002)
General information
User manual
Controls and instruments
Instrument cluster
Control lights
Trip meter and clock
Triple-Info-Display
Multi-Info-Display
Multi-Info-display — Check-control
Multi-Info-Display — On-board computer
Heating and ventilation system
Air Conditioning Control
Heating control
Electronic climate control
Traction control system
Cruise control management
Catalyst for petrol and diesel vehicles
Electronic Engine System Warning Light
Exhaust gas system
Automatic transmission
Driving Instructions
Fuel economy
Fuel grades for gasoline engines
Weekly checks
Weekly inspection locations
Checking the engine oil level
Coolant level
Brake fluid level
Windscreen washer fluid level
Fluid level in power steering system
Windscreen wiper blades
Checking the battery
Maintenance (gasoline)
View of the engine compartment
Operating materials and fluids
Maintenance frequency
Every 15,000 km or 6 months
Every 30,000 km or 2 years
Every 60,000 km or 4 years
Every 2 years regardless of the vehicle mileage
Maintenance (diesel)
View of the engine compartment
Technical specifications
Maintenance frequency
Every 7,500 km or 6 months
Every 15,000 km or 12 months
Every 30,000 km or 2 years
Every 2 years regardless of the vehicle mileage
Troubleshooting
Engine malfunctions
Cooling system malfunctions
Malfunctions of the fuel and exhaust systems
Clutch faults
Manual transmission
Automatic transmission faults
Drive shaft faults
Brake system malfunctions
Suspension and steering faults
Power unit
SOHC gasoline engine
General information about SOHC engine repair
Technical specifications
Checking the compression pressure
Top dead center (TDC) of the piston of the first cylinder
Cylinder head cover — removal and installation
Crankshaft pulley — removal and installation
Timing Belt Covers — Removal and Installation
Timing belt — removal and installation
Timing Belt Tensioner and Pulleys
Replacing the camshaft sealing ring
Camshaft and camshaft housings — removal and installation
Hydraulic tappets — removal and installation
Cylinder head — removal and installation
Oil pan — removal and installation
Oil pump — removal and installation
Flywheel/Drive Plate — Removal and Installation
Replacing the crankshaft sealing rings
Powertrain suspension
DOHC petrol engine
General information about DOHC engine repair
Technical specifications
Compression check
Top dead center (TDC) of the piston of the first cylinder
Cylinder head cover — removal and installation
Crankshaft pulley — removal and installation
Timing Belt Covers — Removal and Installation
Timing belt — removal and installation
Timing Belt Pulleys, Tensioner and Idler Pulley
Replacing camshaft oil seal rings
Camshaft and tappets — removal and installation
Cylinder head — removal and installation
Oil pan — removal and installation
Oil pump — removal and installation
Flywheel/drive plate
Replacing the crankshaft oil seal rings
Powertrain suspension
Diesel engine 1.7 liter
General information about 1.7 liter engine repair
Technical specifications
Checking the compression pressure
Top dead center (TDC) of the piston of the first cylinder
Cylinder head cover — removal and installation
Crankshaft pulley — removal and installation
Timing Belt Covers — Removal and Installation
Replacing the timing belt — removal and installation
Timing Belt Tensioner and Pulleys
Replacing the camshaft sealing ring
Checking and adjusting valve clearances
Camshaft and tappets — removal and installation
Cylinder head — removal and installation
Oil pan — removal and installation
Oil pump — removal and installation
Oil radiator — removal and installation
Flywheel — removal and installation
Replacing the crankshaft sealing rings
Replacing the powertrain mounts
Diesel engine 2.0 liters
General information about 2.0 liter engine repair
Technical specifications
Checking the compression pressure
Top dead center (TDC) of the piston of the first cylinder
Checking and adjusting the valve timing mechanism
Cylinder head cover — removal and installation
Crankshaft pulley — removal and installation
Chain cover — removal and installation
Chain tensioners — removal and installation
Chains and sprockets — removal and installation
Camshafts and tappets — removal and installation
Cylinder head — removal and installation
Oil pan — removal and installation
Oil pump — removal and installation
Oil radiator — removal and installation
Replacing the crankshaft sealing rings
Flywheel — removal, inspection and installation
Powertrain suspensions — inspection, removal and installation
Engine repair
Technical characteristics of the SOHC 1.6L petrol engine
Specifications of the 1.6L DOHC petrol engine
Technical characteristics of petrol engines DOHC 1.8 and 2.0 l
Technical characteristics of the 1.7 l diesel engine
Technical characteristics of the 2.0L diesel engine
Removal and installation of a gasoline engine together with a gearbox
Removal and installation of a diesel engine together with a gearbox
Engine repair
Disassembling the cylinder head
Cleaning and inspection of the cylinder head
Cylinder head assembly
Removal pistons with connecting rods
Removal the crankshaft
Engine Cylinder Block — Cleaning
Pistons and connecting rods — check
Crankshaft — check
Inspection of main and connecting rod bearings
Sequence of engine assembly during major repairs
Installing piston rings
Selection of bearings
Installing the crankshaft
Pistons and connecting rods, checking the working clearances of connecting rod bearings
Checking the operating clearance of the lower connecting rod bearing
Installing pistons with connecting rods
Starting the engine after major repairs
Cooling system
General information about repair of the cooling system
Technical specifications
Cooling system hoses — replacement
Radiator — removal, inspection and installation
Thermostat — removal, inspection and installation
Radiator Fan — Checking, Removing and Installing
Additional radiator fan on 1.7L diesel engines
Additional electric cooling pump on 1.7 l diesel engines
Water pump — removal and installation
Coolant temperature sensor
Radiator Fan Temperature Sensor — Removal and Installation
Coolant level sensor — removal and installation
Fuel system (gasoline)
General information about the gasoline fuel system
Technical specifications
Air filter and intake ducts — removal and installation
Engine Air Temperature Control System
Accelerator cable — removal, installation and adjustment
Accelerator pedal — removal and installation
Fuel — general information
Single-point fuel injection system of the SOCH 1.6L engine
Multi-point fuel injection system Multec-S of the DOCH 1.6 l engine
Multi-point fuel injection system Simtec 56.5 engines 1.8 and 2.0 l
Relieving pressure in the fuel system
Fuel pump — removal and installation
Fuel level sensor — removal and installation
Fuel tank — removal and installation
Throttle body — removal and installation
Checking the fuel injection system
Elements of a single-point fuel injection system
Elements of the multi-point fuel injection system of the 1.6 l engine
Elements of the multi-point fuel injection system of 1.8 and 2.0 l engines
Intake manifold — removal and installation
Exhaust manifold — removal and installation
Exhaust gas system
Fuel system (diesel)
General information about the diesel fuel system
Technical specifications
Air filter and air intake ducts
Accelerator pedal — removal and installation
Filling and bleeding the fuel system
Fuel level sensor
Fuel tank
Checking and adjusting maximum speed
Starting a cold engine
Electrical components of the injection system of the 1.7 l engine
Electrical components of the injection system of the 2.0 l engine
High pressure fuel pump — removal and installation
Checking the fuel injection timing
Adjusting the fuel injection timing
Fuel injectors — removal and installation
Turbocharger — removal and installation
Heat exchanger — removal and installation
Intake manifold — removal and installation
Exhaust manifold — removal and installation
Charging system
General information about the charging system
Technical specifications
Checking the battery
Charging the battery
Battery — removal and installation
Generator — removal and installation
Launch system
General information about the launch system
Technical specifications
Starter — removal and installation
Oil pressure sensor — removal and installation
Oil level sensor — removal and installation
Ignition and preheat
General information about the ignition system
Checking the ignition system
Ignition unit — removal and installation
General information about the pre-heating system of diesel engines
Technical characteristics of the preheating system
Glow plugs — removal and installation
Elements of the pre-heating system 1.7 l
Transmission
Clutch
General information about the clutch
Technical specifications
Bleeding the hydraulic clutch system
Master cylinder — removal and installation
Clutch slave cylinder — removal and installation
Clutch pedal — removal and installation
Clutch master assembly — removal, inspection and installation
Mechanical gearbox
General information about manual transmission
Technical specifications
Gearbox oil change
Adjusting the gear shift mechanism
Gear shift mechanism — removal and installation
Replacing the sealing rings
Reverse Light Switch — Removal and Installation
Gearbox Removal — Removal and Installation
Automatic gearbox
General information about automatic transmission
Technical specifications
Gearbox oil change
Adjusting the selector lever
Selector cable — removal and installation
Selector lever — removal and installation
Replacing the torque converter sealing ring
Electrical transmission controls
Driving style switch — removal and installation
Electronic control device — removal and installation
Gearbox input and output shaft sensors
Gearbox Oil Temperature Sensor
Removal and installation of gearbox — removal and installation
Gearbox overhaul
Drive shafts
Technical specifications
Removal and installation the drive shaft
Replacing the drive shaft joints
Replacement of constant velocity joint boots
Chassis
Brake system
Technical specifications
Bleeding the hydraulic brake system
Brake lines and hoses
Replacing the front brake pads
Replacing rear brake pads on disc brakes
Replacing rear brake shoes on drum brakes
Replacing handbrake brake pads
Front and rear brake discs
Front brake disc — removal and installation
Rear brake disc — removal and installation
Rear brake drum — removal, inspection and installation
Front Caliper — Removal and Installation
Rear Caliper — Removal and Installation
Rear wheel cylinder — removal and installation
Master Brake Cylinder — Removal and Installation
Brake pedal — removal and installation
Vacuum brake booster — checking, removal and installation
One-way valve of the brake booster
Adjusting the handbrake
Handbrake lever — removal and installation
Handbrake cable — removal and installation
Anti-lock braking system (ABS)
Hydraulic modulator and electronic control device
Wheel speed sensor — removal and installation
Vacuum pump for cars with diesel engines
Wheel suspension
Technical specifications
Steering knuckles — removal and installation
Replacing the front hub bearings
Front Lower Frame — Removal and Installation
Front pillar — removal, repair and installation
Front suspension anti-roll bar
Lower control arm of the front suspension
Replacing the lower hinge of the front suspension
Rear hub — removal and installation
Rear pillar — removal, repair and installation
Rear suspension anti-roll bar
Upper arm rear suspension — removal and installation
Lower arm rear suspension — removal and installation
Steering
General information about steering and suspension
Steering wheel — removal and installation
Steering column — removal and installation
Intermediate shaft of the steering column — removal and installation
Replacing the steering gear protective covers
Steering gear — removal and installation
Power steering pump (petrol engines)
Power steering pump (1.7L diesel engine)
Power steering pump (2.0L diesel engine)
Bleeding the Power Steering System
Tie Rod End — Removal and Installation
Steering rod — removal and installation
Wheel alignment angles
Body
Exterior
General information about the car body
Car body care
Repair of minor body damage
Repair of severe body damage
Front bumper — removal and installation
Rear bumper — removal and installation
Radiator grille — removal and installation
Hood — removal and installation
Bonnet struts — removal and installation
Hood Lock Cable — Removal and Installation
Outside mirror — removal and installation
Outside rear view mirror glass — removal and installation
Interior
Caring for upholstery and carpets
Front seat — removal and installation
Rear seat cushion — removal and installation
Rear seat back — removal and installation
Front seat safety belt
Front seat belt buckle and tensioner
Rear seat belt and drum
Center console — removal and installation
Instrument panel — removal and installation
Doors and windows
Doors — removal and installation
Front door trim — removal and installation
Rear door trim — removal and installation
Inner door handle — removal and installation
Front door outer opening handle
External rear door opening handle
Front door lock — removal and installation
Rear door lock — removal and installation
Door window lifter — removal and installation
Door glass — removal and installation
Trunk lid — removal and installation
Trunk lid lock — removal and installation
Trunk lid lock cylinder — removal and installation
Rear door of Hatchback models — removal and installation
Rear door of station wagon models — removal and installation
Trunk lid pillars — removal and installation
Trunk door lock — removal and installation
Tailgate Lock Cylinder — Removal and Installation
Central locking control unit
Trunk Lock Motor — Removal and Installation
Rear Door Lock Motor — Removal and Installation
Fuel filler flap engine
Electric window switch on the center console
Rear door power window switch
Window lift motor — removal and installation
Heating and ventilation
Fan Motor Resistor — Removal and Installation
Heater blower motor — removal and installation
Heater control panel — removal and installation
Heater casing — removal and installation
Heater radiator — removal and installation
Heater switch — removal and installation
Vacuum tank — removal and installation
Vacuum chamber — removal and installation
Electronic climate control unit
Electronic temperature sensor — removal and installation
Electronic Fan Controller — Removal and Installation
Air conditioning system — precautions
Electrical equipment
Equipment and devices
General information and precautions
Technical specifications
Electrical circuits
Open Circuit Detection
Fuses and relays
Switches — removal and installation
External Light Bulbs — Replacement
Interior Light Bulbs — Replacement
External lighting devices
Headlight adjustment
Instrument cluster — removal and installation
Windscreen wiper arms
Windscreen wiper motor and rods — removal and installation
Rear door wiper motor
Windscreen washer — removal and installation
Radio — removal and installation
Loudspeakers — Removal and Installation
Airbag — precautions
Elements of the airbag
Electrical circuits
Abbreviations on electrical diagrams, wire identification, color code
Key to electrical circuits
Electrical diagram of the route 100-200
Electrical diagram of the route 200-300
Electrical diagram of the route 300-400
Electrical diagram of the route 400-500
Electrical diagram of the route 500-600
Electrical diagram of the route 600-700
Electrical diagram of the route 700-800
Electrical diagram of the route 800-900
Electrical diagram of the route 900-1000
Electrical diagram of the route 1000-1100
Electrical diagram of the route 1100-1200
Electrical diagram of the route 1200-1300
Electrical diagram of the route 1300-1400
Electrical diagram of the route 1400-1500
Electrical diagram of the route 1500-1600
Electrical diagram of the route 1600-1700
Electrical diagram of the route 1700-1800
Electrical diagram of the route 1800-1900



Vectra C (2002-2008)
General information
User manual
A few words about this guide
Rules for using this manual
Abstract for Opel Vectra C and Signum cars
List of abbreviations used in the manual
Identification numbers, VIN number, decoding
Overall dimensions and weight characteristics
Technical characteristics of cars
Oils, lubricants, sealants
Recommended lubricants and fluids
Car settings and adjustments
Running-in the first 1000 kilometers
Starting the engine and starting the movement
Driving cars with manual transmission
Driving cars with automatic transmission
Driving cars with CVTronic automatic transmission
Special driving modes
Braking a car
Operation of vehicles with a catalytic converter
Transporting children and installing a child seat
Adjustment and transformation of seats and headrests
Tips for Economical Driving
Towing a trailer and installing a towbar
Vehicle device
Keys and remote control
Unlocking and closing doors and trunk lid
Opening and closing the hood
Opening the fuel tank hatch and filler neck
Upper roof hatch
Single lock
Remote control control
Unlocking and locking doors
Replacing the remote control battery
Anti-theft alarm
Electronic immobilizer
Life and health safety equipment
Seat belts — rules and features of use
Supplemental Restraint System (SRS)
Risk of Carbon Monoxide (CO) Poisoning
Instrument panel and center console
Instrument cluster, gauges, control lamps
Interior controls and equipment
Ventilation, heating and air conditioning (HVAC) systems
Heating the car interior
Automatic operation mode of the climate control system
Infotainment system
Telephone and radio station
Maintenance
General information about maintenance
Purchase of spare parts
Jacking up a car
Towing a damaged vehicle
Starting the engine from an auxiliary power source
Schedule of scheduled maintenance (TO)
Checking fluid levels
Checking the condition of tires, inflation pressure, wheel rotation
Changing engine oil and oil filter
Checking the condition and replacing the multi-rib drive belt of the units
Draining sediment, removing air from the fuel filter (diesel)
Checking and replacing hoses located in the engine compartment
Checking the condition of the cooling system components
Checking, servicing and charging the battery
Checking the condition and replacing the windshield wipers
Inspection of suspension and steering components
Checking the brake system
Checking electrical equipment
Lubrication of locks, hinges and stops
Replacing the air cleaner filter element
Replacing the cabin filter
Replacing the fuel filter
Checking idle speed and exhaust gas composition
Replacing spark plugs (petrol engines)
Checking the condition of the timing belt
Tire pressure monitoring
Troubleshooting
General information about troubleshooting
Engine and system malfunctions
Chassis faults, tire defects
Suspension and steering faults
Brake system malfunctions
Clutch faults
Malfunctions of a manual gearbox
Automatic Transmission (AT) Malfunctions
Heater malfunctions
Windscreen wiper blade defects
Power unit
Engine repair
Engine specifications
General information about engines
Engine cover — removal and installation
Checking the compression pressure in the cylinders
Engine condition diagnostics using a vacuum gauge
Preparatory operations for engine repair
Removal the right engine mount
Removal and installation the crankshaft pulley
Removal and installation camshaft sprockets
Bringing the piston of the first cylinder to the top dead center (TDC) position
Removal and installation a multi-ribbed accessory drive belt
Removal and installation the timing belt/chain
Checking and adjusting the timing valves
Removal, installation and inspection of camshafts and valve lifters
Removal and installation the cylinder head
Removal and installation the oil pan
Removal and installation the oil pump
Measuring engine oil pressure
Removal, checking and installation the flywheel and drive disk
Replacing crankshaft seals
Checking the condition and replacing the powertrain suspension supports
Removal the engine
Engine threaded connections tightening force (Nm)
Cooling system
Engine Cooling System Specifications
Description of the design of the engine cooling system
Antifreeze — General Information and Precautions
Draining and filling the system with coolant
Disconnecting and replacing cooling system hoses
Cooling system maintenance, flushing
Removal and installation the cooling system fan
Removal and installation the cooling system radiator
Removal and installation the water pump
Removal, installation and checking the thermostat
Power and control system
Specifications of the fuel system and engine management
Design of the engine power supply system
Relieving pressure in the fuel system of gasoline engines
Checking and replacing fuel lines and their fittings
Removal air from the fuel system of a diesel engine
Removal dirt and water from the diesel fuel system
Removal and installation air intake tract components
Removal and installation the gas pedal
Removal and installation the fuel pump/fuel level sensor
Removal and installation the fuel filter mounting clamp (diesel)
Removal and installation the fuel tank
Removal and installation the fuel tank ventilation system (EVAP) valve (gasoline)
Gasoline Engine Management System
The operating principle of fuel injection systems of gasoline engines
Removal and installation of fuel injectors
Diesel Engine Control System
The operating principle of diesel engine fuel injection systems
Removal and installation fuel injectors
Removal and installation of fuel injection pump
Turbocharger and Intercooler — General Information
Particulate filter (engines with a working volume of 1.9 l)
Exhaust gas system
Removal and installation of the exhaust system
Removal and installation the particulate filter (engine Z19DT(H))
Removal and installation lambda probes
Emission control systems
Engine electrics
Engine Electrical Specifications
Description of the design of the engine electrical equipment
Main engine powertrain fault codes
Ignition/Glow and Engine Management Systems
On-board diagnostic system OBD
Using an oscilloscope to monitor engine control system operating signals
Removal and installation of spark plugs, coils and ignition modules
Removal, installation and checking glow plugs
Battery — Checking, Disconnecting, Removing and Selecting
Generator — Checking, Removing and Installing
Removal and installation the voltage regulator, checking and replacing the generator brushes
Starter — removal, installation and testing
Transmission
Clutch
Description of the clutch design
Clutch specifications
Removal and installation the clutch master cylinder
Removal and installation the clutch slave cylinder assembly with release bearing
Bleeding air from the hydraulic circuit of the clutch release drive
Removal and installation the clutch pedal
Removal, inspection and installation of clutch components
Car gearbox
General description of a manual gearbox
Adjusting the gear shift drive (manual transmission)
Removal and installation of gear shift drive components (manual transmission)
Removal and installation of manual transmission
Automatic Transmission Specifications
General information about automatic transmission
Adjusting the selector lever position sensor and gear shift drive (automatic transmission)
Removal and installation of gear shift drive components (automatic transmission)
Checking the condition and replacing the working fluid (automatic transmission)
Removal and installation of automatic transmission
Drive shafts
Drive shaft specifications
General information about drive shafts
Removal and installation drive shafts
Removal and installation the intermediate shaft
Checking and replacing constant velocity joints (CV joints)
Replacing CV joint boots
Chassis
Car suspension
General description of suspension and chassis
Suspension, Wheel and Tire Specifications
Removal and installation the front shock absorber strut
Disassembly and repair of the front shock absorber strut and shock absorber spring
Removal and installation the hub nut
Removal and installation the steering knuckle
Removal and installation the control arm of the suspension
Removal and installation the front subframe
Removal, checking and installation rear suspension shock absorbers
Removal and installation rear suspension coil springs
Removal and installation the rear hub assembly (hub assembly)
Steering
Steering Specifications and Description
Removal and installation the driver's front airbag module
Removal and installation the steering wheel
Removal and installation the steering column switch contact block
Tie Rod Ends — Replacement
Removal and installation steering gear boots
Wheel alignment angles
Brake system
Specifications and description of the brake system
Electronic braking control systems
Bleeding the brake system
Checking the condition and replacing brake lines and hoses
Replacing the front disc brake pads
Replacing the rear wheel disc brake pads
Removal and installation front brake calipers/pad guides
Removal and installation rear brake calipers/pad guides
Removal, installation and inspection of the brake disc
Removal and installation of the master brake cylinder (MBC)
Removal and installation the foot brake pedal assembly
Checking, removing and installing the brake booster assembly
Removal and installation the parking brake lever
Removal and installation the parking brake cable
Body
Exterior
Exterior equipment and body parts
Specifications of the body and its elements
Removal and installation of side (door) trims (moldings)
Removal and installation the fairing grille
Removal and installation the front bumper (bumper trim)
Removal and installation the rear bumper
Removal and installation of wheel arch protection (fenders, mudguards)
Removal and installation front fenders
Removal and installation lower outer threshold trims
Removal and installation the hood, adjusting gaps and the hood lock
Side rear view mirror — removal, disassembly, replacement
Interior
Caring for upholstery, trim and carpeting
Removal and installation of sun visors, ceiling handle
Removal and installation interior rear view mirror
Removal and installation the main storage compartment
Removal and installation the central console of the passenger compartment
Removal and installation ashtrays
Removal and installation the automatic transmission selector lever base cover
Removal and installation the decorative strip of the instrument panel
Removal and installation the side decorative panel of the console section of the instrument panel
Removal and installation the lower decorative cover of the instrument panel under the steering column
Removal and installation steering column covers
Removal and installation the door seal
Removal and installation the interior sill trim panel
Removal and installation the front body pillar trim (A-pillar)
Removal and installation the trim of the central body pillar (B pillars)
Removal and installation rear body pillar trim (C and D pillars)
Removal and installation luggage compartment side trim
Removal and installation the rear luggage compartment shelf for hand luggage (Sedan models)
Removal and installation the lower edge trim of the trunk
Removal and installation the front seat
Removal and installation the rear bench seat
Removal and installation the instrument panel
Doors, locks and windows
Removal, installation and adjustment of the trunk lid (Sedan)
Removal and installation trunk lid trim (Sedan)
Removal, installation and adjustment of the trunk lid (Hatchback/Station wagon/Signum)
Trunk lid trim (Hatchback/Station wagon/Signum)
Removal and installation the trunk lid / tailgate lock
Removal, installation and adjustment of side doors
Removal and installation side door locks
Removal and installation external side door handles
Removal and installation front or rear door trim
Removal and installation the rear door window lift handle
Removal and installation triangular door trims
Removal and installation the front door window regulator
Removal and installation the rear door window regulator
Heating and ventilation
Removal and installation interior air duct deflectors
Removal and installation of the control panel for the operation of heating systems
Removal and installation the electric motor of the mixing flap drive
Removal and installation the air circulation system flap drive electric motor
Removal and installation the electric motor for the air flow distribution control drive
Removal and installation the air supply hose to the passenger footwell
Removal and installation the HVAC fan drive motor
Removal and installation the resistive assembly of the heater fan electric motor
Removal and installation of additional heater (diesel)
Removal and installation the heater heat exchanger
Electrical equipment
Equipment and devices
General description of on-board electrical equipment
Troubleshooting electrical equipment
Fuses and relays — location and purpose
Replacing fuses
Relays — general information and checking serviceability
Removal and installation the horn
Removal and installation windshield washer nozzles
Removal and installation the wiper arms (leashes)
Removal and installation the windshield washer reservoir and pump
Removal and installation the windshield wiper motor
Removal and installation the rear window wiper motor (Station wagon/Signum)
Removal and installation the instrument cluster
Removal and installation steering column switch levers
Removal and installation the information display
Removal and installation the exterior lighting switch panel
Removal and installation switches on the console section of the instrument panel
Removal and installation switches in the rear of the center console
Removal and installation electric window switches
Removal and installation the cigarette lighter
Removal and installation the infotainment system assembly
Removal and installation of loudspeakers (audio speakers)
Headlights and lighting
Power characteristics of on-board lighting lamps
Replacing headlight bulbs
Removal and installation the headlight
Removal and installation fog lights
Replacing the fog light bulb
Removal and installation turn signal repeaters
Removal and installation the rear combination light and replacing its bulbs
Removal and installation an additional brake light bulb
Removal and installation the license plate light
Removal and installation the lampshade of individual front seat lights
Replacement of interior, trunk and threshold lighting lamps
Electrical circuits
Symbols used in electrical equipment diagrams
Engine Management System — Simtec 71.5-2 for Z18XE engine
Fuel pump wiring diagram
Horn Wiring Diagram
Electrical diagram of the cooling system fan
Electrical diagram of the heating system
Front door window lifter wiring diagram
Rear door window lifter wiring diagram
Wiring diagram of external rear view mirrors
Single Lock Wiring Diagram — Driver's Door
Single Lock Wiring Diagram — Front Passenger Door
Single Lock Wiring Diagram — Rear Side Doors and Tailgate
Wiring diagram for middle and rear windscreen wipers
Brake and Reverse Light Switch Wiring Diagram
Rear combination lamp wiring diagram (except for Station wagon)
Wiring diagram for license plate and towing hitch illumination
Wiring diagram of halogen headlights and fog lights



Zafira A (1999-2005, petrol)
General information
Governing bodies
Description of the design
Overall dimensions of the car
Technical specifications
Vehicle Identification Numbers
Keys to the car
Controls and instruments
Instrument panel
Information display
Ignition switch (lock)
Manual transmission shift lever
Automatic transmission mode selector
Steering column switches
Control unit for external and internal lighting
Air conditioning control unit
User manual
Adjusting the position of the steering wheel and seat
Adjusting the rear view mirrors
Use of seat belts
Opening the hood
Unlocking the tailgate or trunk lid
Checking the levels of technical fluids — reference data
Checking the engine oil level
Checking the oil level in a manual transmission
Checking the level of working fluid in the automatic transmission
Checking the coolant level
Checking the power steering fluid level
Checking the brake fluid level
Filling with windshield washer fluid
Refueling a car
Checking tire pressure
Removal the spare tire and tool kit
Wheel — replacement
Towing a car
Maintenance
Safety precautions when servicing and repairing a car
Tools, accessories and operating materials
Universal tools
Special tools and devices
Operating and repair materials
Preparing the car for maintenance and repair
Periodic maintenance
Possible car malfunctions and their causes
Power unit
Engine repair
Engine — General Information
Engine — reference data
Cleaning the engine and underhood space
Engine — technical condition check
Engine trim panel — removal and installation
Checking the compression in the engine cylinders
Lubrication system — checking oil pressure
Lubrication system of 1.4 and 1.6 DOHC engines — oil and oil filter replacement
Engine lubrication system 1.8 DOHC — oil and oil filter replacement
Accessory Drive Belt — Checking Condition and Replacing
Accessory Drive Belt — Tensioner Replacement
Timing Belt — Checking Condition, Adjusting Tension and Replacing
Timing Belt — Tensioner Replacement
Cylinder head cover for 1.4 and 1.6 DOHC engines — removal, gasket replacement and installation
1.8 DOHC Engine Cylinder Head Cover — Removal, Gasket Replacement and Installation
Camshaft Seals — Replacement
Hydraulic valve lifters — replacement
Valve stem seals — replacement
Intake manifold and pipeline of 1.4 and 1.6 DOHC engines — replacement of gaskets
1.8 DOHC Engine Intake Manifold — Gasket Replacement
Exhaust manifold — gasket replacement
Front Crankshaft Oil Seal — Replacement
Rear Crankshaft Oil Seal — Replacement
Engine oil pan — removal and installation
Oil pump — removal, inspection and installation
Cylinder head of 1.4 and 1.6 DOHC engines — gasket replacement
1.8 DOHC Engine Cylinder Head Gasket Replacement
Cylinder head — check
Valves — lapping
Right Powertrain Mount — Replacement
Left Powertrain Mount — Replacement
Rear Powertrain Mount — Replacement
Front rod on cars with manual transmission
Front rod on cars with automatic transmission
Control system
Engine Management System — Reference Data
Description of the control system design
Information sensors
Executive devices
Safety precautions for maintenance and repair of the engine management system
Engine management system — technical condition check and fault diagnostics
Fuel line — checking operating pressure
Fuel Line — Pressure Relief
Air filter — replacing the filter element
Air filter — removal and installation
Fuel filter — replacement
Spark plugs — checking and replacing
Ignition module for 1.4 and 1.6 DOHC engines — checking and replacement
1.8 DOHC Engine Ignition Module — Checking and Replacing
Crankshaft Position Sensor — Replacement
Camshaft Position Sensor — Replacement
Coolant Temperature Sensor — Checking and Replacing
Knock Sensor — Checking and Replacing
1.4 and 1.6 DOHC Engine Cylinder Air Temperature Sensor — Checking and Replacing
Absolute pressure sensor in the intake manifold of 1.4 and 1.6 DOHC engines — replacement
1.8 DOHC Engine Mass Air Flow Sensor — Replacement
Oxygen Concentration Sensors — Replacement
Throttle assembly — removal, gasket replacement and installation
Throttle Pedal Replacement
Throttle Cable Replacement
Injectors — checking and replacement
Fuel pump — check and replacement
Fuel Pressure Regulator — Checking and Replacing
Fuel tank — removal and installation
Adsorber — replacement
Evaporative Canister Purge Valve — Checking and Replacing
Exhaust Gas Recirculation Valve — Replacement
Electronic control unit for engines 1.4 and 1.6 DOHC — replacement
Electronic Engine Control Unit 1.8 DOHC — Replacement
Cruise control unit — removal and installation, replacement of the drive cable
Cooling system
Cooling system — reference data
Cooling system — technical condition check
Coolant — Replacement
Thermostat — Checking and Replacing
Coolant pump — replacement
Electric cooling fans — checking and replacement
Main electric fan (installed behind the cooling system radiator)
Additional electric fan (installed in front of the cooling system radiator)
Electric cooling fans — checking and replacing the additional resistor
Electronic control unit for cooling and air conditioning system — replacement
Radiator of the cooling system — replacement
Exhaust system
Exhaust system — reference data
Exhaust system — design description
Exhaust system — technical condition check
Exhaust system suspension cushions — replacement
Main muffler — replacement
Intermediate muffler — replacement
Intake pipe — replacement
Exhaust manifold — replacement
Transmission
Clutch
Clutch — reference data
Clutch — design description
Clutch — checking technical condition
Clutch release hydraulic drive — bleeding
Clutch Master Cylinder — Replacement
Clutch slave cylinder — check and replacement
Clutch — Checking and Replacing
Mechanical gearbox
Manual transmission — reference data
Manual gearbox — technical condition check
Gearbox — Checking the level and changing the oil
Gearshift Drive — Removal, Repair and Installation
Gearshift mechanism drive lever — replacement and adjustment
Gearshift Rod Seal — Replacement
Front Wheel Drive Seals — Replacement
Gearbox — removal and installation
Gearbox primary shaft seal — replacement
Automatic gearbox
Automatic transmission — reference data
Automatic transmission — design description
Automatic transmission — technical condition check
Gearbox — replacement of working fluid
Automatic transmission mode selector cable — replacement and adjustment
Gas Pedal Sensor — Checking and Replacing
Automatic transmission special mode switches — checking and replacement
Automatic transmission operating mode indicator unit — replacement
Automatic transmission selector lock solenoid — checking and replacing
Automatic transmission selector position microswitches — checking and replacement
Automatic transmission mode selector — removal, repair and installation
Automatic transmission operating mode sensor — checking and replacement
Electronic control unit of automatic transmission — replacement
Front wheel drives
Front Wheel Drives — Reference Data
Front Wheel Drives — Design Description
Front Wheel Drives — Technical Condition Check
Front Wheel Drive — Removal and Installation
Outer drive joint — removal, replacement of protective cover and installation
Inner drive joint — removal, replacement of protective cover and installation
Chassis
Hubs, wheels and tires
Hubs, Wheels and Tires — Reference Data
Description of the design
Wheel care
Wheels, tires and hubs — technical condition check
Front Wheel Hub — Replacement
Rear wheel hub — replacement
Wheel alignment angles — check
Front suspension
Front Suspension — Reference Data
Description of the front suspension design
Front suspension — technical condition check
Ball joint — replacement
Front Anti-Roll Bar — Replacing Struts
Front Suspension Arm — Replacement
Front suspension strut — removal and installation
Front suspension strut — repair
Front suspension anti-roll bar — removal and installation of the rod, replacement of the cushions
Front Suspension Subframe — Removal and Installation
Front Suspension Subframe — Silent Block Replacement
Rear suspension
Rear Suspension — Reference Data
Description of the rear suspension design
Rear suspension — technical condition check
Rear shock absorbers — inspection and replacement
Rear suspension springs — replacement
Rear suspension beam — removal, replacement and installation
Steering
Steering — Reference Data
Description of the steering design
Steering — checking technical condition
Steering wheel — removal and installation
Steering column trim — removal and installation
Steering shaft — replacement
Tie Rod End — Replacement
Steering Tie Rod Protective Boot — Replacement
Steering rod — replacement
Power Steering System — Bleeding
Power Steering Pump — Replacement
Steering gear — removal and installation
Brake system
Reference data — brake system
Description of the design
Brake system — checking technical condition
Service brake system drive — check
Parking brake — check
Front brakes — check
Rear disc brakes — check
Rear drum brakes — check
Anti-lock braking system — check
Hydraulic brake drive — bleeding
Hydraulic brake drive — brake fluid replacement
Master Brake Cylinder — Replacement
Brake booster — replacement
Brake hoses — replacement
Brake pipes — replacement
Front brake pads — replacement
Front Brake Caliper — Removal, Repair and Installation
Front brake discs — replacement
Rear brake drums of the rear drum brake mechanism — replacement
Rear brake shoes of the rear drum brake mechanism — replacement
Rear brake cylinders of the rear drum brake mechanism — removal and installation
Rear brake pads of the rear disc brake mechanism — replacement
Rear Disc Brake Caliper — Removal and Installation
Rear brake discs of the rear disc brake mechanism — replacement
Parking brake — adjustment
Parking brake actuator lever — replacement
Parking Brake Cables — Replacement
Replacing the rear (wheel) cable on a vehicle with rear drum brakes
Replacing the main (trunk) cables on a vehicle with rear drum brakes
Replacing the main cables on a car with rear disc brakes
Replacing the front (central) cable
Body
Maintenance and care
Reference data
Checking the technical condition
Cleaning and washing of the body
Body polishing
Lubrication of hinges and locks
Processing of door seals
Glass care
Salon care
Exterior
Radiator grille — removal and installation
Hood lock — replacement and adjustment
Hood Lock Drive Handle — Replacement
Bonnet Lock Drive Cable — Replacement
Front fender liner — removal and installation
Front bumper — replacement
Astra Front Fender — Replacement
Zafira Front Fender — Replacement
Fuel filler cap — removal and installation
Astra model rear bumper — replacement
Zafira rear bumper — replacement
Gas struts for the tailgate — replacement
Astra model trunk door trim — removal and installation
Zafira tailgate trim — removal and installation
Tailgate Lock Switch (Cylinder) — Replacement
Tailgate Lock — Replacement and Adjustment
Electric drive for locking the luggage compartment door — replacement
Windshield — Replacement
Front door glass — replacement
Rear Door Glass — Replacement
Rear side window model Astra — replacement
Front side glass model Zafira — replacement
Installing engine crankcase protection
Mudguards — removal and installation
Decorative door sill trim for Astra model — removal and installation
Decorative trim for tailgate — replacement
Side doors
Checking the operation of the electric heating of the mirror element
Replacing the mirror element
Checking the electric drive for mirror adjustment
Replacing the side mirror of the Astra model
Replacing the side mirror of the Zafira model
Door trims for Astra model — removal and installation
Door trims for Zafira model — removal and installation
Front door lock switch (cylinder) — replacement
External door handle — replacement
Door lock — replacement and adjustment
Door opening limiter — replacement
Diagnosis of faults in electric windows
Replacing the front door window lifter
Replacing the rear door window lifter
Climate control
General information about the air conditioning system
Air conditioning system — technical condition check
Astra Air Conditioning Filter — Replacement
Air conditioning filter model Zafira — replacement
Checking the electric fan and its electrical circuits
Replacing the electric fan of the Astra model
Replacing the electric fan of the Zafira model
Astra climate control unit — checking and replacement
Zafira climate control unit — check and replacement
Electric Fan Booster Resistor — Checking and Replacing
Recirculation flap actuator — replacement
Electrical equipment
Equipment and devices
Electrical equipment — reference data
Description of the electrical equipment system
Electrical equipment — technical condition check
Checking and repairing electrical circuits
Checking the relay
Checking electrical consumers
Fuse and relay mounting blocks
Mounting Blocks — Replacing Fuses and Relays
Description of the design of the ignition switch (lock)
Ignition Switch (Lock) Cylinder — Replacement
Ignition Switch Contact Group — Checking and Replacing
Ignition Key Interlock Solenoid — Checking and Replacing
Steering column switches — checking and replacement
External and internal lighting control unit — removal, replacement of backlight lamp and installation
Hazard warning light switch — checking and replacing
Electric Mirror Control Unit — Checking and Replacing
Electric window control unit — check and replacement
Passenger door power window control keys — checking and replacing
Brake light switch — replacement and adjustment
Reverse Light Switch — Checking and Replacing
Open Door Sensor — Checking and Replacing
Description of the design of control and measuring instruments and sensors
Instrument cluster — removal and installation
Instrument cluster — replacing bulbs
Multifunction display — removal, replacement of lamps and installation
Oil Pressure Sensor — Checking and Replacing
Low Brake Fluid Sensor — Checking and Replacing
Cigarette lighter — adjustment and replacement of the socket, replacement of the backlight lamp
Car radio — removal and installation
Speakers of the acoustic system — removal and installation
Power devices
Battery — reference data
Battery — Removal and Installation
Battery — Maintenance
Generator — reference data
Description of the generator design
Generator — testing without removing from the car
Generator — replacement
Voltage Regulator and Brush Assembly — Replacement
Starter — reference data
Description of the starter design
Starter — technical condition check
Starter — removal and installation
Solenoid Relay — Replacement
Starter — disassembly and assembly
Lighting and signaling
Reference data
Description of the design
Checking the serviceability of outdoor lighting fixtures
Headlight adjustment
Maintenance of outdoor lighting and light signaling devices
Headlight — bulb replacement
Astra headlight unit — removal and installation
Headlight unit model Zafira — removal and installation
Headlight Corrector — Replacement
Fog Light — Bulb Replacement
Fog light — replacement
Side turn signal — removal, bulb replacement and installation
Astra model rear light — removal and installation
Astra Tail Light — Bulb Replacement
Zafira model rear light — removal and installation
Zafira Tail Light — Bulb Replacement
Astra Additional Brake Light Replacement
Additional brake light for Zafira model — replacement
Astra License Plate Light — Removal, Bulb Replacement and Installation
Zafira license plate light — removal, bulb replacement and installation
Front passenger compartment light without individual lighting
Front passenger compartment light with individual illumination
Astra rear interior lights
Zafira rear interior light
Astra model luggage compartment illumination lamp
Trunk light for Zafira model
Sound signals — replacement
Windshield wipers and washers
Reference data
Description of the design of the windshield wiper and windshield washer
Windscreen wiper — checking technical condition and diagnostics of faults
Windscreen wiper blades — replacement
Astra Front Windscreen Wiper Drive Replacement
Front windscreen wiper drive model Zafira — replacement
Astra Rear Wiper Drive — Replacement
Zafira Rear Window Wiper Drive — Replacement
Windscreen washer — checking the technical condition and diagnostics of malfunctions
Windscreen washer nozzles — adjustment and replacement
Windscreen Washer Pump — Replacement
Windshield washer reservoir — replacement
Electrical circuits
Designations on electrical equipment diagrams
Scheme 1. Engine starting and battery charging system
Scheme 2. Airbag control system
Diagram 3. Audio system
Scheme 4 and 5. Engine management system 1.4 and 1.6 DOHC
Scheme 6. Electric windows
Scheme 7 and 8. Engine management system 1.8 DOHC
Scheme 9. Anti-lock and anti-slip systems
Scheme 10. Vehicle speed sensor (vehicles not equipped with anti-lock braking system)
Scheme 11. Engine cooling system (cars with air conditioning)
Scheme 12. Engine cooling system (cars without air conditioning)
Scheme 13. Information display
Scheme 14. Low and high beam headlights
Scheme 15. Fog lights and lamps
Scheme 16. Direction indicators
Scheme 17. Reversing lights
Scheme 18. License plate lighting
Scheme 19. Electrical heating of the rear window
Scheme 20. Interior lighting
Scheme 21. Brake lights, cigarette lighter
Scheme 22. Windscreen wipers and washers
Scheme 23. Sound signal
Scheme 24. Lighting of the glove compartment
Scheme 25. Electric door lock drive
Scheme 26. Instrument panel
Scheme 27. Automatic transmission (AT)
Scheme 28. Climate control system with air conditioner
Scheme 29. Multifunctional information display
Scheme 30. Power steering
Scheme 31. Cruise control system
Scheme 32. Electric drive and electric heating of outside mirrors
Scheme 33. Climate control system
Scheme 34. Time interval block
Scheme 35. Engine management system 1.6 SOHC



Frontera A (1991-1998, petrol)
General information
Introduction to guide
Opel Frontera cars — summary
Vehicle Identification Numbers
Purchase of spare parts
Service technology, tools and workplace equipment
Jacking and towing a car
Starting the engine from an auxiliary power source
Checking the vehicle's readiness for operation
Automotive chemicals, oils and lubricants
Car fault diagnostics
User manual
Location of components and controls
Instrument panel and indicator lights
Keys and door locks
Locking the rear doors to prevent them from being opened by children
Remote control for door locks and alarms
Turning the anti-theft alarm on and off
Replacing the remote control battery
Programming the remote control
Single (central) lock
Electronic engine immobilization system
Anti-theft alarm system
Tailgate (5-door models)
Tailgate (3-door models)
Rear windows and roof panel of 3-door airtop models
Rear windows of 3-door softtop models (with folding roof)
Opening and closing the hood
Expansion of luggage compartment volume (3-door models)
Expansion of luggage compartment volume (5-door models)
Cigarette lighter and ashtrays
Seat belts
Airbags
Devices for safe transportation of children in a car
Seat headrests
Devices for traffic safety and passenger comfort
Adjusting the position of the seats and steering column
Ignition, engine start and steering column lock switch
Engine Starting Information
Lighting and signaling device control switches
Control of windshield wipers and washers
Rear view mirror adjustment drive
Door window lift drive
Upper hatch drive
Control of air flow for heating and ventilation of the passenger compartment
Driving a car
Refueling a car
Maintenance
Maintenance Specifications
Schedule of current maintenance
Routine car maintenance
Information about car setup
Checking fluid levels
Checking the condition of the tires and their pressure
Changing engine oil and oil filter
Checking the power steering fluid level
Wheel rotation
Checking the condition and replacing the engine compartment hoses
Checking the condition, adjusting the tension and replacing the drive belt (only for engines with tension adjustment)
Checking and adjusting engine idle speed and CO levels
Checking battery condition, care and charging
Checking and replacing spark plugs
Checking and replacing spark plug wires, cover and distributor rotor
Checking the oil level in the manual transmission and transfer case
Checking the differential fluid level of the front and rear axles
Checking the fuel system
Checking the functioning of the cooling system
Checking the condition of the exhaust system
Checking the condition of suspension and steering components
Checking the condition of the protective covers of the front wheel drive shafts
Check the brake system and replace the brake fluid with subsequent bleeding
Checking the condition and replacing the windshield wipers
Filling the cooling system coolant
Replacing the fuel filter
Replacing transmission oil in manual transmission and transfer case
Replacing the differential lubricant of the front and rear axles
Replacing the engine timing belt
Power unit
Engine repair
General information about gasoline engines
Petrol Engine Specifications
Removal and installation of OHC engine
Removal and installation of DOHC engine
Disassembling the engine
Engine assembly
Cylinder head and valves — removal and installation
Pistons and connecting rods — removal, inspection and installation
Cylinder Block — Cleaning and Checking
Crankshaft and crankshaft bearings
Camshaft Drive — Removal, Checking and Installation
Engine mounts — removal and installation
Checking the compression in the cylinders
Lubrication system
Engine lubrication system — general information
Oil pan — removal and installation (2.0L engine, before 1997)
Oil pump — removal and installation (2.0L engine, before 1997)
Oil pump repair (2.0L engine)
Oil pan — removal and installation (2.0L engine, since 1997)
Oil pump — removal and installation (2.0L engine, since 1997)
Oil pan — removal and installation (2.4L engine)
Oil pump — removal and installation (2.4L engine)
Oil pump repair (2.4L engine)
Oil filter — removal and installation
Oil radiator (if installed) — removal and installation
Cooling system
Cooling and Heating Systems — General Information
Engine Cooling System Specifications
Checking the radiator and radiator cap
Removal and installation the radiator
Replacing the cooling fan
Coolant pump — removal and installation
Replacing and tensioning the V-belt
Thermostat and thermostat housing
Power and exhaust system
Power and exhaust system specifications
Fuel system of injection engines — general information
Power supply system malfunctions
Injection system — general information
Fuel injection system Bosch M1.5.4 for OHC engine
Fuel injection system Bosch M1.5.4 for DOHC engine
Bosch Motronic M1.5 system for 2.0 and 2.4 l engines
Safety precautions when working with the power supply system
Exhaust and emission control systems
Gas pedal and gas control drive
Air filter and air supply system
Exhaust gas recirculation system
Exhaust air mixing system
Engine electrics
Engine electrical equipment — general information
Engine Electrical System Specifications
Ignition system — general information
Ignition system Bosch M1.5.4
Ignition system Bosch M1.5.4 for DOHC engine
Bosch Motronic M1.5 system for 2.0 and 2.4 l engines
Checking the ignition timing
Spark plugs — general description
Safety precautions when working with ignition system components
Charging and starting systems — general information
Safety precautions when working with a generator and regulator
Removal and installation the generator
Bosch Generator Repair
Starter — removal, installation and repair
Battery — Removal, Installation and Maintenance
Transmission
Clutch
Clutch — General Information
Clutch specifications
Removal and installation the clutch
Clutch repair
Clutch installation
Checking the clutch without removing it
Clutch release mechanism — removal and installation
Bleeding the Clutch Hydraulic System
Adjusting the height and free travel of the pedal
Mechanical gearbox
Manual Transmission Specifications
Transmission oil
Removal and installation of MSG gearbox
Removal and installation of the MUA gearbox
Removal and installation the gear shift lever
Removal and installation the gear selector lever
Removal and installation the shift linkage
Gearbox repair
Cardan shafts
Cardan shaft and final drive specifications
Front wheel drive
Removal and installation the front wheel hub
Front propeller shaft — removal and installation
Removal and installation front wheel drive shafts
Replacement of the constant velocity joint boot
Automatic hub lock
Manual hub lock
Rear Wheel Drive — General Information
Fixing rear axle leaks
Removal and installation rear axle shafts
Replacing the rear axle bearing
Removal and installation the rear propeller shaft
Differential — disassembly and assembly
Chassis
Brake system
Brake system — general information
Brake system specifications
Replacing the front brake pads
Removal, repair and installation of front brake calipers
Brake discs — removal and installation
Removal and installation the rear brake drum
Replacing rear brake pads
Rear Wheel Cylinder — Removal and Installation
Removal and installation the rear brake shield
Removal and installation rear brake pads
Removal, repair and installation of the rear caliper
Replacing the rear brake disc cover
Replacing the parking brake pads
Master Brake Cylinder — Removal and Installation
Bleeding the brake system
Vacuum brake booster — removal and installation
Parking brake — removal, installation and adjustment
Pressure regulator — removal and installation
Brake hoses for front and rear brake mechanisms
Anti-lock braking system (ABS) — removal and installation
Front suspension
Suspension and steering specifications
Front Wheel Suspension and Front Axle — General Information
Removal and installation the torsion bar
Removal and installation shock absorbers
Removal and installation the anti-roll bar
Removal and installation the lower wishbone
Removal and installation the upper wishbone
Removal and installation the ball joint
Removal and installation the steering knuckle
Front axle — removal, installation and repair
Checking and adjusting work on the car
Rear suspension
Rear wheel suspension and rear axle — general information
Removal and installation of the axle housing (flat spring suspension)
Removal and installation of the axle housing (suspension with coil springs)
Removal and installation a coil spring
Removal and installation the shock absorber
Removal and installation the trailing arm
Removal and installation the middle arm
Removal and installation the transverse reaction rod and rubber bushings
Removal and installation the anti-roll bar
Rear leaf spring suspension — removal and installation
Steering
Power steering — general information
Removal and installation the pendulum arm
Steering knuckle and pendulum arm
Replacing outer tie rods and tie rod ends
Removal and installation the steering wheel
Removal and installation the steering column
Replacing the steering lock and steering column bearing
Disassembly and assembly of the steering column
Steering gear — general information
Removal and installation the steering gear
Removal and installation the power steering pump
Replacing the V-belt of the power steering pump drive
Airbag — Removal and Installation
Steering wheel adjustment
Adjusting the steering wheel free play
Removal air from the hydraulic system
Body
Repair and care
General information about the car body
Car body care
Care of vinyl trim panels
Caring for upholstery and carpets
Removal traces of minor scratches on the body
Car body dent repair
Repair of rusted holes and punctures
Puttying and painting the body surface
Repair of significant body damage
Electrical equipment
Equipment and devices
On-board electrical equipment — general information
Diagnostics of faults of on-board electrical equipment
Fuses — description and location
Fusible Links — Description and Replacement
Circuit breakers (thermal relays)
Relay — description and replacement
Headlights — removal, installation and adjustment
Removal and installation the horn
Beam range adjustment servo motor
Removal and installation windshield wiper arms
Removal and installation of the drive motor and rods
Rear window cleaner
Electrical circuits
Explanations of electrical circuits of electrical equipment diagrams
Electrical circuits with coordinates 100-199
Electrical circuits with coordinates 200-299
Electrical circuits with coordinates 300-399
Electrical circuits with coordinates 400-499
Electrical circuits with coordinates 500-599
Electrical circuits with coordinates 600-699
Wiring harness diagram (2-door car)
Wiring harness diagram (4-door car)



Ascona C (1981-1988)
General information
Maintenance
Front-wheel drive models OPEL ASCONA
Overall dimensions, weight and fuel data
Identification numbers
Routine maintenance
Recommended working fluids and lubricants
Supplement: New Features and Information on Later Models — Introduction
Information on later models — specifications
Power unit
Gasoline engines
Engine — Specifications
General description
Engine — Routine Maintenance
Work possible without removing the engine
Oil Pressure Regulator Valve — Removal and Installation
Timing Belt — Replacement
Front camshaft oil seal — replacement (engine is still on the car)
Camshaft — removal (engine is on the car)
Cylinder head — removal and installation
Camshaft housing and camshaft — disassembly and assembly
Pallet — removal and installation
Oil pump — removal and installation
Connecting rod and piston groups — removal and installation
Flywheel — removal and installation
Front crankshaft oil seal (pulley side) — replacement
Rear crankshaft oil seal (flywheel side) — replacement
Engine/gearbox mounts — replacement
Engine — Removal Methods
Engine — removal (manual gearbox remains on the car)
Engine — removal (with manual gearbox)
Engine and manual transmission — disconnecting after removal from the car
Engine — removal (automatic transmission remains on the car)
Engine — removal (with automatic transmission)
Engine and Automatic Transmission — Disconnecting After Removal from Vehicle
Engine disassembly — general part
Engine Accessories — Removal
Engine — complete disassembly
Engine lubrication systems and crankcase ventilation — description and maintenance
Engine Oil and Oil Filter — Replacement
Oil pump — overhaul
Cylinder head — disassembly, inspection, replacement of damaged parts and removal of carbon deposits
Engine — inspection and replacement of parts (general part)
Engine parts — inspection and repair or replacement
Engine — assembly (general part)
Engine — assembly
Engine — installation (manual gearbox remained on the car)
Engine and manual transmission — connection before installation on the car
Engine — installation (with manual gearbox)
Engine — installation (automatic transmission remained on the car)
Engine and automatic transmission — connection before installation on the car
Engine — installation (with automatic transmission)
Engine — first start after major overhaul
Engine — troubleshooting
Engine — modifications since 1987 (general information)
Diesel engines
Diesel Engine — Operating Principle
Key diesel engine data
Removal and installation the timing belt
Removal and installation the cylinder head
Replacement of camshaft housing, removal and installation of camshaft
Compression check
Engine lubrication system
Diesel injection equipment
Idle speed problems
Checking the adjustment of the injection pump thrust torque
Cleaning and replacing the air filter element
Checking and adjusting valve timing
Adjusting the valve timing
Diesel injection device malfunctions
Cooling system
Cooling and heating systems — specifications
General information
Cooling system — routine maintenance
Cooling system — draining liquid
Cooling system — flushing
Antifreeze mixture
Cooling system — filling with fresh coolant
Radiator — removal, inspection and installation
Thermostat — Removal, Checking and Installation
Water pump — removal and installation
Generator Drive Belt — Removal, Installation and Tensioning
Electric Radiator Fan — Removal and Installation
Fan Thermal Switch — Removal and Installation
Coolant Temperature Sensor — Removal and Installation
Heater — description
Heater Parts — Removal and Installation
Vents and grilles — removal and installation
Cooling and heating system — troubleshooting
Cooling system (late models)
Fuel and exhaust system
Fuel and exhaust system — specifications
General description
Fuel and exhaust system — routine maintenance
Air purifier — description and testing
Air Cleaner — Maintenance, Removal and Installation
Fuel pump — description, maintenance, inspection, removal and installation
Fuel tank sensor — removal and installation
Fuel tank — removal and installation
Fuel tank ventilation chamber — description, removal and installation
GM Varajet Carburetor — Description
GM Varajet Carburetor — Idle Speed and Mixture Control
GM Varajet Carburetor — Engine Adjustment
GM Varajet Carburetor — Removal and Installation
GM Varajet Carburetor — Overhaul
Carburetor Pierburg 2EZ — description
Carburetor Pierburg 2EZ — regulation of idle speed and mixture composition
Carburetor Pierburg 2EZ — adjustment on the engine
Carburetor Pierburg 2EZ — removal and installation
Carburetor Pierburg 2EZ — overhaul
Carburetor Pierburg 2EZ — adjustment on the removed carburetor
Injector system — description
Injector system — precautions
Injector system — regulation of idle speed and mixture composition
Throttle valve of the injector system — regulation
Throttle switch of the injection system — regulation
Injector system parts — removal and installation
Unleaded high octane fuel
Throttle Control Cable — Adjustment and Replacement
Choke Cable — Removal and Installation
Collectors — removal and installation
Exhaust system — removal and installation
Fuel system — troubleshooting
Fuel and Exhaust System (Late Models)
Contact ignition system
Ignition system — specification
Ignition system with mechanical contact breaker — general description
Ignition System — Routine Maintenance
Breaker contacts — adjustment of the gap and angle of the closed state of the contacts
Breaker contacts — removal and installation
Capacitor — removal, inspection and installation
Distributor — removal and installation
Distributor — disassembly, inspection and assembly
Ignition timing angle — adjustment
Spark plugs and high tension wires — common part
Ignition coil — common part
TDC position sensor
Ignition Switch — Removal and Installation
Ignition system with mechanical contact breaker — troubleshooting
Contactless ignition system
Contactless ignition systems — general description
Contactless Ignition Systems (All Models) — Precautions
Contactless Ignition Systems — Routine Maintenance
Distributor — removal and installation
Distributor — disassembly, inspection and assembly
Ignition timing — regulation
Ignition coil — common part
Ignition module — removal and installation
Ignition system (late models)
Transmission
Clutch
Contactless ignition system — troubleshooting
Clutch — Specification
Clutch — General Description
Clutch — adjustment
Clutch cable — removal and installation
Clutch pedal — removal and installation
Clutch — removal, inspection and installation (engine and gearbox remain on the car)
Clutch — removal, inspection and installation (engine or gearbox removed from vehicle)
Release bearing, clutch release lever, bushings and seal — removal and installation
Clutch — troubleshooting
Clutch and manual transmission (late models)
Mechanical gearbox
Manual Transmission — Specifications
Manual transmission — general description
Manual Transmission — Routine Maintenance
Gear Shift Lever — Removal and Installation
Gear Shift Lever Reverse Cable — Removal and Installation
Gear Shift Lever Mechanism — Removal and Installation
Gear shift lever mechanism — adjustment
Gearbox — removal and installation
Gearbox type F10 and F10.4 — disassembly into main components
Gearshift mechanism cover (type F10 and F 10.4 boxes) — overhaul
Gearbox housing (type F10 and F 10.4) — overhaul
Drive shaft (type F10 and F 10.4 boxes) — overhaul
Driven shaft (type F10 and F 10.4 boxes) — overhaul
Synchronizers — overhaul
Gearbox type F10 and F10.4 — assembly
Gearbox type F10.5 — description
Gearbox type F10.5 — disassembly and assembly
Gearbox type F16 and F16.4 — disassembly and assembly
Gearbox type F16.5 — disassembly
Gearbox type F16.5 — assembly
Manual transmission — fault diagnosis
Automatic gearbox
Automatic transmission — specifications
Automatic transmission — general description
Automatic transmission — routine maintenance
Downshift Cable — Replacement and Adjustment
Gear Shift Lever Cable — Removal, Installation and Adjustment
Automatic transmission — removal and installation
Automatic transmission — fault diagnosis
Drive shafts
Drive shafts — specifications
Description and maintenance
Drive shaft — removal and installation
Drive shaft joint — bellows replacement
Drive shaft joint — replacement
Troubleshooting — Drive Shafts
Chassis
Steering
Steering — Specifications
General description
Routine Maintenance — Steering
Rod End Cap — Removal and Installation
Steering — removal and installation
Steering rack bellows — replacement
Steering — inspection
Steering wheel air freshener — removal and installation.
Steering wheel — removal and installation
Steering column — removal and installation
Steering column — inspection
Steering column lock — removal and installation
Steering Angles and Wheel Layout — General Description
Power Steering — Blowing Out
Power Steering Pump Drive Belt — Tensioning
Fault Diagnosis — Steering
Brake system
Brake system — specifications
General description
Routine maintenance
Disc pads — inspection and replacement
Caliper (type ATE) — removal, inspection and installation
Caliper (type GMF) — removal, inspection and installation
Brake disc — inspection, removal and installation
Brake Disc Shield — Removal and Installation
Rear brakes (on models manufactured before 1984) — lining
Rear Brake Shoes (Pre-1984 Models) — Inspect and Replace
Self-adjusting rear brakes — description
Self-adjusting rear brakes — inspection and replacement
Rear Brake Cylinder — Removal, Inspection and Installation
Rear Brake Plate — Removal and Installation
Brake Drum — Inspection and Renewal
Master Brake Cylinder — Removal and Installation
Master Cylinder (ATE Type) — Inspection and Repair
Master Cylinder (GNF Type) — Inspection
Pressure Regulating Valves
Flexible Hoses and Rigid Tubes — Inspection and Replacement
Hydraulic system — blowing
Vacuum Servo Hose — Replacement
Vacuum servo unit (booster) — checking the operation
Vacuum servo unit — removal and installation
Brake Pedal Remote Control Assembly — Disassembly and Assembly
Brake Pedal Remote Control Rod — Removal and Installation
Handbrake — adjustment
Handbrake Cables — Replacement
Handbrake lever — removal, inspection and installation
Handbrake warning switch — removal and installation
Brake pedal — removal and installation
Switch that turns on the headlights when braking — removal and installation
Fault Diagnosis — Brake System
Car suspension
Suspension — specifications
General description
Routine Maintenance — Suspension
Front suspension struts — removal and installation
Front Hub Bearing — Replacement
Front Suspension Strut — Inspection
Front Suspension Control Bracket — Removal and Installation
Control Bracket Bushings — Replacement
Control Bracket Ball Joint — Replacement
Control Bracket Support — Removal and Installation
Front anti-roll bar
Rear hub bearings — lining
Rear Hub Bearings — Replacement
Rear shock absorber — removal, inspection and installation
Rear anti-roll bar — removal and installation
Rear Coil Spring — Removal and Installation
Short axle rear suspension — removal and installation
Rear Axle — Removal and Installation
Flexible bushings of the closing lever — replacement
Level Control System — Description
Level control system (manual) — setup
Level Control System Components — Removal and Installation (General Description)
Rear wheel arrangement
Wheels and Tyres — General Care and Maintenance
Fault Diagnosis — Suspension
Body
Exterior
Bodywork and fixtures — specifications
General description
Door hinges, hood and trunk lids, locks and handles — lubrication
Hood — removal and installation
Bonnet Lock Cable — Replacement
Grille and radiator — removal and installation
Front bumper — removal and installation
Rear bumper — removal and installation
Front wing — removal and installation
Outside rear view mirror — removal and installation
Outside rear view mirror cover (manual control) — removal and installation
External rear view mirror cover (electric) — removal and installation
Outside rear view mirror motor — removal and installation
Rear Air Deflector (Estate) — Removal and Installation
Rear Ventilation Grille (Estate) — Removal and Installation
Electrical System — Specifications
Bodywork (late models)
Interior
Front seat — removal and installation
Rear seat — removal and installation
Front panel — removal and installation
Glove Compartment (Glove Box) — Removal and Installation
Center console — removal and installation
Headrests — Removal and Installation
Seat Belts — Care and Maintenance
Doors and windows
Interior Door Trim Panel — Removal and Installation
Window lift mechanism — removal and installation
Door glass — removal and installation
Small fixed rear door glass — removal and installation
Front door lock — removal and installation
Front Door Outside Handle — Removal and Installation
Front Door Lock Cylinder — Removal, Disassembly, Assembly and Installation
Rear Door Lock — Removal and Installation
Rear Door Outside Handle — Removal and Installation
Door — removal and installation
Rear Door (Hatchback) — Removal and Installation
Rear Door Lock (Hatchback) — Removal and Installation
Rear Door Support Pillar (Hatchback and Estate) — Removal and Installation
Rear Door (Estate) — Removal and Installation
Rear Door Lock (Estate) — Removal and Installation
Rear Door Cylinder (Estate) — Removal and Installation
Interior Trunk Trim Panels (Estate) — Removal and Installation
Trunk lid — removal and installation
Trunk lid lock and cylinder — removal, disassembly, assembly and installation
Windshield — Removal and Installation
Rear window or rear door glass — removal and installation
Opening side window — removal and installation
Fixed side glass — removal and installation
Roof hatch (removable type) — operation description
Sunroof (Sliding Type) — Operation, Removal and Installation
Sunroof (Sliding/Tilting Type) — Operation and Maintenance
Hatch Cover (Sliding/Tilting Type) — On-Site Engine Replacement
Sunroof (sliding/tilting type) — removal and installation (entire structure)
Sunroof (sliding/tilting type) — replacement of parts (with the structure removed from the vehicle)
Electrical equipment
Equipment and devices
General description
Service and Maintenance — Electrical System
Fuses — Checking and Replacing
Relay — location, installation
Switches — removal and installation
Starter Delay Switch (Automatic Transmission) — Adjustment
Sound signal(s) and switch
Watch — removal and installation
Cigarette lighter — removal and installation
Instrument panel — removal and installation
Instruments — removal and installation
Speedometer Cable — Replacement
Light bulbs — replacement
Headlights — removal, installation, modifications
Headlight beams — adjustment
Front fog lights — adjustment
Tail Light Assembly — Removal and Installation of the Complete Saloon and Hatchback Assembly
Reversing lights and rear fog lights (Estate) — removal and installation of the structure
Windscreen wiper arms and blades — removal and installation
Windshield Wiper Motor and Linkages — Removal and Installation
Rear Window Wiper Motor — Removal and Installation
Windshield washer system
Rear window washer system
Headlamp Washer/Wiper System
Washer fluid
Central locking system — description, processes of removal and installation of components
On-board computer — description, replacement of parts
Electrical Accessories — Series Installation
Radio Antenna — Removal and Installation
Radio receivers and tape recorders — installation (general description)
Radio receivers and tape recorders — interference suppression (general information)
Rear Window Defogger — Maintenance
Electrically adjustable outside rear view mirror
Electric power windows
Troubleshooting — Electrical System
Electrical system (late models)
Power devices
Battery — Checking and Maintenance
Battery — Removal and Installation
Battery — charging
Generator — Precautions
Generator — General Description
Generator — removal and installation
Generator — troubleshooting
Generator Brushes (Delco-Remy Type) — Checking, Removing and Installing
Generator brushes (Bosch type) — checking, removal and installation
Starter Motor — General Description
Starter Motor — Checking in a Car
Starter motor — removal and installation
Starter Repair — General Information
Starter Solenoid — Removal and Installation
Starter Motor Brushes — Checking and Replacing
Starter motor — disassembly and assembly
Electrical circuits
Electrical diagram for models up to 1983
Electrical diagram for 1984 models
Electrical diagram for 1985 models
Electrical diagram for 1986 models
Electrical diagram for models from 1987
Electrical diagram for models from 1988



Vivaro A (2001-2014)
General information
User manual
Tire pressure
Remote control (plip) for central locking
Special lock
Electric door drive from inside
Front doors
Side doors
Rear hinged door
Rear liftgate
Anti-theft system
Electronic engine immobilizer
Front seats
Front headrests
Rear view mirrors
Instrument panel
Instrument panel
Setting the time
Windscreen wipers and washers
Outdoor lighting
Sound signal and flashing light signal
Fuel tank
Blower deflectors
Heating and ventilation system
Air conditioning
Car window lifters
Ashtray and cigarette lighter
Rear bench seats
Transportation of items
Hood — opening
Engine oil level
Liquid levels
Replacing light bulbs
Fuse box
Towing a car
Windscreen wiper blades
Emergency fuel shut-off system
Type plates
Dimensions of the car
Vehicle weight
Power unit
F4R petrol engine
Tightening the cylinder head
Adjusting the engine accessory drive belt
Volumes of working fluids
Checking oil pressure
Removal and installation the engine
Removal and installation the timing belt
Engine technical data
Technical characteristics of fuel injection system components
Removal and installation the throttle body
Removal and installation the intake manifold
Removal and installation the exhaust manifold
Removal and installation of fuel rail and injectors
Removal and installation of pistons and connecting rods
Removal and installation oxygen sensors
Removal and installation the accelerator pedal position sensor
Removal and installation the crankshaft speed sensor
Removal and installation the coolant temperature sensor
Removal and installation the intake air temperature sensor
Removal and installation the knock sensor
Removal and installation the generator
Removal and installation the starter
Removal and installation the ignition coil
Cooling system
Diesel engine F9Q
Oil pressure
Removal and installation of engine and gearbox
Removal and installation the timing belt tension roller
Removal and installation the timing belt
Removal and installation the cylinder head
Air intake system
Removal and installation of collectors
Removal and installation the air flow meter
Boost pressure control valve
Boost pressure adjustment
Removal and installation a turbocharger
Removal and installation the charge air cooling radiator (intercooler)
Fuel injection system
Technical characteristics of fuel injection system components
Removal and installation the fuel pump
Removal and installation the fuel filter
Removal and installation the high pressure fuel pump
Removal and installation a high pressure accumulator
Removal and installation injectors
Removal and installation the fuel pressure sensor
Removal and installation the accelerator pedal position sensor
Centralized coolant temperature control
Removal and installation the fuel injection system control unit
Crankcase ventilation system
Exhaust gas recirculation system
Battery charging system
Removal and installation the generator
Engine starting system
Diesel engine G9U
Engine specifications
Oil pressure
Removal and installation of the gearbox engine
Removal and installation the pallet
Removal and installation the oil pump
Removal and installation the accessory drive belt
Removal and installation the timing belt
Removal and installation the air filter
Removal and installation the air distributor
Removal and installation the intake manifold
Removal and installation the exhaust manifold
Pressure regulation
Removal and installation a turbocharger
Fuel injection system
Technical characteristics of fuel injection system components
Removal and installation the high pressure fuel pump
Removal and installation injectors
Removal and installation the pressure regulator
Removal and installation the high pressure accumulator protective cover
Removal and installation the accelerator pedal position sensor
Removal and installation of the injection system control unit
Centralized coolant temperature control
Exhaust gas recirculation system
Removal and installation the generator
Removal and installation the starter
Cooling system
Transmission
Clutch and drive shafts
Removal and installation the clutch housing with pressure plate assembly
Removal and installation the clutch release bearing
Removal and installation axle shafts
Manual gearbox
Removal and installation of manual transmission
Replacing the primary shaft seal of the gearbox
Replacing the differential flange seal
Disassembly and assembly of the gearbox
Disassembling and assembling the differential
Internal transmission controls
Removal and installation bearing supports in the clutch housing
Removal and installation needle bearings
Gear Selector and Shift Cables
Gear shift lever housing
Gear Shift Lever Support Protective Plate
Chassis
Front suspension
Removal and installation steering knuckles
Removal and installation the shock absorber strut
Removal and installation front suspension arms
Removal and installation the anti-roll bar
Removal and installation the wheel hub bearing
Influence of front wheel alignment angles
Checking and adjusting the front wheel alignment angles
Front suspension diagnostics
Control values of front wheel alignment angles
Removal and installation the steering gear
Removal and installation the steering column
Rear suspension
Removal and installation the wheel hub
Rear suspension spring
Removal and installation the rear shock absorber
Removal and installation the rear axle beam
Brake system
Technical characteristics of the main elements of the brake mechanisms
Brake system diagnostics
Removal and installation front brake pads
Removal and installation front brake calipers
Removal and installation the guide pads of the front brake mechanisms
Removal and installation rear brake pads
Removal and installation the master brake cylinder
Removal and installation the brake booster
Removal and installation a vacuum pump
Removal and installation the brake pedal
Removal and installation the parking brake system drive
Removal and installation the brake force regulator
Body
Exterior
Hood — fastening
Front wing
Front door
Front bumper
Radiator grille
Rear bumper
Lifting a car
Interior
Interior trim
Removal and installation the front bench seat
Removal and installation the rear bench seat
Electrical equipment
Heating and ventilation
Removal and installation of the interior ventilation system
Removal and installation the ventilation and heating control panel
Removal and installation heater control flap rods
Air distribution unit
Removal and installation the heater radiator
Removal and installation the heater fan
Removal and installation the power module
Air conditioner
Removal and installation the capacitor
Removal and installation the receiver-dryer
Removal and installation the compressor
Removal and installation the gearbox
Pressure sensor
Evaporator sensor
Removal and installation the outside temperature sensor
Equipment and devices
Removal and installation the battery
Removal and installation the headlight
Headlight corrector
Removal and installation fog lights
Removal and installation rear lights
Relays and fuses
Removal and installation the instrument panel
Removal and installation the instrument panel
Fuel level sensor
Removal and installation windshield wipers
Removal and installation rear window wipers
Removal and installation the windshield washer pump
Electrical diagrams
Engine cooling system with air conditioning
Engine cooling system without air conditioning
TECSHIFT automated gearbox and G9U 730 EDC 16 SZ engine management system
TECSHIFT automated gearbox
Airbags and information display
Airbags, remote control and signal
Anti-theft alarm, immobilizer and daytime running lights
Central lock
Power windows (left-hand drive) and heated seats
Power windows (right hand drive)
Instrument cluster (before 05.2005)
Instrument cluster (since 05.2005)
Radio receiver and tachograph
Exterior rear view mirrors
Power supply for the height control system, diagnostic connector, power distribution
Additional socket, ashtray light, glove compartment light, heated rear window
Petrol Engine Management System F4R 720 Sagem S 2000 RPM (I)
Petrol Engine Management System F4R 720 Sagem S 2000 RPM (II)
Engine Management System F9Q 760/762 EDC 15 C13
Instrument panel
Diesel engine management system F9Q 760, F9Q 762, EDC 15 C13
Diesel engine management system G9U 730 EDC 15 C13 (I)
Diesel engine management system G9U 730, EDC 15 C13 (II)
Rear lights (I)
Rear lights (II)
ABS 430 with ESP driving stability program
ABS system 430
Air conditioning compressor
Headlight corrector
Windscreen wipers and washers
Parking lights, direction indicators
Outdoor lighting
Engine starting, battery charging, power distribution
Rear air conditioning system, additional heater (fuel)
Heater for cars with engines F9Q 760/F9Q 762 and G9U 730
Navigation system and Telematic system
Radio and telephone
Loudspeakers — diagram
Information displays
Wiring harness layout diagram
Signatures of elements of basic electrical circuit diagrams
Wiring connector designations
Abbreviations of elements of basic electrical circuit diagrams

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