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Astra F (1991-1998, petrol)
General information
Maintenance
Introductory information about cars Opel Astra F
Dimensional and weight characteristics
Characteristics of vehicle components
Lubricants and fluids
Engine compartment — 1.4L C 14 NZ engine
Engine Compartment — 1.6L C 16 SE Engine
Engine Compartment — 2.0L C 20 XE Engine
Front bottom view — 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
Characteristics of a single overhead camshaft engine
Characteristics of the engine with two overhead camshafts
General information about the engine
Compression test
#1 Piston Top Dead Center — Location
Camshaft cover — removal and installation
Crankshaft pulley — removal and installation
Timing belt covers — removal and installation
Ignition distributor belt — removal, installation and adjustment
Timing belt sprockets — removal and installation
Belt tension indicator (engines 1.4 and 1.6 l) — 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 (engine with two camshafts) — removal and installation
Engine removed
Indications for removal of the engine
Engine — removal and installation (manual box remains on the car)
Node engine / manual transmission — removal and installation
Engine — removal and installation (automatic transmission on a car)
Node engine / automatic transmission — 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 — installing and checking the clearance of the main journals
Piston / connecting rod assembly — installation and clearance check
Engine — first start after repair
Exhaust gas toxicity control
Cooling system
Specifications
Cooling systems — general information
Coolant hoses — disconnect and replace
Radiator — removal, inspection and installation
Expansion tank — removal and installation
Thermostat — removal, inspection and installation
Cooling fan — check, removal and installation
Cooling system switches — check, removal and installation
Coolant Temperature Gauge Sensor
Coolant level sensor
Coolant pump — removal and installation
Heating and ventilation
Parts of the heating and ventilation system
Interior ventilation and heating system — general information
Christmas trees control the heating / ventilation system — 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 / heater system — removal and installation
Fuel supply (carburetor)
Specifications
General information about carburetor engines
Air cleaner air temperature control — check
Fuel pump — check, removal, installation
Fuel gauge 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 — fault diagnosis, repair and adjustment
Carburetor float and needle valve — removal, inspection and installation
Secondary Chamber Vacuum Diaphragm Throttle Controller
Carburetor Economizer Diaphragm — Replacement
Carburetor accelerator pump diaphragm — replacement
Automatic air damper — removal, installation, adjustment
Vacuum regulator for slightly 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 — Replacing Parts
Fuel supply (injector)
General information about fuel injection
Fuel pump — check, removal and installation
Fuel filter — removal and installation
Fuel tank — removal and installation
Throttle cable — removal, installation and adjustment
Unleaded gasoline — general information
Catalytic converter — general information
Fuel injection systems
Components of the Multec single point fuel injection system — removal and installation
Electronic control unit
Components of the Multec multipoint fuel injection system — removal and installation
Motronic M1.5.2 fuel injection system components — removal and installation
Details of the fuel injection system (Motronic M2.5) — removal and installation
Electronic traction control (RTS)
Electronic Traction Control (ETS) Components
Intake manifold (Multec single point injection) — removal and installation
Intake manifold (Multec multi-point 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 — parts replacement
Emission control
Emission control systems — general information
Components of the crankcase gas control system
Exhaust gas cleaning system
Evaporative Emission System — Check
Activated carbon box — replacement
Fuel Tank Vent Valve — Replace
Exhaust Gas Recirculation System — Check
Exhaust gas recirculation valve — cleaning and replacement
Ignition system
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 Amplifier Module — Removal and Installation
Transmission
Clutch
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
Specifications
General information about manual transmission
Gearbox Oil — Draining and Refilling
Gear Shift Mechanism — Adjustment
Gearshift mechanism — removal, repair and installation
Speedometer drive — removal and installation
Manual transmission oil seals — replacement
The switch of a light signal of a backing — removal, installation and check
Manual transmission — removal and installation
Manual transmission — repair, general information
Automatic gearbox
Specifications
General information about automatic transmission
Switch cable — removal, installation and adjustment
Selector lever — removal and installation
Oil seals (drive shafts) on the differential side
Reverse Light Switch/Starter Inhibit Circuit
Transmission mode switches — removal and installation
Fluid temperature sensor — removal and installation
Inlet / outlet speed sensors — removal and installation
Electronic control unit — removal and installation
Automatic transmission — removal and installation
Repair of an automatic transmission — general information
Drive shafts
Specifications
General information about drive shafts
Drive Shafts — Removal
Drive Shafts — Installation
Drive shaft repair — general information
Chassis
Brake system
Specifications
Anti-lock braking system (ABS)
Hydraulic System — Bleeding (bleeding)
Pipelines and hoses of the hydraulic system — check, removal and installation
Front brake pads — removal
Front brake caliper — removal, repair and installation
Brake disc — check, removal, installation
Guard of a forward brake disk — removal and installation
Rear brake pads — removal
Rear brake drum — removal, inspection and installation
Rear brake wheel cylinder — removal, repair and installation
Rear wheel brake pads (rear wheel disc brakes) — replacement
Rear wheel brake caliper (rear disc brakes) — removal, repair and installation
Handbrake pads (rear disc brakes) — replacement
Rear wheel brake platter — removal and installation
Brake pedal — removal and installation
Hydraulic booster — removal and installation
Brake booster check valve — check, removal and installation
Master brake cylinder — removal, repair and installation
Handbrake — adjustment
Handbrake lever — removal, repair and installation
Handbrake cables — removal and installation
Rear pressure control valve — removal, installation and adjustment
Stoplight switch — removal and installation
Brake system warning lamps — general information
Anti-lock braking system ABS, components — removal and installation
Car suspension
Suspension Specifications
Front and rear suspension device
Front suspension strut — removal and installation
Front suspension strut — repair
Front wheel bearing — replacement
Lower arm front suspension — removal and installation
Bushings of the lower arm of the front suspension — replacement
Ball joint of the lower arm of the front suspension — replacement
Anti-roll bar bar — 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
Coil spring rear suspension — removal and installation
Rear anti-roll bar — removal and installation
Torsion beam rear suspension / trailing arms — removal and installation
Rear suspension trailing arm bushings — replacement
Rear suspension level control system — general information
Components of the rear suspension level control system — removal and installation
Steering
Steering Specifications
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 a shaft of a steering wheel — removal
Rubber bellows steering gear — 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
Tie rod — removal and installation
Wheel installation — general information
Body
Exterior
General information about the body
Front and rear bumpers — removal and installation
Radiator grill — removal and installation
Windshield fairing panel — removal and installation
Hood and hinges — removal and installation
Bonnet lock parts — removal and installation
Hood lock cable — removal and installation
Doors — removal, installation and adjustment
Door handle and lock parts — removal and installation
Window glass doors and power windows — removal and installation
Rear door, hinges and support legs — 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
Sliding window electrical equipment — removal and installation
Mirrors — repair, removal and installation
Windshield and tailgate window glass — general information
Rear small side windows — removal and installation
Sliding roof parts — removal and installation
Seats — removal and installation
Front seat belt tension system
Electrical equipment
Equipment and devices
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 tension
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
Dashboard — removal and installation
Dashboard 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
Flexible speedometer shaft — removal and installation
Wiper arms — removal and installation
Rear door wiper motor and arm — removal and installation
Components of the windshield / rear door washer system — 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 to the electrical circuit diagrams of the car
Key to circuit diagrams
Diagram for battery, starter, alternator and radiator fan (up to February 1992)
Carburetor wiring diagram (until February 1992)
Fuel injection circuitry (up to February 1992)
Automatic transmission wiring diagram (until February 1992)
Wiring diagram for diesel and turbodiesel (until February 1992)
Wiring diagrams: control, information display, radio, clock, instruments (up to February 1992)
Wiring diagrams for lights and headlights (before February 1992)
Wiring diagrams: door lock, anti-theft system, heating fan (before February 1992)
Wiring Diagrams: Wiper, Horn, Outside Mirror (Before February 1992)
Wiring Diagrams: ABS, traction control (before February 1992)
Wiring diagrams: battery, starter, alternator, carburetor (since March 1992)
Fuel injection circuitry (since March 1992)
Wiring diagram for automatic transmission (since March 1992)
Direct Ignition Wiring Diagram (since March 1992)
Wiring diagram for diesel and turbodiesel (since March 1992)
Wiring diagrams: control, radio, clock, instruments, lights (since March 1992)
Wiring diagrams for lights and headlights (since March 1992)
Wiring diagrams: door lock, anti-theft system, heating fan (since March 1992)
Wiring diagrams: wiper, washer, horn (since March 1992)
Wiring Diagrams: ABS, traction control (since March 1992)
Astra G (1998-2004, petrol)
General information
User manual
Introduction to the manual for Opel Astra G
General technical data of cars
Unlocking the door
Seat adjustment
Steering column adjustment
Optimal driver seat position
Putting on the seat belt
Adjustment of rear-view mirrors
Ignition lock and engine start
Heated rear window and outside mirror
Drying glass covered with moisture droplets or frost
Controls and instruments
Deciphering nomograms on controls
Switches and buttons
Manual Transmission
Automatic transmission
Control lamps on the instrument panel
Control devices on the panel
Setting the time and date
Starting the engine from the battery of another car
Towing a car
Using the car as a towing vehicle
Location of warning triangle and first aid kit
Spare wheel
Fuses and Protected Circuits
Replacing lamps in a car
Engine oil level
Diesel engine fuel filter
Cooling liquid
Hydraulic brake fluid
Windscreen and headlight washers
Towing a trailer or van
Car care
Troubleshooting the car on the road
Auxiliary battery start
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 hydraulic brake fluid level
Checking tire condition 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
Wiper blades
Battery care
Checking lamps and fuses
Recommended Lubricants and Fluids
Maintenance
Vehicle technical data
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 on the road
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 — the procedure for checking and interpreting the results
The order of installation of the piston of the 1st cylinder in the TDC of the compression stroke
Cylinder head cover — removal and installation
Crankshaft pulley — removal and installation
Camshaft drive belt covers — removal and installation
Camshaft timing belt — removal and installation
Tensioner and sprockets — removal and installation
Camshaft oil seal — replacement
Camshaft bearing housing and camshaft — removal and installation
Hydropushers — removal and installation
Cylinder head — removal and installation
Oil pan — removal and installation
Oil pump — removal, inspection and installation
Flywheel / torque converter drive plate — removal and installation
Crankshaft seals — replacement
Power unit supports — removal and installation
Twin shaft engines
Technical data
Description of engines
Compression — the order of verification and interpretation of the results
The procedure for installing the piston of the 1st cylinder at TDC of the compression stroke
Cylinder head cover — removal and installation
Crankshaft pulley — removal and installation
Camshaft drive belt covers — removal and installation
Camshaft timing belt — removal and installation
Tensioner and sprockets — removal and installation
Camshaft oil seal — replacement
Camshaft and pushers — 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 plate — removal and installation
Crankshaft seals — replacement
Balancing mechanism — removal and installation (only for engines 2.0 l)
Engine repair
Technical data (clearances 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 — check
Engine Overhaul — Assembly Procedure
Piston rings — installation
Crankshaft — mounting and checking the clearances in the main bearings
Connecting rod and piston group — installing and checking clearances in connecting rod bearings
Engine — start after overhaul
Cooling and heating
Technical data
Cooling system — general information
Cooling System — Fluid Change
Checking the condition of the hoses
Radiator — removal and installation
Thermostat — removal and installation
Fan — check, removal and installation
Cooling system sensors and devices — removal and installation
Coolant pump — removal and installation
Details of the ventilation and interior heating system — 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 actuator pedal — removal and installation
Injection systems — general information
Fuel system decompression
Fuel pump — removal and installation
Fuel level sensor — removal and installation
Fuel tank — removal and installation
Throttle pipe — removal and installation
Sensors and devices of a single nozzle system — removal and installation
Sensors and devices of multi-injector 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
Charge system — check
Generator drive belt — removal, tension adjustment and installation
Generator drive belt tensioner — removal and installation
Generator — removal and installation
Generator — replacement of brushes
Engine starting system — check
Starter — removal and installation
Starter — check and repair
Emergency 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 — bleeding
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
Changing the oil in the gearbox
Gear change mechanism — adjustment
Gear change mechanism — removal and installation
Gearbox seals — replacement
The switch of a signal of a backing — check, removal and installation
Gearbox — removal and installation
Gearbox disassembly — general information
Gearbox — checking the oil level
Automatic gearbox
Technical data
General information
Automatic Transmission — Fluid Change
Transmission control cable — adjustment
Transmission control cable — removal and installation
Automatic transmission seals — replacement
Switches for transmission control systems — removal, installation and adjustment
Automatic transmission — removal and installation
Machine
Drive shafts
Technical data
General information
Half shafts — removal and installation
Axle joints — check and replacement
Covers of hinges of semiaxes — replacement
Chassis
Brake system
Technical data
General information
Hydraulic Brake — Bleeding
Tubes and hoses of brakes — replacement
Front brake pads — replacement
Rear disc brake pads — removal and installation
Rear drum brake pads — replacement
Brake discs — check, removal and installation
Rear brake drums — removal, inspection and installation
Front brake caliper — removal, disassembly and installation
Rear brake caliper — removal and installation
Wheel cylinder rear drum brakes — removal, disassembly and installation
Brake master cylinder — removal, disassembly and installation
Brake pedal — removal and installation
Vacuum brake booster — check, removal and installation
Vacuum booster check valve — removal and installation
Parking brake — adjustment
Handbrake lever — removal and installation
Handbrake cables — removal and installation
The switch of a signal of braking — removal, installation and adjustment
Parking brake warning light switch — removal and installation
Anti-Lock Braking System and TC-sensing control of grip of the front drive wheels with the road surface — an overview
Components and assemblies of anti-lock ABS and TC brake systems — removal and installation
Dosing valve — removal and installation
Features of the 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 traction — removal and installation
Suspension arm — removal and installation
Ball joint — removal and installation
Rear wheel hub with bracket — removal and installation
Rear wheel bearings — check and replace
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
Pneumatic system for adjusting the height of the rear suspension — general information
Spool for adjusting the height of the rear suspension and air supply line — removal and installation
Steering
Steering wheel — removal and installation
Steering column — removal and installation
Steering column intermediate shaft — removal and installation
Steering gear covers — replacement
Steering gear — removal and installation
Power steering electric pump — removal and installation
Removing air from the hydraulic booster circuit
Tie rod ends — removal and installation
Tie rods — removal and installation
Wheel alignment — general information
Body
Interior
Rear-view mirror in the cabin — 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 lining panels — removal and installation
Center floor section — removal and installation
Glove box — removal and installation
The forward panel of facing of salon — removal and installation
Exterior
Technical data
General information
Body — maintenance and repair
Body repair — minor damage
Body repair — major damage
Hinges and locks — maintenance and repair
Windshield and Fixed Glass — Replacement
Bumpers — removal and installation
Radiator grill — removal and installation
Box under the windshield (lining the niche of the engine compartment) — removal and installation
Hood — removal, installation and adjustment
Hood hinges — removal and installation
Bonnet lock parts — removal and installation
Hood lock cable — removal and installation
Doors — removal, installation and adjustment
Inner door handle — removal and installation
Outer Door Handle — Removing and Stopping
Door locks — removal and installation
Drum switch of the lock — removal and installation
Door lock retainer
Door glass — removal and installation
Window regulator — removal and installation
Trunk lid — removal and installation
Trunk lid hinge — removal and installation
Parts of the trunk lid — removal and installation
Rear compartment cover — removal and installation
Rear compartment lid hinges — removal and installation
Rear compartment cover parts — removal and installation
Details of the centralized locking system — removal and installation
Power window parts — removal and installation
External rear-view mirror — removal and installation
Optical element of the exterior mirror — removal and installation
Exterior mirror parts — removal and installation
Windshield, rear window and corners — general information
Hatch glass panel — removal and installation
Hatch components and parts — removal and installation
Protective panels of wings — removal and installation
Tank filler cap — removal and installation
Details of the outer lining of the body — removal and installation
Electrical equipment
Equipment and devices
Technical data
General information
Finding the source of a malfunction in an electrical system — a 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 panel — removal and installation
Display — removal and installation
Cigarette lighter — removal and installation
Sound signal — removal and installation
Wiper arms — removal and installation
Windshield wiper motor and drive — removal and installation
Rear window wiper motor and drive — removal and installation
Washer parts — removal and installation
Receiver / radio / CD player / navigation box — 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 shutdown
Devices of the pneumatic safety system — removal and installation
Wiring diagrams Opel Astra
General description and designation of electrical circuits Astra
Scheme 2. Launch and charge systems
Scheme 3. X14XE and X16XEL engine control systems
Scheme 4. X14XE and X16XEL engine control systems (continued) and electric windows
Scheme 5. X16SZR engine management system
Scheme 6. Engine control system Х18ХЕ-1
Diagram 7. X18XE-1 engine management system (continued), ABS with traction control system and speed sensor (vehicles without ABS)
Diagram 8. X20XEV engine management system
Diagram 9. X20XEV engine management system (continued)
Diagram 10. Engine cooling system, information display
Diagram 11. Front lighting
Scheme 12. Fog, side light headlights, and reverse light and direction indicators
Diagram 13. License plate lights, brake lights, interior lighting, rear window defroster and cigarette lighter
Diagram 14. Multifunctional timer
Diagram 15. Glove box lighting, horn, sunroof and central locking
Scheme 16. Power steering, exterior mirrors, cruise control and heater
Diagram 17. Typical air conditioning system and automatic transmission
Diagram 18. Automatic transmission (continued)
Diagram 19. Multifunctional display
Diagram 20. Display on the instrument panel
Wiring diagrams Opel Zafira
General description and designations of wiring diagrams Zafira
Scheme 2. Launch and charge systems
Scheme 3. X16XEL engine management systems
Diagram 4. X16XEL engine management systems (continued)
Scheme 5. Engine control system Х18ХЕ-1
Diagram 6. X18XE-1 engine management system (continued), ABS with traction control system and speed sensor (vehicles without ABS)
Diagram 7. Windshield washer/wiper and auxiliary heating
Diagram 8. Engine cooling system, information display
Diagram 9. Front lighting
Scheme 10. Fog, side light headlights, and reverse light and direction indicators
Diagram 11. License plate lights, brake lights, interior lighting, rear window defroster and cigarette lighter
Diagram 12. Multifunctional timer
Scheme 13. Illumination of the glove box, horn, sunroof and central locking
Scheme 14. Power steering, exterior mirrors, cruise control and heater
Diagram 15. Typical air conditioning system and automatic transmission
Diagram 16: Automatic transmission (continued)
Diagram 17. Multifunction display
Diagram 18. Display on the instrument panel
Astra G (1998-2004)
General information
Introduction to manual
Introduction to the Operation and Maintenance Manual
Opel Astra and Zafira cars — abstract
Vehicle identification numbers
Purchase of spare parts
Service technology, tools and equipment of the workplace
Jacking and towing
Starting the engine from an auxiliary power source
Vehicle readiness checks
Automotive chemicals, oils and lubricants
Troubleshooting
User manual
Car technical data
Dashboard
Information display
Additional electronic devices
Vehicle access and protection
Car interior lighting
Elements of car security systems
Car interior equipment
Heating, ventilation and climate control
Car operation techniques
Maintenance
General maintenance information
Schedule of ongoing maintenance
Current 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 the engine oil and oil filter
Checking the condition and replacing the accessory drive belt
Removal of sludge from the diesel engine fuel filter
Check of a condition and replacement of the hoses located in an impellent compartment
Checking the Condition of the Cooling System Components
Checking, servicing and charging the battery
Checking the condition and replacing the wiper blades
Inspection of suspension and steering components, checking the condition of the protective covers of the drive shafts
Checking the brake system
Checking electrical equipment
Monitoring the condition of the anti-corrosion coating of the car body and bottom
Lubrication of locks, hinges and stops
Resetting the service interval indicator
Replacing the Air Cleaner Element — Diesel Models after 09.2000
Cabin filter replacement
Fuel Filter Replacement — Diesel Models after 09.2000
Check of turns of idling and structure of the fulfilled gases
Replacing the air cleaner filter element — all petrol and diesel models from 10.2000
Replacing the fuel filter — diesel models from 10.2000
Replacing spark plugs, checking the condition of the explosive wiring
Fuel Filter Replacement — Petrol Models
Power unit
SOHC gasoline engines
General information about engines
Specifications of all engines
Checking the compression pressure in the cylinders
Diagnostics of the engine condition 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 of a cover of the gas-distributing mechanism
Removal and installation of the crankshaft pulley
Removing and installing timing cover
Removing and installing timing belt
Removal and installation of the timing belt tensioner and timing gears
Camshaft oil seal replacement
Removal, condition check and installation of a camshaft with a gas distribution mechanism housing
Removal, condition check and installation of components of a drive of valves
Removal and installation of a head of cylinders
Removal and installation of the oil pan
Removal, service and installation of the oil pump
Removal, condition check and installation of a flywheel / drive disk
Replacing the crankshaft seals
Checking the condition and replacing the suspension bearings of the power unit
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 of a cover of the gas-distributing mechanism
Removal and installation of the crankshaft pulley
Removing and installing timing cover
Removing and installing 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 of a head of cylinders
Removal and installation of the oil pan
Removal and installation of the engine oil level sensor
Removal, service and installation of the oil pump
Removal, condition check and installation of a flywheel / drive disk
Replacing the crankshaft seals
Checking the condition and replacing the suspension bearings of the power unit
Removal, installation and adjustment of the crankshaft balancing mechanism (engines 2.0 l)
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 the valve timing (2.0 l engines)
Removal and installation of a cover of the gas-distributing mechanism
Removal and installation of the crankshaft pulley
Removing and installing timing cover
Removal and installation of timing chain tensioners (engines 2.0 l)
Removing and installing timing belt
Removal and installation of the belt tensioner and timing gears (engines 1.7 l)
Removing and installing timing chains and sprockets, checking the condition of components (2.0 l engines)
Replacing the camshaft oil seal (engines 1.7 l)
Checking and adjusting valve clearances (1.7L DOHC engines)
Removal and installation of the camshaft (s) and valve drive components
Removal and installation of the gas distribution mechanism housing (engines 1.7 l DOHC)
Removal and installation of a head of cylinders
Removal and installation of the oil pan
Removal, service and installation of the oil pump
Replacing the oil pump seal (engines 1.7 l)
Removal and installation of the oil cooler
Removal, condition check and installation of a flywheel / drive disk
Replacing the crankshaft seals
Checking the condition and replacing the suspension bearings of the power unit
Engine repair
General and overhaul of the engine
Removing the power unit from the car — methods and precautions
Removal, disconnection and installation of the engine
Alternative options for engine reconditioning schemes
Engine disassembly sequence
Disassembly of the cylinder head
Cleaning and checking the condition of the cylinder head
Cylinder head assembly
Removal of connecting rod and piston assemblies
Removing the crankshaft
Cleaning and checking the condition of the cylinder block
Honing cylinder mirrors
Checking the condition of the components of the connecting rod and piston group
Checking the condition of the crankshaft
Checking the condition of the main and connecting rod bearings of the crankshaft
Engine assembly procedure
Installation of piston rings
Installing the crankshaft and checking the operating clearances of the main bearings
Installing connecting rod and piston assemblies and checking the working clearances in the connecting rod bearings of the crankshaft
Trial run and running-in of the engine after overhaul
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 refilling)
Removal, installation and check of serviceability of functioning of the thermostat
Removal and installation of a radiator of system of cooling
Check of serviceability of functioning, removal and installation of the fan of system of cooling
Check of serviceability of functioning, removal and installation of electric components of a chain of management of the engine cooling system
Checking the condition of the water pump
Removal and installation of the water pump
Supply system
Power System and Exhaust Specifications
General information and precautions
Relieving pressure in the power supply system of gasoline engines
Check of a condition and replacement of fuel lines and their union connections
Removal of air from the fuel path of a diesel engine
Removal of contaminants from the diesel engine power system
Removal and installation of components of an inlet air path
Removing, installing and adjusting the throttle cable — petrol models
Removal and installation of an accelerator pedal
Removal and installation of the fuel pump — petrol models
Removal and installation of the gauge of a stock of fuel
Removal and installation of the fuel tank
Removal and installation of the throttle body — petrol models
Injection system (gasoline)
General information and precautions
The principle of operation of fuel injection systems
Check of serviceability of functioning of system of injection of fuel
Removal and installation of components of the Multec central fuel injection system
Removal and installation of components of systems of distributed fuel injection Multec-S and Simtec-70
Intake Air Temperature Control System (Central Injection Models) — Principle of Operation and Functional Check
Removal and installation of the inlet pipeline
Removal and installation of a final collector
Injection system (diesel)
Diesel injection and turbocharging systems
Checking and adjusting the maximum engine speed
Checking and adjusting fuel injection timing settings
Removal and installation of electrical components of the power system
Signals and voltages at the outputs of the control module
Removal and installation of injection pump
Removal and installation of fuel injectors
Removal and installation of a turbocharger
Removal and installation of the intercooler (intercooler)
Removal and installation of the inlet pipeline
Removal and installation of a final collector
Exhaust system
System of release of the fulfilled gases — the general information, removal and installation
Exhaust emission control systems — general information
Check of serviceability of functioning and replacement of components of systems of decrease in toxicity of the fulfilled gases
Charge and launch system
General information and precautions
Battery — general information, condition check, replacement, storage and commissioning
Checking the condition and replacing the battery wires
Checking the proper functioning and condition of the components of the charge system
Removing and installing alternator drive belt tensioner
Removal and installation of the generator
Generator brush replacement
Checking the proper functioning of the state of the components of the launch system
Removal and installation of a starter
Check of a condition and recovery repair of a starter
Ignition system (gasoline)
General information and precautions
Ignition system specifications for all engines
Electronic control system for ignition (and injection) of gasoline engines
Checks of serviceability of functioning of system of ignition
Troubleshooting — general information and preliminary checks
OBD system — general information
Application of oscilloscope to observe working control system
Removal and installation of the ignition module
Checking and setting the ignition timing
Removal and installation of the ignition switch
Removal and installation of the emergency oil pressure sensor
Removal and installation of the engine oil level sensor
Removal and installation of the engine oil temperature sensor (diesel models)
Preheat system (diesel)
Preheat system — general information
Checking the proper functioning of the preheating system
Removing, checking and installing glow plugs
Removal and installation of components of the preheat system
Transmission
Manual gearbox
General information about the manual transmission
Mechanical box specifications
Adjustment of a drive of a gear change
Removal and installation of the mechanism of a gear change
Replacement of oil seals
Check of serviceability of functioning, removal and installation of the sensor-switch of reversing lights
Removal and installation of 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
Specifications of automatic box
Gear selector adjustment
Removal and installation of a cable of a choice of transfers
Removal and installation of assembly of the lever of the selector AT
Replacement of oil seals
ATF cooler — general information
Removal and installation of electrical components of the AT control system
Removal and installation of AT
Overhaul of AT — general information
Clutch
General information about the clutch and drive shafts
Clutch and drive shaft specifications
Clutch — general information and checking the condition of the components
Removal and installation of the clutch master cylinder
Removing and installing clutch slave cylinder assembly with release bearing
Removal of air from the hydraulic path of the clutch release drive
Removal and installation of the clutch pedal
Removal, condition check and installation of coupling components
Drive shafts
Drive shafts — general information
Removal and installation of power shafts
Check of a condition and replacement of hinges of equal angular speeds (SHRUS)
Replacement of protective covers SHRUS
Chassis
Brake system
General information about the brake system
Brake Specifications
Anti-lock brake system (ABS) and traction control (TCS) — general information and fault codes
Bleeding the brake system
Checking the condition and replacing brake lines and hoses
Replacing the pads of the disc brake mechanisms of the front wheels
Replacing the pads of the disc brake mechanisms of the rear wheels
Replacement of shoes of drum brake mechanisms of back wheels
Check of a condition, removal and installation of a brake disk
Removal, condition check and installation of a brake drum
Removal, refurbishment and installation of front wheel disc brake calipers
Removal, refurbishment and installation of rear wheel disc brake calipers
Removal, service and installation of wheel cylinders of drum brake mechanisms of back wheels
Removal and installation of the main brake cylinder
Removing and installing the foot brake pedal
Check of serviceability of functioning / tightness, removal and installation of assembly of the vacuum amplifier of brakes
Removal, check of serviceability of functioning and installation of the check valve of the vacuum booster of brakes
Removal and installation of the brake booster servo vacuum pump (diesel models)
Check of serviceability of functioning of the vacuum pump of the brake booster servo drive (diesel models)
Parking brake actuator adjustment
Removal and installation of the parking brake lever
Removal and installation of parking brake cables
Removal, installation and adjustment of the gauge-switch of stoplights
Removal and installation of the gauge switch of a control lamp of a cocking of a parking brake
Removal and installation of ABS and TCS components
Removal, installation and adjustment of the pressure regulator valve in the hydraulic circuits of the brake mechanisms of the rear wheels
Wheel suspension
General information about suspension and steering
Suspension and steering specifications
Removal and installation of a rotary fist
Checking the condition and replacing the hub assembly
Removal and installation of the front subframe
Removal, refurbishment and installation of the front suspension strut
Removal and installation of the front anti-roll bar
Removal, refurbishment and installation of the lower arm of the front suspension
Replacing the lower ball joint
Removal and installation of the rear hub assembly
Check of a condition and replacement of bearings of back wheels
Removing, checking the condition and installing the rear shock absorber
Removal and installation of helical springs of a back suspension bracket
Removal and installation of a torsion beam of a back suspension bracket
Replacing the rubber-metal hinges of the trailing arms of the torsion beam
Rear axle ride height adjustment system — general information and adjustment
Removal and installation of the air valve and the line of the rear axle ride height regulator (Universal models)
Steering
Removal and installation of a steering wheel
Removal and installation of a steering column
Removal, condition check and installation of an intermediate shaft of a steering column
Replacement of protective covers of a case of the steering mechanism
Removal and installation of the steering mechanism
Removal and installation of the steering pump
Removal of air from the hydraulic path of the power steering
Removal and installation of tips of steering draughts
Removal and installation of steering draft
Wheel alignment
Body
Exterior
General information and precautions
Body Specifications
Car body and underbody care
Repair of minor damage to body panels
Repair of seriously damaged body panels
Servicing car hinges and locks
Windshield and other fixed glass replacement
Removal and installation of bumpers
Removal and installation of front fenders
Removal and installation of a decorative grille of a radiator
Removal, installation and adjustment of a cowl
Removal and installation of hood hinges
Removal and installation of components of the lock of a cowl
Removal and installation of a cable of a drive of a release of a latch of the lock of a cowl
Removal and installation of door rear-view mirrors
Removal and installation of glass of a door rear-view mirror
Removal and installation of components of the electric drive of rear-view mirrors
Removal and installation of elements of the panel of a fairing of a windshield
Removal and installation of wheel arch protection lockers — general information
Removal and installation of a door of the hatch of a jellied mouth of a fuel tank
Removal and installation of body trim elements
Interior
Care of vinyl trim elements
Upholstery and carpet care
Removal and installation of components of a single lock
Removal and installation of components of the electric drive of window regulators (at the corresponding complete set of the car)
Removal and installation of an internal rear-view mirror
Removal and installation of front seats
Removal and installation of rear seats
Removal and installation of modules of emergency pretensioners of seat belts of forward seats
Removal and installation of seat belts
Removal and installation of the top adjustable anchor knots of seat belts
Removal and installation of interior trim panels
Removal and installation of the center console
Removal and installation of a ware box
Removal and installation of the instrument panel
Doors and windows
Removal, installation and adjustment of doors
Removal and installation of the internal door handle
Removal and installation of the external door handle
Removal and installation of door locks
Removal and installation of cylinders of locks of forward doors
Removal and installation of the drummer of the door lock
Removal and installation of door glasses
Removal and installation of a regulator of a window regulator
Removing and installing the luggage compartment lid (Sedan models)
Removing and installing tailgate hinges
Removal and installation of trunk lid components
Removing and installing the tailgate (Hatchback and Station wagon models)
Removal and installation of tailgate hinges
Removal and installation of tailgate components
Removal and installation of glass of the top hatch
Removal and installation of components of the top hatch
Ventilation and heating
Removal and installation of deflectors of air ducts
Removal and installation of the resistive assembly of the heater fan drive electric motor
Removal and installation of the heater fan drive electric motor
Removal and installation of the control panel for the operation of heating / ventilation / air conditioning systems
Removal and installation of the main body of the heater
Removal and installation of the heater heat exchanger
Removal and installation of the heater switch
Check of serviceability of functioning and service of systems of heating and air conditioning
Removal and installation of the air conditioning compressor
Removal and installation of the evaporator of the air conditioning system
Removal and installation of the condenser of the air conditioning system
Removal and installation of the receiver-drier of the air conditioning system
Removing and installing an additional fan
Electrical equipment
Equipment and devices
General information and precautions
Onboard Electrical Specifications
Search for the causes of electrical equipment failures
Fuses — general information
Relay — general information and function check
Removal and installation of switches
Replacement of lamps of external lighting and signaling devices
Replacing interior lighting bulbs
Removal and installation of external lighting / signaling devices
Adjusting the direction of the optical axes of the headlights
Removal and installation of a combination of devices
Removal and installation of components of the panel of devices
Removal and installation of the cigarette lighter
Removal and installation of klaxon horns
Removal and installation of levers (leashes) of screen wipers
Removal and installation of elements of a drive of screen wipers
Removal and installation of components of system of washing of glasses
Check of serviceability of functioning and restoration repair of a heater of back glass
Removal and installation of the audio system / navigation unit
Removal and installation of elements of remote control of the functioning of the audio system
Removing and installing loudspeakers
Removing and installing the radio antenna
Anti-theft system and engine immobilization system — general information
Vehicle speed sensor (VSS) — general information
Supplemental Security System (SRS)
Removal and installation of SRS elements
Electrical circuits
Wiring diagrams — general information
Designation of the elements depicted in the diagrams
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 engine management system
Automatic transmission
Cooling system with A/C (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 (TCS) (Astra and Zafira petrol)
ABS and traction control (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 gasoline)
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)
Stop lights (Astra diesel)
Stop lights (Astra petrol)
Stop lights (Zafira diesel)
Stop lights (Zafira petrol)
License plate light (Astra petrol)
License plate light (except Astra petrol)
Fog lights, rear lights (all models)
Klaxon (Zafira petrol and diesel)
Klaxon (Astra petrol and diesel)
Airbags (SRS) (all models)
Heated rear window (all models)
Washers and glass cleaners (Astra petrol)
Washers and glass cleaners (except Astra petrol)
Exterior mirrors (Astra petrol)
Exterior mirrors (except Astra petrol)
Power windows (Astra petrol)
Power windows (except Astra petrol)
Interior lighting (Astra petrol and diesel)
Interior lighting (Zafira petrol and diesel)
Cigarette lighter (all models)
Glove box lighting (all models)
Three function display (Astra petrol and diesel)
Three function display (Zafira petrol and diesel)
Multifunction display (Astra and Zafira petrol)
Multifunction 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)
Dashboard (Astra and Zafira petrol)
Dashboard (Astra and Zafira diesel)
Astra H (2004-2009)
General information
Introduction to the guide
Introduction to the manual for Opel Astra H
Opel Astra and Zafira cars — abstract
Vehicle identification numbers
Purchase of spare parts
Spare parts identification
Poddomkrachivanie car
Towing a car
Starting the engine from an auxiliary power source
Automotive chemicals, oils and lubricants
List of used abbreviations
Troubleshooting
Troubleshooting. Introduction
Engine malfunctions
Malfunctions of the electrical equipment of the engine
Starter malfunctions
Lubrication system malfunctions
Cooling system malfunctions
Clutch malfunctions
Malfunctions of the manual gearbox (RKPP)
Malfunctions of automatic transmission (AT)
Bridge faults
Brake system malfunctions
Suspension and steering problems
Wiper blade failures
Tire failures
Power system malfunctions
Heater malfunctions
User manual
Specifications
First 1000 km
Keys
Doors
Hood
Fuel tank filler neck
Main storage box
Top hatch
Single lock
Elements of security systems. general information
Seat belts
Transportation of children
Seat adjustment and transformation
Supplemental Security System (SRS)
Risk of carbon monoxide (CO) poisoning
Instrument panel and center console
Control and measuring devices
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 ceiling console
Controls located on door assemblies
Cigarette lighter, ashtrays
Power take-off socket
Storage boxes and pockets
Interior rear-view mirror
Sun visors
Folding tables
Luggage compartment equipment
Seats
Tri-Function Information Display (TID)
Multifunction Information Display (BID)
Graphic Information Display (GID)
Control system (Check Control)
Ventilation, heating and air conditioning (HVAC) systems: general information
Air distribution elements
HVAC control panel
HVAC system with manual adjustment
HVAC system with automatic temperature control (climate control)
Selection of the level of intensity of the air flow of the automatic mode
Selecting the direction of airflow distribution
Activating/deactivating the air conditioner
Turning on and off the automatic air circulation control system
Infotainment system. general information
Anti-theft system
Information display
General management bodies of the infotainment system
Radio receiver
CD/MP3 player
Remote controls (DU) audio system
Twin Audio System
Telephone and radio station
Preparing for a car trip
Requirements for the physical condition of the driver
Engine starting
Features of driving vehicles equipped with a manual gearbox (manual transmission)
Features of driving vehicles equipped with automatic transmission (AT): general information
Automatic transmission shift control
Features of AT control with Active Select system
Features of driving vehicles equipped with an Easytronic robotic gearbox
Special Driving Modes
Sport driving mode (SPORT)
Winter driving mode
Interactive Dynamic Driving System (IDS+)
Speed control system (Tempostat)
Automatic ride height adjustment
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 the driver
Economic driving tips
Trailer towing: general information
Drawbar hitch
Main characteristics of driving with a trailer
Trailer Stability Assist (TSA)
Tips for driving 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 cars
Active warning system about the time of scheduled maintenance
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
Battery electrolyte
Hydraulic fluid brake and clutch
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
Oil filter replacement
Filling with fresh engine oil
Engine oil temperature measurement
Check of a condition and replacement of a multirib belt of a drive of units
Draining sediment, removing air from the filter (diesel models)
Check of a condition and replacement of the hoses located in an impellent compartment
Checking the Condition of the Cooling System Components
Battery — general information
Battery maintenance and charging
Checking the condition and replacing the wiper blades
Inspection of suspension and steering components, checking the condition of the protective covers of the drive shafts
Checking the brake system
Checking electrical equipment
Monitoring the condition of the anti-corrosion coating of the car body and bottom
Lubrication of locks, hinges and stops
Replacing the air cleaner element
Cabin filter replacement
Fuel Filter Working Element Replacement — Diesel Models
Check of turns of idling and structure of the fulfilled gases
Replacing Spark Plugs (Petrol Models)
Spark Plug Status 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
Diagnostics of the engine condition using a vacuum gauge
Some preparatory operations
Bringing the piston of the first cylinder to the position of top dead center (TDC) of the end of the compression stroke
Removal and installation of a multirib belt of a drive of auxiliary units
Removal and installation of a toothed belt / timing chain (adjusting the valve timing)
Checking and adjusting timing valves
Removal and installation of camshafts and valve lifters, checking the condition of components
Removal and installation of a head of the block of cylinders
Removal and installation of the oil pan
Removal and installation of the oil pump
Removal and installation of the engine oil level sensor
Removal, condition check and installation of a flywheel/drive disk
Replacing the crankshaft seals
Replacing camshaft seals
Checking the condition and replacing the suspension bearings of the power unit
Removing the engine
Cooling and heating
Specifications
General information
Antifreeze — General Information and Precautions
Emptying and filling the system with coolant
Disconnecting and replacing cooling system hoses
Maintenance of the cooling system, flushing
Removal and installation of the cooling fan
Removal and installation of a radiator of system of cooling
Removal and installation of the water pump
Removal, installation and check of serviceability of functioning of the thermostat
Removal and installation of the outdoor temperature sensor
Removal and installation of the control panel of functioning of systems of heating/ventilation/air conditioning (HVAC)
Removal and installation of deflectors of air ducts
Removing and installing the HVAC fan drive motor
Removal and installation of the resistive assembly of the heater fan drive electric motor
Removal and installation of an additional electric heater (diesel models)
Removal and installation of the electric motor for the drive of the damper of the air circulation mode
Removal and installation of the electromotor of a drive of a distributive gate
Removing and installing the circulation damper housing (Astra models with air conditioning)
Removal and installation of the heater heat exchanger
Power and exhaust system
Specifications
Supply system. General information and security measures
Relieving pressure in the power supply system of gasoline engines
Check of a condition and replacement of fuel lines and their union connections
Removal of air from the fuel path of a diesel engine
Removal of contaminants and water from the diesel engine power system
Removal and installation of components of an inlet air path
Removing and installing the gas pedal
Removal and installation of the fuel pump
Removal and installation of the gauge of a stock of fuel
Removal and installation of a collar of fastening of the fuel filter (diesel models)
Removal and installation of glow plugs (diesel engines)
Removal and installation of the fuel tank
Petrol engine control system. General information and precautions
The principle of operation of fuel injection systems
Removal and installation of fuel injectors
Diesel engine control system. general information
Removal and installation of fuel injectors
Removal and installation of injection pump
Turbocharger and intercooler — general information
Particulate filter (engines with a displacement of 1.9 l)
System of release of the fulfilled gases. general information
Exhaust emission control systems — general information
Ignition system
Engine Electrical System Specifications
Engine electrical system. General information and precautions
Troubleshooting — General Information and Preliminary Checks
OBD self-diagnosis system
Using an oscilloscope to observe control system signals
Launch and charge system
Removal and installation of the ECM
Candles, coils and ignition module — general information
Ignition timing — general information
Removal and installation of glow plugs
Battery — disconnecting, removing and installing, purchasing a new battery
Checking the condition and replacing the battery wires
Generator — general information, check, removal and installation
Removal and installation of the voltage regulator
Starter — general information, removal and installation
Transmission
Mechanical gearbox
Manual Gearbox and Clutch Specifications
Clutch. general information
Removal and installation of the clutch master cylinder
Removing and installing clutch slave cylinder assembly with release bearing
Removal of air from the hydraulic path of the clutch release drive
Removal and installation of the clutch pedal
Removal, condition check and installation of coupling components
Removal and installation of the Easytronic clutch control module
Manual gearbox (RKPP). general information
Adjustment of a drive of a gear change
Removal and installation of components of a drive of a gear change
Transmission oil change
Removal and installation of manual transmission
Removing and installing the shift control module (Easytronic)
Automatic gearbox
Specifications of automatic 4-speed transmission
General information
Gear selector adjustment
Removal and installation of a cable of a choice of transfers
Check of a condition of working liquid АТ
Removal and installation of AT
Drive shafts
Specifications
General information
Removal and installation of power shafts
Removal and installation of an intermediate shaft
Check of a condition and replacement of hinges of equal angular speeds (SHRUS)
Replacement of anthers SHRUS
Chassis
Brake system
Brake Specifications
General information
Electronic Brake Control Systems
Bleeding the brake system
Checking the condition and replacing brake lines and hoses
Replacing the pads of the disc brake mechanisms of the front wheels
Replacing the pads of the disc brake mechanisms of the rear wheels
Removing, installing and checking the brake disc
Removal and installation of calipers / guide pads of disc brakes
Removal and installation of the main brake cylinder (GTZ)
Removing and installing the foot brake pedal
Check of a condition, removal and installation of assembly of the vacuum amplifier of brakes
Parking brake actuator adjustment
Removal and installation of the parking brake lever
Removal and installation of parking brake cables
Removal and installation of the gauge-switch of stoplights
Removal and installation of the gauge switch of a control lamp of a cocking of a parking brake
Car suspension
Specifications
General information
Front suspension. Removal and installation of a shock-absorber rack
Disassembly of the shock absorber strut / removal and installation of the shock absorber / front suspension spring
Removal and installation of a stupny nut of a forward suspension bracket
Removal and installation of the front subframe
Removal, check of a condition and installation of shock-absorbers of a back suspension bracket
Removal and installation of helical springs of a back suspension bracket
Removal and installation of the rear hub assembly
Steering
Removal and installation of the driver's frontal airbag module
Removal and installation of a steering wheel
Removal and installation of the contact block of understeering switches
Removal and installation of tips of steering draughts
Removal and installation of anthers of the steering mechanism
Wheel alignment — general information
Body
Interior
Care of vinyl trim elements
Upholstery and carpet care
Removing and installing sun visors
Removal and installation of the ceiling handle / glasses case
Removal and installation of a saloon rear-view mirror
Removal and installation of casings of a steering column
Removal and installation of the lower decorative covers of the panel of devices
Removal and installation of the main glove box
Removal and installation of a decorative lath of the panel of devices
Removal and installation of a door seal
Removal and installation of the center console
Removal and installation of a cover of the basis of the lever of a gear change/selector
Removal and installation of an ashtray
Removal and installation of an overlay of console section of the panel of devices
Removal and installation of section of finishing of the panel of devices under a steering column
Removal and installation of the side decorative panel of the center 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 trim elements — Zafira models
Removal and installation of a forward seat
Removal and installation of a back seat
Exterior
Specifications
Outdoor equipment and body elements. general information
Minor damage to the windshield as a result of stone impact
Removal and installation of body linings (moldings)
Removal and installation of a lattice of a fairing
Removal and installation of a cover of a back bulkhead of an impellent compartment (Zafira models)
Removal and installation of wheel arch protection (lockers)
Removal and installation of a front bumper/bumper overlay
Removal and installation of a rear bumper/bumper lining
Removal and installation of a decorative grille of a radiator
Removal and installation of front fenders
Removing and installing the fixed A-pillar glass (Zafira models)
Removal, installation and adjustment of a cowl
Removal and installation of a cable of a drive of a release of a latch of the lock of a cowl
Removal, installation and adjustment of the tailgate
Removal and installation of an upholstery of a door of a back
Removal and installation of the lock of a door of a back
Removal, installation and adjustment of side doors
Removal and installation of side door locks
Removal and installation of external handles of lateral doors
Removal and installation of the basis of the external handle of a door
Removal and installation of an upholstery of lateral doors
Removal and installation of the handle of a window regulator of back doors
Removal and installation of a window regulator of a forward door
Removal and installation of a mechanical window regulator of a back door
Removal and installation of glass of a door rear-view mirror
Removal and installation of a door rear-view mirror
Removal and installation of a cover of a door rear-view mirror
Electrical equipment
Equipment and devices
Specifications
General information
Search for the causes of electrical equipment failures
Fuses — general information
Relay — general information and function check
Removal and installation of the horn horn
Removal and installation of sensors of system of the help at a parking
Removal and installation of nozzles of washer glasses
Removing and installing washer fluid reservoir / pump
Removal and installation of levers (leashes) of screen wipers
Removal and installation of an electric motor of a drive of cleaners of a windshield
Removal and installation of the electric motor of a screen wiper of back glass
Removal and installation of the rain sensor
Replacing headlight bulbs
Removal and installation of the electric motor of the drive for adjusting the position of the headlights (halogen-type headlights, Astra models)
Removal and installation of the headlight unit
Removal and installation of fog lights
Fog Light Bulb Replacement
Removal and installation of repeaters of indexes of turns
Removal and installation of the rear combined lamps / replacement of lamps
Removal and installation of a lamp of a stoplight of the top level
Removal and installation of a license plate light, lamp replacement
Removal and installation of the assembly of directional individual lamps of the front seats
Replacing interior lamps
Removal and installation of a combination of devices
Removal and installation of the information display
Removal and installation of the panel of switches of external lighting / illumination of devices
Electrical circuits
Symbols used on 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 wipers. Rain sensor. Headlight washers
Exterior mirrors (L/R)
Power window wiring diagram
Stoplight switch. Reversing light switch
Rear window heater. A/C system compressor
Traction hitch. Sound signal
Headlights (except xenon). Fog lights
Rear combination lamps. License plate light
Interior interior lighting 1. Illumination of the main glove box
Interior 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
Passport data of the car
Car keys
Dashboard
Instrument cluster
On-board computer
The device of the ventilation, heating and air conditioning system
Automatic control unit for dual-zone climate control
Side door locks
Side door power windows
Tailgate (trunk lid)
Trunk — device and content
Seat belts
Front seat adjustment
Rear seat — unfolding
Use of child seats
Steering wheel adjustment
Rear view mirrors
Interior lighting
Sun visors
Storage compartments and electrical outlet
Opening and closing the hood
Removing the antenna
Roof rack
User manual
Gearbox control
Safety regulations
Helpful Hints for Operation
Recommendations for traffic safety
Vehicle break-in
Vehicle operation during the warranty period
Preparing the car for departure
Refueling a car with gasoline
Using the jack
Towing a car
Faults en route
General engine starting techniques
Faults in the starting system
Checking the ignition system
Checking the engine power system
Fuel Injection System Malfunctions
Idling has disappeared
Interruptions in the engine
Engine diagnostics by appearance of spark plugs
The car is jerking
The car accelerates badly
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 current sources
Electrical faults
Extraneous knocks in the engine
Extraneous knocks in the suspension and transmission
Vibration and bumps in the steering wheel
Emergency Brake Check Signals
Bleeding the brake system
Checking the brake system
Actions in case of a puncture
Wheel replacement
Maintenance
Maintenance Schedule
Maintenance safety rules
Checking wheels and tires
Checking the level and adding oil to the lubrication system
Checking the level and topping up the coolant
Checking and adding brake fluid to 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
Cylinder compression check
Valve clearance adjustment
Removal and installation of mudguards and engine crankcase protection
Replacement of the left support of a suspension bracket of the power unit
Replacement of the right support of a suspension bracket of the power unit
Replacing the front suspension support of the power unit
Replacing the rear support suspension of the power unit
Setting the piston of the first cylinder to the TDC position
Accessory drive belt replacement
Replacement of the timing belt
Removal, troubleshooting and installation of the flywheel
Replacing the cylinder head cover gasket
Replacing the cylinder head gasket
Replacement of valve stem seals
Replacing the intake pipe gasket
Replacing the crankshaft seals
Replacing the oil sump seal
Replacing camshaft seals
Replacing the oil level guide seal
General information about the cylinder head
Removal, troubleshooting and installation of camshafts
Lapping of valves
Removal and installation of the engine
Engine disassembly
Troubleshooting engine parts
Engine Assembly
Cooling and lubrication system
Design features of the lubrication system
Changing engine oil and oil filter
Removal and installation of the oil pump
Removal and installation of the oil filter housing
Features of the design of the cooling system
Possible malfunctions of the cooling system
Checking the hoses and connections of the cooling system
Coolant replacement
Removal and installation of the electric fan of the radiator of the cooling system
Replacing the cooling system radiator
Removal and installation of a broad tank
Water pump replacement
Removal and installation of the thermostat
Engine power system
Design features of the engine power system
Checking the pressure in the power system
Reducing the pressure in the power system
Replacing the air filter element
Removal and installation of the air filter, an air duct and the muffler
Removal, repair and installation of the fuel pump
Replacing the fuel tank and its filler pipe
Removal and installation of the fuel rail
Removing, checking and installing injectors
Removal and installation of the throttle assembly
Removing and installing the throttle control pedal
Exhaust system
Features of the device of the fuel vapor recovery system
Removal and installation of an adsorber of system of catching of steams of fuel
Removing, checking and installing the adsorber purge valve
Design features of the exhaust system
Replacement of pillows of a suspension bracket of system of release of the fulfilled gases
Replacement of the main and additional mufflers
Downpipe replacement
Removal and installation of the collector, replacement of its gasket
Removal and installation of thermal screens
Transmission
Clutch
Clutch Design Features
Possible clutch malfunctions
Checking the travel of the clutch release pedal
Bleeding the hydraulic clutch release
Replacing the working fluid in the hydraulic clutch release
Removal and installation of clutch
Replacement of the working cylinder of a drive of deenergizing of coupling with the bearing
Clutch Master Cylinder Replacement
Replacement of the pipeline of a hydrodrive of deenergizing of coupling
Removal and installation of the clutch pedal
Car gearbox
Design features of a manual transmission
Possible malfunctions of a manual transmission
Design features of an automatic transmission
Checking the level, topping up and changing the oil in the gearbox
Replacing gearbox seals
Removal and installation of a transmission
Disassembly and assembly of a manual transmission
Repair of a secondary shaft of a mechanical transmission
Repair of the synchronizer of a manual transmission
Manual transmission differential repair
Replacing the transmission control cables
Removal and installation of the scenes of the gear lever
Gearbox control drive adjustment
Drive shafts
Front wheel drive design features
Possible malfunctions of the front wheel drive
Removal and installation of front wheel drives
Replacement of hinges of equal angular speeds of drives of forward wheels
Chassis
Front suspension
Design features of the front suspension
Checking the technical condition of the front suspension parts on the car
Removal and installation of a shock-absorber rack of a forward suspension bracket
Front suspension shock absorber repair
Replacing the upper support of the shock absorber strut of the front suspension
Replacing the ball joint of the shock absorber strut of the front suspension
Replacing the front suspension arm
Replacing parts of the front suspension anti-roll bar
Removal and installation of a rotary fist
Front wheel hub replacement
Removing and installing front suspension subframe
Checking and adjusting wheel alignment
Rear suspension
Rear suspension design features
Replacing the shock absorber rear suspension
Replacing the rear suspension spring
Replacing the rear wheel hub
Removal and installation of a beam of a back suspension bracket
Removal and installation of the Watt mechanism
Steering
Steering design features
Inspection and testing of the steering on the car
Checking the free play (backlash) of the steering wheel
Removal and installation of a steering wheel
Removal and installation of a casing of a steering column
Removal and installation of a steering column
Replacing the outer tie rod end
Replacing the steering rod and its protective cover
Steering gear replacement
Brake system
Features of the brake system
Checking the position of the brake pedal
Checking the tightness of the hydraulic drive of the brake system
Checking the operation of the vacuum brake booster
Checking the degree of wear of brake pads and discs
Checking the parking brake
Bleeding the hydraulic drive of the brake system
Brake Fluid Replacement
Replacing the reservoir of the main brake cylinder
Replacing the master brake cylinder
Replacing the vacuum brake booster
General information about replacing brake hoses and tubes
Replacement of brake hoses
Replacement of brake pipes
Removing and installing the brake pedal
Replacing the brake pads of the brake mechanism of the front wheel
Front wheel brake caliper replacement
Replacing the brake disc of the front wheel brake mechanism
Replacing the brake pads of the brake mechanism of the rear wheel
Rear wheel brake caliper replacement
Replacing the brake disc of the rear wheel brake mechanism
Parking brake actuator adjustment
Replacing the rear parking brake cables
Removal and installation of the parking brake lever
Wheels and tires
Wheel marking
Checking the radial and lateral runout of the disc
Tire Design Features
Tire classification
Tire marking
Tips for choosing tires
Tubeless tire repair
Tips for using wheels
Wheel storage
Body
Exterior
Body design features
Removal and installation of facing of a radiator
Removal and installation of fender liner
Removal and installation of a forward bumper
Removal and installation of a back bumper
Removal and installation of a forward wing
Removal and installation of a lattice of a box of an air inlet
Removal and installation of a cowl
Removal, installation and adjustment of the lock of a cowl
Removal and installation of an external mirror
Removal and installation of the shelf of fastening of the rechargeable battery
Control body dimensions
Interior
Removal and installation of a forward seat
Removal and installation of a back seat
Removal and installation of floor tunnel lining
Removal and installation of an internal mirror
Design features of the instrument panel
Removal and installation of glove boxes
Replacing handrails in the cabin
Replacing sun visors
Doors and windows
Removal and installation of an upholstery of a forward door
Front door glass replacement
Replacing the power window of the front door
Replacing the outside handle and front door lock switch
Replacement of the internal handle of a drive of the lock of a forward door
Replacing the front door lock
Replacing the front door opening limiter
Removal and installation of a forward door
Removal and installation of an upholstery of a back door
Rear door glass replacement
Replacing the power window rear door
Rear Door Exterior Handle Replacement
Replacing the inner handle of the tailgate lock actuator
Replacing the rear door lock
Replacing the tailgate opening limiter
Removal and installation of a back door
Replacing tailgate stops
Removal and installation of an upholstery of a door of a back
Removal and installation of an external lining of a door of a back
Replacing the tailgate lock
Removal and installation of a door of a back
Removal and installation of a cover of the hatch of a bulk pipe of a fuel tank
Removal and installation of the lock of a cover of the hatch of a bulk pipe of a fuel tank
Replacement of the fixed glazing of the body
Body Care
Car body wash
Polishing of the paintwork
Engine wash
Anti-corrosion body protection
Preparation and anti-corrosion treatment of body cavities
Body sealing
Caring for trim panels made of polymer materials
Upholstery and carpet care
Body armature lubrication
Cleaning drainage holes
Heating and air conditioning
General information about heating, ventilation and air conditioning systems
Features of the heating system device
Features of the air conditioning system
Features of the device of the ventilation system
Safety in the repair and maintenance of the air conditioning system
Removing refrigerant from the air conditioning system
Replacement of O-rings
Features of the air conditioner compressor device
Removal and installation of the compressor of the conditioner
Condenser replacement
Replacing the pressure sensor
Replacing the outside temperature sensor
Replacing the ambient air pollution sensor
Removal and installation of the block of management of system of heating and ventilation
Replacing the cabin air filter
Security systems
Design features of the passive safety system (SRS)
Removing and installing the driver's airbag and its contact ring
Removal and installation of seat belts
Electronic control unit for additional passive safety system
Removal and installation of the shock sensor
Removal and installation of the switch of a pillow of safety of the forward passenger
Design features of the anti-lock braking system (ABS)
Removal and installation of the hydroelectronic block ABS
Replacing wheel speed sensors
Electrical equipment
Equipment and devices
Design features of electrical equipment
Diagnostics of malfunctions of onboard electrical equipment
Location of fuses and fuse-links and their replacement
Removal and installation of the mounting block of the trunk
Design and testing of the ignition switch (lock)
Replacing the contact group of the ignition switch (lock)
Replacing the ignition switch (lock) cylinder
Removal and installation of the switch (lock) of ignition
Replacement and maintenance of spark plugs
Features of the design of the engine management system
Removal and installation of the ignition module
Removal and installation of the electronic engine control unit
Check and replacement of gauges of a control system of the engine
Removal and installation of brushes of a screen wiper of a wind window
Removal and installation of levers of a screen wiper of a windscreen
Removal and installation of a trapezoid and a gearmotor of a screen wiper of a wind window
Replacing the tailgate window wiper motor
Removal and installation of a washer glass of a wind window
Replacing the power window control unit and switches
Replacing the front door power window motor
Replacing the rear door power window motor
Replacing the joystick control exterior mirrors
Removal and installation of the electric motor of the radiator fan of the cooling system
Electric heating of glass of a window of a door of a back
Design features of the instrument cluster
Removal and installation of a combination of devices
Replacing the control unit for outdoor lighting and backlight brightness
Removal and installation of the central display
Removal and installation of the car radio
Removing and installing speakers
Removal and installation of control units on a steering wheel
Removal and installation of the immobilizer
Removing and installing the socket block and USB connector
Replacing the oil pressure warning light sensor
Replacing the fuel gauge sensor
Replacing the Low Oil Level Sensor
Checking and replacing the reverse light switch
Replacement of the switch of a control lamp of inclusion of a parking brake
Lighting and signaling
Design of lighting, light and sound signaling
Checking and adjusting the headlights
Lamp replacement
Removal and installation of the electrical control unit
Headlight Replacement
Replacement of a lateral lantern of the index of turn
Replacing the rear light located on the tailgate
Replacing the rear light located on the wing
Replacement of an additional brake light
Replacing license plate lights
Replacement of ceiling lamps for interior lighting
Replacing the trunk light
Replacing the fog lamp and turn signal unit
Glove box light replacement
Replacing paddle shifters
Removal and installation of a sound signal
Power devices
Battery design features
Battery care
Removing and installing the battery
Charging the battery
Generator design features
Removal and installation of the generator
Alternator pulley replacement
Generator repair
Starter design features
Removal and installation of a starter
Starter repair
Electrical circuits
Wiper Wiring Diagram
Wiring diagram for windshield washers
Engine management sensors
Fuel injectors and ignition module
Starter and battery
Starter wiring diagram
The engine control unit
Fuel pump
Variable valve timing system
Power supply of the engine control unit
Oxygen Sensors and Evaporative Emission System
Pressure and temperature sensors
Direction indicators and alarms
Parking lights
High and low beam headlights (halogen)
High and low beam headlights (xenon)
Brake light wiring diagram
Reversing and license plate lights



Corsa B (1993-2000)
General information
Introduction to guide
Introduction to the Operation and Maintenance Manual
Opel Corsa B, Tigra and Combo cars — abstract
Vehicle identification numbers
Purchase of spare parts
Service technology, tools and equipment of the workplace
Jacking and towing
Starting the engine from an auxiliary power source
Vehicle readiness checks
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 car security systems
Car interior equipment
Heating, ventilation and air conditioning systems
Car operation techniques
Maintenance
Vehicle Maintenance Specifications
Schedule of ongoing maintenance
General information about maintenance
General information about settings and adjustments
Fluid level checks
Checking the condition of the tires and their inflation pressure, rotating the wheels
Changing the engine oil and oil filter
Checking the condition and replacing the accessory drive belt
Removal of sludge from the diesel engine fuel filter
Check of a condition and replacement of the hoses located in an impellent compartment
Checking the Status of Components
Checking, maintenance and charging
Checking the condition and replacing the brushes
Check of system of release of the fulfilled gases
Checking the brake system
Checking electrical equipment
Monitoring the condition of the anti-corrosion coating of the car body and bottom
Checking and adjusting idle speed and maximum speed
Filter element replacement
Inspection and maintenance of air conditioning and ventilation
Fuel filter replacement
Checking the composition of the 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 clutch pedal adjustment
Brake Fluid Replacement
Automatic fluid change (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
Diagnostics of the engine condition 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 of a cover of the gas-distributing mechanism
Removal and installation of the crankshaft pulley
Removing and installing timing cover
Removing and installing timing belt
Removal and installation of timing gears
Camshaft oil seal replacement
Removal, condition check and installation of a camshaft with a gas distribution mechanism housing
Removal, condition check and installation of valves
Removal and installation of a head of cylinders
Removal and installation of the oil pan
Removal, service and installation of the oil pump
Removal, condition check and installation of a flywheel / drive disk
Replacing the 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 of a cover of the gas-distributing mechanism
Removal and installation of the timing belt (engines 1.4 and 1.6 l)
Removal and installation of gear wheels of crankshaft and camshafts and intermediate rollers (engines 1.4 and 1.6 l)
Removal and installation of camshafts
Removal and installation of a head of cylinders
Removal and installation of the oil pan
Removal, service and installation of the oil pump
Replacing camshaft seals
Removal, condition check and installation of a flywheel / drive disk
Replacing the crankshaft seals
Removal and installation of 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)
Removing and installing timing belt
Removal and installation of the crankshaft pulley
Removing and installing timing cover
Camshaft oil seal replacement
Removal and installation of a camshaft
Removal and installation of a head of cylinders
Removal and installation of the oil pan
Removal, service and installation of the oil pump
Removal, condition check and installation of a flywheel or drive disk
Replacing the crankshaft seals
Checking the condition and replacing the suspension bearings of the power unit
Engine repair
General information about engine overhaul
Removing the power unit from the car — methods and precautions
Removal, disconnection and installation of the engine
Alternative options for engine reconditioning schemes
Engine disassembly sequence
Disassembly of the cylinder head
Cleaning and checking the condition of the cylinder head
Cylinder head assembly
Removal of connecting rod and piston assemblies
Removing the crankshaft
Cleaning and checking the condition of the cylinder block
Honing cylinder mirrors
Checking the condition of the components of the connecting rod and piston group
Checking the condition of the crankshaft
Checking the condition of the main and connecting rod bearings of the crankshaft
Engine assembly procedure
Installation of piston rings
Installing the crankshaft and checking the operating clearances of the main bearings
Installing connecting rod and piston assemblies and checking the working clearances in the connecting rod bearings of the crankshaft
Trial run and running-in of the engine after overhaul
Cooling system
Engine Cooling Specifications
General information and precautions
Antifreeze — general information
Disconnecting and replacing cooling system hoses
Maintenance of the cooling system (emptying, flushing and refilling)
Removal, installation and check of serviceability of functioning of the thermostat
Removal and installation of a radiator of system of cooling
Check of serviceability of functioning, removal and installation of the fan of system of cooling
Check of serviceability of functioning of the gauge of temperature of a cooling liquid (ECT)
Checking the condition of the water pump
Removal and installation of the water pump
Supply system
Power System and Exhaust Specifications
General information and precautions
Relieving pressure in the power supply system of gasoline engines
Check of a condition and replacement of fuel lines and their union connections
Removal of air from the fuel path of a diesel engine
Removal of contaminants from the diesel engine power system
Removal and installation of components of an inlet air path
Replacing and adjusting the throttle cable
Removal and installation of an accelerator pedal
Checking and replacing the fuel pump — petrol models
Replacing the Fuel Gauge
Removal and installation of the fuel tank
Removal and installation of the throttle body — petrol models
Injection system (gasoline)
General information and precautions
The principle of operation of fuel injection systems
Check of serviceability of functioning of system of injection of fuel
Checking and replacing the engine temperature sensor
Injection system (diesel)
General information about the diesel fuel injection system
Checking and adjusting the maximum engine speed
Checking and adjusting fuel injection timing settings
Checking the thermocouple
Removal and installation of nozzles
Fuel filter heating element
Exhaust systems
Exhaust system — general information
System of release of the fulfilled gases — removal and installation
Factory Installed Exhaust System Replacement Guidelines
Catalytic converter
Removal and installation of the additional air supply pump (X14XE and X16XE engines)
Control system (gasoline)
Engine Electrical System Specifications
General information and precautions
Electronic control system for ignition (and injection) of gasoline engines
Checks of serviceability of functioning of system of ignition
Troubleshooting — general information and preliminary checks
OBD system — general information
Using an oscilloscope to monitor the operating parameters of a control system
Checking the ignition coil (C14NZ engine)
Removal and installation of the distributor of ignition (engine C14NZ)
Removal and installation of the DIS ignition control unit
Checking and basic adjustment of the ignition timing (C14NZ engine)
Octane correction
Preheat system (diesel)
General information about the preheat system
Checking the proper functioning of the preheating system
Removing, checking and installing glow plugs
Checking the glow plug relay
Charge and launch system
General information and precautions
Battery — general information, condition check, replacement, storage and commissioning
Checking the condition and replacing the battery wires
Checking the proper functioning and condition of the components of the charge system
Removal and installation of the generator
Generator brush replacement
Checking the proper functioning of the state of the components of the launch system
Removal and installation of a starter
Check of a condition and recovery repair of a starter
Transmission
Mechanical gearbox
Manual Gearbox Specifications
General information about the manual transmission
Adjustment of a drive of a gear change
Removal and installation of manual transmission
Manual transmission repair — general information
Automatic gearbox
Automatic transmission specifications
General information about automatic transmission
Gear selector adjustment
Removal and installation of a cable of a choice of transfers
Removal and installation of assembly of the lever of the selector АТ
Removal and installation of automatic transmission
Overhaul of AT — general information
Clutch and drive shafts
Clutch and drive shaft specifications
General information about the clutch and drive shafts
The design of the clutch and its drive components
Removal and installation of clutch
Removing, checking and installing the clutch release bearing
Clutch cable replacement
Checking the condition of the clutch components
Drive shafts — general information
Removal and installation of power shafts
Check of a condition and replacement of hinges of equal angular speeds (SHRUS)
Replacement of protective covers of SHRUS
Chassis
Brake system
Brake Specifications
General information about the brake system
Anti-Lock Brake System (ABS) — General Information and Fault Codes
Bleeding the brake system
Checking the condition and replacing brake lines and hoses
Replacing the pads of the disc brake mechanisms of the front wheels
Removal and installation of brake shoes
Replacing the brake linings of drum brakes
Check of a condition, removal and installation of a brake disk
Removal, condition check and installation of a brake drum
Removal, refurbishment and installation of front wheel disc brake calipers
Removal, service and installation of wheel cylinders of drum brake mechanisms of back wheels
Check of serviceability of functioning and tightness of the vacuum amplifier of brakes
Replacing and checking the brake booster servo vacuum pump (diesel models)
Parking brake actuator adjustment
Removal and installation of parking brake cables
Replacement of the gauge switch of stoplights
Pressure control valve in the hydraulic circuits of the brake mechanisms of the rear wheels
Front suspension
Suspension and steering specifications
Suspension and steering design
Removal and installation of an amortization rack
Dismantling, checking and assembling the shock absorber
Removal and installation of the transverse suspension arm
Removal and installation of the stabilizer bar
Rear suspension
Removal and installation of the rear shock absorber
Removal and installation of a spring of a back suspension bracket (Corsa and Tigra models)
Removal and installation of the anti-roll bar (Corsa and Tigra models)
Removal and installation of the wheel bearing
Wheel bearing clearance adjustment
Steering
Removal and installation of a steering wheel
Removal and installation of steering draft
Removal and installation of a tip of steering draft
Removal and installation of the power steering fluid reservoir
Removal of air from the hydraulic path of the power steering
Removal and installation of the power steering pump
Wheel alignment
Body
Ventilation and heating
Removal and installation of the cabin air filter
Removing and installing the fan speed switch
Removal and installation of deflectors of air ducts
Removal and installation of the heating control unit
Removal and installation of drafts of a drive of gates of a heater
Removal and installation of the heater fan
Removing and installing an additional resistor
Check of serviceability of functioning and service of systems of heating and air conditioning
Exterior
Body Specifications
General information and precautions
Car body and underbody care
Repair of minor damage to body panels
Repair of seriously damaged body panels
Servicing car hinges and locks
Windshield and other fixed glass replacement
Removal and installation of a lining and a bearing beam of bumpers
Removal and installation of a decorative grille of a radiator (models since 03.1997 of release)
Removal and installation of the wheel arch locker
Removal and installation of the panel of a fairing of a windscreen
Removal and installation of a cowl
Bonnet hinge replacement
Removal and installation of a forward wing
Replacing the lining of the rear wheel arch (Corsa and Combo models)
Removal and installation of an external mirror and an electric motor of its drive
Removal and installation of the exterior mirror housing
Interior
Care of vinyl trim elements
Upholstery and carpet care
Seat belt tensioner
Precautions for handling the emergency seat belt pretensioner and side airbag
Removal and installation of a forward seat
Removal and installation of a back seat
Removal and installation of the center console
Removal and installation of lateral facing of a foot well of the forward passenger
Removal and installation of a ware box
Removal and installation of an internal mirror and installation of a plate of its fastening
Removal and installation of the instrument panel
Doors and windows
Removal and installation of facing of doors
Removal and installation of glass of a forward door
Removal and installation of glass of a back door (Corsa model)
Removal and installation of a window regulator
Removal and installation of the external door handle
Removal and installation of the cylinder of the lock of a forward door
Removal and installation of the door lock
Frost protection of locks and seals
Removal, installation and adjustment of the door
Removing and installing the tailgate (Corsa and Tigra models)
Removal and installation of the tailgate lock (Corsa and Tigra models)
Removing, installing, disassembling and assembling the outer handle and tailgate lock cylinder (Corsa model)
Sliding roof panel
Electrical equipment
Equipment and devices
Onboard Electrical Specifications
General information and precautions
Search for the causes of electrical equipment failures
Fuses — general information
Relay — general information and function check
Removal and installation of the electric motor of a single lock
Removal and installation of the switch and the electromotor of adjustment of range of light (Models Corsa and Combo)
Removal and installation of the switch of heating of a seat
Removal and installation of a horn
Anti-theft device and alarm
Removal and installation of a combination of devices
Removal and installation of measuring devices and indexes
Removal and installation of control lamps and the printed circuit board of a combination of devices
Replacing the backlight lamp of the heating control unit panel
Removal and installation of the steering column switch
Removal and installation of switches of a back foggy lamp (fog lamp) and heating of seats
Removal and installation of the switch of external and internal lighting
Removal and installation of the alarm switch
Removal and installation of the ignition lock cylinder and its contact element
Installing the radio
Removing and installing speakers
Antenna Installation
Removal and installation of a screen wiper of a windscreen
Removal and installation of the front wiper motor
Removal and installation of the rear wiper motor
Removal and installation of the reservoir and washer pump
Check K/L of low level of a brake liquid
Check of serviceability of functioning and restoration repair of a heater of back glass
Lamps and lighting
Light range adjustment
Replacing bulbs in headlights
Replacement of incandescent lamps for outdoor lighting devices
Replacing Tigra Headlights, Parking Lights and Front Indicator Bulbs
Replacement of incandescent lamps for interior lighting, luggage compartment and glove box
Removal and installation of a headlight
Headlight adjustment
Removal and installation of the rear combination lamp
Removal and installation of a fog lamp
Electrical circuits
Wiring diagrams — general information
Lighting: outdoor and indoor lighting
Lighting: rear fog light and brake light
Windshield and rear window cleaners, headlight lens washer
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, horn
Radio installation: Speakers and antenna
Single lock: Control unit and its executive links
Electrical equipment: Power window
Electrical equipment: Outside mirror
Electrical equipment: Seat heating, sliding roof panel, power steering



Corsa C (2000-2006, petrol)
User manual
Car access
Vehicle identification
Refueling capacities of units and systems. Recommended consumables
Refueling a car
Car keys
Door lock control using the key in the driver's door lock
Sliding doors (Combo)
Tailgate (Limousine, Combo)
Centralized trunk locking
Swing doors (Combo)
Anti-theft alarm device
Bonnet — opening and closing
Power window control
Power sliding roof
Power Foldable Sliding Roof (Limousine)
Power Sliding Roof (Combo)
Governing bodies
Light and sound alarms
Car dashboard
Information display
Paddle switches
Emergency light signal
Sound signal
Wiper control
Switching on the glass and headlight washer
Rear window wiper and washer control
Infotainment system control
Active head restraints
Parking pilot
Maintenance intervals «ECO Service-Flex»
Cigarette lighter — location
Socket for accessories
Ashtrays — location and opening
Front storage box
Spectacle compartment
Holder for small items
Sun visors
Exterior mirrors
Auto-dimming interior mirror
Lighting control
Seat control
Seat adjustment
Seat headrest control
Boot space extension (Corsa)
Folding the rear seatback
Raising the rear seats
Removing the luggage compartment cover
Trunk extension (Combo)
Folding the front passenger seat back
Tailgate Closing (Combo)
Dismantling and installation of the trunk casing
Guard rail (Combo)
Mounting behind the rear seats
Mounting behind the front seats
Luggage net (Combo)
Hooks for bags
Storage box under the front passenger seat
Glove box above the front seats (Combo)
Seat belts
Airbag system «Opel Full Size»
Opel Child Safety System
Heating and air conditioning
Heating and ventilation system with additional air conditioning
General description of climate control
Air conditioner control
Seat heating
Switching indicators in the keys
Climate control
Air intake openings
Driving and maintenance
Starting a gasoline engine
Diesel engine start
Parking brake
Car parking
Manual Transmission
Easytronic gearbox
Driving a car with an automatic transmission
Driver Tips
Starting the Engine with the Auxiliary Starter 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
Oil pressure check (Z10XE, Z10XEP)
Checking engine compression (Z10XE, Z10XEP)
Checking the valve timing (Z10XE, Z10XEP, without air conditioning)
Compression Pressure Check (Z10XE, Z10XEP, Air Conditioned)
Fuel pressure check (Z10XE, Z10XEP, air-conditioned)
Controlling the valve timing by acting on the camshaft Z10XEP, Z12XE, Z14XEP (from late 2004 to 2005)
Valve timing adjustment (Z10XE, Z10XEP, without air conditioning)
V-ribbed belt replacement (Z10XE, Z10XEP, air-conditioned)
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 fill and bleed (Z10XE, Z10XEP)
Replacing the coolant temperature sensor (Z10XE, Z10XEP, without air conditioning)
Removal and installation of the pump of a cooling liquid (Z10XE, Z10XEP, with the conditioner)
Removal and installation of a thermostat with a coolant pipe (Z10XE, Z10XEP, without air conditioning)
Radiator replacement (Z10XE, Z10XEP, with A/C)
Removal and installation of the oil filter housing (Z10XE, Z10XEP, without air conditioning)
Engine oil change (Z10XE, Z10XEP)
Removal and installation of the oil pan (Z10XE, Z10XEP, without air conditioning)
Oil pressure switch replacement (Z10XE, Z10XEP)
Injection system
Replacement of fuel injectors (one or all) (Z10XE, Z10XEP, without air conditioning)
Fuel filter replacement (petrol engines)
Removal and installation of the electric fuel pump
Replacing the exhaust manifold seal (Z10XE, Z10XEP, without air conditioning)
Engines 1.4, 1.6 and 1.8 l
Engine repair
Specifications of gasoline engines
Test values for motors
Engine Pressure Loss Check (1.4-1.6L Engines)
Engine Pressure Loss Check (1.8L Engine)
Checking engine compression
Checking the tightness of the engine (CO content in the cooling system)
Oil consumption measurement
Removal and installation of the flywheel (engine 1.4 l)
Replacement of a back epiploon of a cranked shaft
Replacing valve stem seals (cylinder head installed)
Checking the axial free play of the crankshaft
Removal and installation of a head of the block of cylinders (engine 1,4-1,6 l)
Checking the clearance in the connecting rod bearing
Connecting rod bearing replacement
Replacing piston rings
Replacing a piston with a connecting rod
Cooling and lubrication system
Filling and bleeding the cooling system
Checking the tightness of the cooling system
Removal and installation of the pump of a cooling liquid
Intercooler Replacement — Removal and Installation
Replacing the oil pump (engine 1.4 l)
Injection system
General information about the fuel injection system
Removal and installation of fuel injectors
High pressure fuel line replacement
Fuel pump module
Replacing the dosing module — removal and installation
Replacing the fuel pressure regulator — removal and installation
Fuel return damper replacement
Replacing the fuel level sensor — removal and installation
Fuel tank
Replacement of a tube of a jellied mouth of a fuel tank
Evaporative Emission System
Replacing the Front Vent Tube
Removing and installing the activated charcoal tank
Removal and installation of 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, inspection and installation of thrust plate and clutch disc (without SAC)
Clutch Pedal Replacement
Mechanical gearbox
Possible malfunctions of the mechanical box
Gears and shift lever
Checking and repairing a mechanical box
Checking the transmission oil level (Gearbox F13)
Removing and installing gearbox (F13)
Automatic gearbox
General information about automatic transmission
Torque converter — general information
Main gear — general information
Adjustment of a cable of the selector of switching of automatic transmission
Automatic transmission designation (AF 13-II)
Checking the condition of the transmission oil (AF13-II)
Oil pressure test (AF13-II)
Checking the position switch of the gear lever (AF13-II)
Unlocking the stopper of the gear lever in case of violation of its operation
Shift Lever Position Switch Adjustment (AF13-II)
Adjustment of the cable system of the gear shift drive (AF13-II)
Replacing the shift cable system (AF13-II)
Replacement of the switch of the locking device of the gear lever
Replacing the Wiring Harness in the Shift Lever Assembly (AF13-II)
Replacing the control unit of the electronic gearshift switch
Replacing the glow lamp of the gearshift indicator in the gear lever console (AF 13-II)
Drive shafts
General information about drive shafts
Possible malfunctions of the wheel drive
Measurement of radial and lateral runout of a wheel bearing
Measuring the slope clearance of a bearing block
Removal and installation of the wheel shaft — removal and installation
Replacement of the internal constant velocity joint
Replacement of the outer constant velocity joint
Disassembly of the outer constant velocity joint
Chassis
Wheels and tires
Wheel and tire repair
Tire condition
Tire change
Puncture-proof tires (RunFlat tires)
Rim and tire identification
Wheel suspension
Possible suspension and wheel failures
General Suspension Information
Chassis adjustment values
Removal and installation of the front axle stabilizer
Removal and installation of a forward rotary fist
Removal and installation of the forward lever of an independent suspension bracket
Replacing all rubber bearings of the front stabilizer
Removal and installation of a forward amortization rack with the shock-absorber
Disassembly and assembly of shock absorber
Checking the angular clearance of the rear wheel bearing assembly
Removal and installation of the rear axle
Removal and installation of the rear stabilizer
Removal and installation of the rear shock absorber
Steering
Possible steering problems
How EPS works
Steering column cover
Steering gear / tie rods
Steering wheel play check
Steering wheel force check
Bleeding the power steering system
Checking tie rod ends and seals
Checking constant velocity joints
Checking the tightness of the power steering
Checking the level of hydraulic booster fluid
Troubleshooting under operating conditions
Brake system
General information about the brake system
Front brakes
Rear brake mechanisms
Brake booster
Master brake cylinder
Checking and adjusting elements of the brake system
Checking the level of brake fluid in the reservoir of the hydraulic drive of the working brake system
Removal of air from the hydraulic drive of the working brake system
Brake hoses
Parking brake adjustment
Removal and installation of forward brake hoses
Replacement of tubes of the brake system — removal and installation
Removal and installation of an overlay of brake pads of a forward wheel
Removal and installation of a protective casing of a brake of a forward wheel
Replacing the brake disc of the front wheel
Removal and installation of a brake board of a back wheel
Removal and installation of brake shoes of a back wheel
General information about the anti-lock braking system
Repair manual for ABS 5.3, ABS 5.3 / PBS, ABS 8.0, ABS 8.0 PZS
Repair manual for PBS (anti-skid system)
Removal and installation / replacement of the ABS hydraulic unit (ABS 8.0, ABS 8.0 PZS)
Body
Exterior
Features of the design of the car body
Removal and installation of a forward bumper
Removal and installation of the front beam holder (shock limiter)
Wing replacement — removal and installation
Removal and installation of protective lining inside the wing
Removal and installation of the rear bumper — removal and installation
Removal and installation of a molding of an entrance opening
Removal and installation of a forward protective level
Removing and installing water repellent
Replacing the optional roof frame seal
Removal and installation of a cowl — removal and installation
Doors and windows
Central and door locks
Removal and installation of the lock of a forward door
Removal and installation of the external handle of a forward door
Front Door Lift Window Glass Guide Replacement
Removal and installation of an internal covering of a forward door
Remove and install the front/rear door power window slot bar inside
Removal and installation of a bracket of the lock of a forward door
Removal and installation of consolidation of a forward door
Removal and installation of a back door — removal and installation
Removal and installation of an internal covering of a back door
Removal and installation of consolidation of a back door
Removal and installation of a back folding door
Removal and installation of the lock of a back folding door
Removal and installation of the external handle of a back folding door
Removal and installation of a pneumatic spring of a back folding door
Removal and installation of consolidation of a back folding door
Removal and installation of an internal covering of a back folding door
Removal and installation of consolidation of glass in a back folding door
Replacing the control element of the external rear-view mirror, adjustable from the inside
Removing and installing or replacing the windshield
Electrical equipment
Equipment and devices
General information about the electrical system
Accumulator battery
Generator — general information
Removal and installation of the generator (engine Z18XE, with air conditioning)
Replacing the generator drive pulley — removal and installation
Alternator Regulator Replacement (Z18XE Engine, Air Conditioned)
Generator check
Starter replacement (Z10XE, Z10XEP, without air conditioning)
Removal and installation of a starter (Z14XE, Z16YNG, with air conditioning)
Windshield Wiper Arm Replacement
Removal and installation of the switch of a window regulator
Removal and installation of the rear wiper motor
Replacing Both Linkage Wiper Bearings
Lighting system
Checking and adjusting headlights, exterior lighting, interior lamp, headlight switch
Fog lamp adjustment — removal and installation
Removal and installation of headlights — removal and installation
Removal and installation of rear fog lights
Replacing a High Beam Bulb
Replacing a dipped beam bulb
Xenon headlight bulb replacement
Turn signal bulb replacement (xenon headlight)
Removal and installation of a starter of a xenon lamp
Replacing the High Beam Bulb/Parking Light Bulb (Xenon Headlight)
Replacing an Incandescent Lamp / Trunk or Luggage Compartment Lamp
Removal and installation of license plate lighting / incandescent lamps
Removal and installation of the switch of a control lamp of a parking brake
Replacing the front interior lamp / bulbs
Removal and installation of the rear interior lamp / incandescent lamp
Removal and installation of the cigarette lighter / incandescent lamp
Electrical circuits
Wire color codes
Scheme No. 1: Z10XEP engine, Motronic 7.6.1 (part 1)
Scheme No. 2: Z10XEP engine, Motronic 7.6.1 (part 2)
Scheme No. 3: Z12XEP engine, Motronic 7.6.1 (part 1)
Scheme No. 4: Z12XEP engine, Motronic 7.6.1 (part 2)
Scheme No. 5: Z14XEP engine, Motronic 7.6.1 (part 1)
Scheme No. 6: Z14XEP engine, Motronic 7.6.1 (part 2)
Scheme No. 7: fuel pump, Motronic 7.6.1
Scheme No. 8: Z14XE engine, Multec S (F) (part 1)
Scheme No. 9: Z14XE engine, Multec S (F) (part 2)
Scheme No. 10: fuel pump, Multec S (F)
Schematic #11: Z18XE engine, Simtec 71 (Part 1)
Schematic #12: Z18XE engine, Simtec 71 (part 2)
Plan #13: Fuel pump, Simtec 71
Scheme No. 14: Engine cooling system (Z10XEP without air conditioning and ECO)
Scheme No. 15: Engine cooling system (Z10XEP / Z12XEP / Z14XEP with air conditioning)
Scheme No. 16: Engine cooling system (Z14 XE / Z18XE with air conditioning)
Scheme No. 17: Starting and Charging System
Scheme No. 18: voltage distribution
Diagram #19: Body Control Module — Power Supply (Diagnostic Connector)
Scheme No. 20: Manual transmission with automatic clutch (Easytronic)
Plan #21: Electric Power Steering, Anti-Theft Alarm System
Plan #22: Anti-Lock Braking System and Traction Control (ABS 8)
Scheme No. 23: Power windows and outside rear-view mirror
Scheme No. 24: central control of door locks (hatchback)
Diagram #25: Stoplight Switch, Rear Lighting (Hatchback), Clutch Switch
Scheme No. 26: air conditioning
Scheme No. 27: headlights (except xenon headlights)
Scheme No. 28: headlights (xenon headlights)



Corsa C (2000-2006)
General information
Introduction to guide
Opel Corsa C and Meriva cars — abstract
Vehicle identification numbers
Purchase of spare parts
Jacking up the car
Towing a car
Starting the engine from an auxiliary power source
Automotive chemicals, oils and lubricants
List of used abbreviations
Troubleshooting
Troubleshooting — General
Engine Troubleshooting
Detection of malfunctions of the electrical equipment of the engine
Starter Troubleshooting
Troubleshooting the engine power system
Troubleshooting the engine lubrication system
Troubleshooting the engine cooling system
Heater Troubleshooting
Clutch Troubleshooting
Troubleshooting a Manual Transmission
Troubleshooting automatic transmission
Troubleshooting the brake system
Troubleshooting Suspension and Steering
Wiper blade defects
Chassis, tire defects
Vehicle device
Vehicle Specifications
Running in the car for the first 1000 km
Car keys
Doors — opening and closing
Bonnet — opening and closing
Fuel tank filler neck
Main storage box
Top hatch
Single lock
Driver's door lock control
Remote Control
Unlocking and locking the doors in emergency mode
Replacing the remote control battery
Anti-theft system
General information about the security system
Seat belts
Transportation of children
Seat adjustment and transformation
Supplemental Security System (SRS)
Danger 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
Instrument panel controls to the left of the steering column
Controls on the console section of the instrument panel
Controls on the center console
Overhead console controls
Sliding/tilting sunroof controls
Controls on door assemblies
Cigarette lighter, ashtrays
Power take-off socket
Glove 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 driving
Driving vehicles with a manual transmission (manual transmission)
Driving vehicles with automatic transmission (AT)
Driving vehicles with an Easytronic robotic gearbox
Special Driving Modes
Vehicle braking
Tire pressure monitoring
Operation of vehicles with a catalytic converter
Features of driving a car with power steering
Additional tips for the driver
Economic driving tips
Trailer towing
Maintenance
Specifications for maintenance
Schedule of scheduled maintenance (MS)
General maintenance information
General information about settings and adjustments
Checking Fluid Levels — General
Engine oil — check
Engine coolant — check
Windshield/rear window/headlight washer fluid
Brake system and clutch drive fluid
Manual transmission oil — check
Automatic transmission oil (ATF) — check
Wheels and tires — general information and designation
Wheels and tires — checking condition and pressure
Wheel rotation
Changing the engine oil and oil filter
Check of a condition and replacement of a multirib belt of a drive of 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 wiper blades
Checking the condition of shock absorbers
Checking the Condition of Suspension and Steering Components
Checking the condition of the wheel bearings
Checking the condition of the protective anthers of the drive shafts
Checking the brake system
Checking electrical equipment
Control of anti-corrosion coating of the car body and bottom
Lubrication of locks, hinges and stops
Replacing the air cleaner element
Cabin filter replacement
Fuel filter replacement
Check of turns of idling and structure of the fulfilled gases
Replacing spark plugs, checking high-voltage wiring
Checking the condition of the timing belt and rollers
Power unit
Engine repair
Engine Repair Specifications
General information about engines
The list of works performed without removing the engine from the car
Engine cover
Checking the compression pressure in the cylinders
Diagnostics of the engine condition using a vacuum gauge
Removal and installation of a cover of a multirib belt and protection of a crankcase of the engine
Removing the right engine mount
Removal and installation of the crankshaft pulley
Removal and installation of gear wheels / sprockets of camshafts
Bringing the piston of the first cylinder to the position of top dead center (TDC)
Removal and installation of a belt of a drive of auxiliary units
Removal and installation of a toothed belt / timing chain
Checking and adjusting timing valves (Y17DT (L) /Z17DTH engines)
Removing and installing camshafts and valve lifters, checking timing components
Removal and installation of a head of the block of cylinders
Removal and installation of the oil pan
Removal and installation of the oil pump
Engine oil pressure measurement
Removal, condition check and installation of a flywheel/drive disk
Replacing the crankshaft seals
Replacing camshaft seals
Checking the condition and replacing the suspension bearings of the power unit
Removing the engine
Cooling system
Cooling and Heating Specifications
Engine Cooling System — Design Description
Antifreeze — General Information and Precautions
Emptying and filling the system with coolant
Disconnecting and replacing cooling system hoses
Maintenance of the cooling system, flushing and checking for leaks
Removal and installation of the cooling fan
Removal and installation of a radiator of system of cooling
Removal and installation of the water pump
Removal, installation and check of serviceability of the thermostat
Power and exhaust system
Power supply and exhaust specifications
General information and security measures
Relieving pressure in the power supply system of gasoline engines
Checking and replacing fuel lines and their fittings
Removal of air from the fuel path of a diesel engine
Removal of contaminants and water from the diesel engine power system
Removal and installation of components of an inlet air path
Removing and installing the gas pedal
Removal and installation of the fuel pump / fuel supply sensor
Removal and installation of a collar of fastening of the fuel filter (diesel)
Removal and installation of the fuel tank
Turbocharger and intercooler — general information
Exhaust system — general information
Removal and installation of system of release of the fulfilled gases
Removal and installation of lambda probes (petrol models)
Exhaust emission control systems
Control system
General information and precautions
The principle of operation of petrol injection systems / Opel-Twinport system
Removal and installation of fuel injectors (gasoline)
Diesel engine control system
The principle of operation of diesel fuel injection systems
Removal and installation of the fuel distribution line of the Z13DT engine
Removal and installation of fuel injectors (diesel)
Removal and installation of injection pump (diesel)
Engine electrical equipment
Engine Electrical Specifications
General information and precautions
Troubleshooting in the ignition system
OBD self-diagnosis system
Using an oscilloscope to observe control system signals
Removal and installation of candles, ignition modules and high-voltage wires
Ignition timing — general information
Removal, installation and check of glow plugs (diesel)
Battery — Shutdown
Purchasing a new battery
Removing and installing the battery
Check of a condition and replacement of wires of the storage battery
Generator — general information
Alternator voltage test
Removal and installation of the generator
Removal and installation of the voltage regulator
Checking and replacing the generator brushes
Starter — general information
Removal and installation of a starter
Check of the traction relay of a starter
Check of a condition and recovery repair of a starter
Transmission
Clutch
Clutch and Gearbox Specifications
General information about manual transmission
Clutch design and operation
Removal and installation of the clutch master cylinder
Removal and installation of the clutch cylinder with release bearing
Removal of air from the hydraulic path of the clutch drive
Removal and installation of the clutch pedal
Removal, condition check and installation of coupling components
Features of removing and installing the Easytronic clutch
Removal and installation of the Easytronic clutch control module
Mechanical gearbox
Manual gearbox — general information
Adjustment of a drive of a gear change
Removal and installation of components of a drive of a gear change
Transmission oil change
Removing and installing the shift control module (Easytronic)
Removal and installation of manual transmission
Automatic gearbox
Automatic transmission specifications
General information about automatic transmission
Adjustment of a drive of a gear change
Removal and installation of components of a drive of a gear change
Check of a condition and replacement of working liquid AT
Removal and installation of an automatic transmission
Drive shafts
Drive Shaft Specifications
General information about drive shafts
Removal and installation of the hub nut
Removal and installation of power shafts
Right drive shaft with intermediate shaft (diesel)
Checking the condition and constant velocity joints (CV joints)
Double Compensation CV Joint Replacement
Features of replacing a tripod-type CV joint (Z10XE engines)
Replacement of anthers SHRUS
Vibration damper (right drive shaft)
Chassis
Brake system
Brake Specifications
General information and precautions
Electronic Brake Control Systems
Bleeding the brake system
Checking the condition and replacing brake lines and hoses
Replacing the pads of the disc brake mechanisms of the front wheels
Replacing the pads of the disc brake mechanisms of the rear wheels
Front brake calipers and guide pads
Rear brake calipers and guide pads
Removing, installing and checking the brake disc
Brake drum, drum brake shoe replacement
Wheel brake cylinder (drum brakes)
Removal and installation of the main brake cylinder (GTZ)
Check, removal and installation of assembly of the vacuum amplifier of brakes
Removing and installing the foot brake pedal assembly
Removal and installation of the parking brake lever
Removal and installation of sections of a cable of a drive of a parking brake
Parking brake actuator adjustment
Removal and installation of the gauge-switch of stoplights
Wheel suspension
Suspension and steering specifications
General information about car suspension
Removal and installation of a forward shock-absorber rack
Dismantling, removal and installation of the front shock absorber
Removal and installation of a rotary fist
Removal and installation of the hub assembly of the front wheel
Removal and installation of the transverse front arm
Removal and installation of the front subframe
Removal, check and installation of shock-absorbers of a back suspension bracket
Removal and installation of helical springs of a back suspension bracket
Removal and installation of the rear hub assembly and wheel bearing
Wheel alignment — general information
Steering
Safety precautions when working with the steering system
Removal and installation of the driver's airbag module
Removal and installation of a steering wheel
Removal and installation of tips of steering draughts
Removal and installation of anthers of the steering mechanism
Body
Exterior
Vehicle body specifications
General information about the car body
Minor damage to the windshield as a result of stone impact
Removal and installation of the lower spoiler (Corsa Eco models)
Removal and installation of a bulkhead cover of an impellent compartment (Meriva)
Removal and installation of side (door) linings (moldings)
Removal and installation of a lattice of a fairing
Removal and installation of the front bumper and bumper lining
Removal and installation of the rear bumper and bumper lining
Removal and installation of protection (lockers) of wheel arches
Removal and installation of front fenders
Removal and installation of lining (molding) wheel arch (Corsa)
Removal and installation of the lower outer sills
Removal, installation and adjustment of a cowl
Interior
Care of vinyl trim elements
Upholstery and carpet care
Removing and installing sun visors
Removing and installing ceiling handle and eyeglass case
Removal and installation of a saloon rear-view mirror
Removal and installation of the main glove box
Removal and installation of an anther of the lever of a gear change (models with manual transmission)
Removal and installation of the center console
Panels of lateral facing of console section of the panel of devices
The lower decorative cover of the panel of devices under a steering column
Dashboard trim strip (Meriva models)
Removal and installation of interior trim thresholds
Removing and installing A-pillar trim
Removal and installation of B-pillar trim
Removal and installation of the rear side trim (3-door hatchback)
Removal and installation of finishing of pillars C and D
Dashboard lower trim panels (Meriva models)
Removal and installation of an overlay of a threshold of a door of a back
Removal and installation of furnish of sidewalls of a luggage space
Removing and installing the front seat belt (Corsa C)
Upper seat belt anchor height adjuster (Corsa C)
Removal and installation of a back seat belt (Corsa C)
Removal and installation of locks of back seat belts (Corsa C)
Removal and installation of a forward seat
Removal and installation of a back seat
Bench seat back support bracket (Corsa C)
Doors and windows
Removal, installation and adjustment of the tailgate (Corsa C/Meriva)
Removal and installation of an upholstery of a door of a back
Removal and installation of the lock of a door of a back
Removal, installation and adjustment of side doors
Removal and installation of side door locks
Removal and installation of external handles of lateral doors
Removal and installation of the lock cylinder
Removal and installation of the internal door handle
Removal and installation of the window regulator handle
Removal and installation of an upholstery of lateral doors
Removal and installation of triangular overlays of forward doors
Removal and installation of a door rear-view mirror
Removal and installation of glass of a door rear-view mirror
Removal and installation of a cover of a door rear-view mirror
Removal and installation of a window regulator of a forward door
Removal and installation of a window regulator of a back door
Removal and installation of a sealant of a doorway
Heating and air conditioning
Interior heating, ventilation and air conditioning (HVAC) systems
Removal and installation of air duct deflectors (Corsa C)
Removal and installation of air deflectors (Meriva)
Complete removal and installation of the HVAC control panel
Removing and installing the HVAC control panel switch box
Removing and installing the HVAC fan drive motor
Removal and installation of the heater fan drive electric motor
Removing and installing the air distribution damper assembly (Corsa)
Removal and installation of an additional heater (diesel models)
Removal and installation of the heater heat exchanger
Electrical equipment
Equipment and devices
Fuses and relays — location and designation
General information about on-board electrical equipment
Search for the causes of electrical equipment failures
Fuses — general information
Removal and installation of the engine compartment fuse box (Corsa C)
Relay — general information and function check
Removal and installation of the horn horn
Removal and installation of nozzles of washer glasses
Removal and installation of levers (leashes) of screen wipers
Removal and installation of the electric motor of cleaners of a windshield
Removal and installation of the electric motor of a screen wiper of back glass
Removing and installing washer fluid reservoir and pump
Removal and installation of a combination of devices
Removal and installation of levers of understeering switches
Removal and installation of the information display
Switch panel for outdoor lighting, instrument lighting
Removal and installation of the alarm switch
Removing and installing the cigarette lighter panel (Corsa models)
Power window and door mirror switches
Removal and installation of contact switches of doors
Removal and installation of the contact switch of a cowl (Corsa models)
Removing and installing the infotainment system assembly
Removing and installing loudspeakers
Removal and installation of the external antenna (Corsa C models)
Lamps and lighting
Power characteristics of onboard lighting lamps
Replacing headlight bulbs
Removal and installation of the headlight unit
Removal and installation of fog lights
Fog Light Bulb Replacement
Removal and installation of repeaters of indexes of turns
Removal and installation of the rear combined lamps and replacement of lamps
Removal and installation of a fog lamp
Removal and installation of a lamp of a stoplight of the top level
Removal and installation of a plafond of illumination of license plate, replacement of a lamp
Replacing interior lamps
Electrical circuits
Symbols used on electrical equipment diagrams
Engine management system Z10XE
Engine management system Z12XE
Engine management system Z14XE
Engine management system Z16SE
Engine management system Z18XE
Engine management system Z13DT
Engine cooling system Z10XEP/Z12XE/Z14XEP/Z16SE/Z18XE
Heating system, fuel pump, heated rear window
Robotic gearbox Easytronic
Automatic transmission
Anti-lock brake system (ABS), multifunction display
Anti-lock brake system (ABS) with traction control (TC)
Anti-theft alarm system, electric power steering
Door rear-view mirrors, electric power windows
Single lock
Interior lighting, interior mirror, door switches, cigarette lighter, horn
Glass cleaners and washers, headlight washers
Radio receiver (audio system)
Seat heating
Turn signal switch, alarm switch...
Halogen headlights
Tail lights, brake light switch, clutch switch
License plate lights, fog lights, fog lights



Insignia A (2008-2017)
General information
Repair on the road
Circuit breakers
Device for removing fuses
Fuse box in the engine compartment
Fuse box in the dashboard
Fuse box in the luggage compartment
Car instrument
Replacement wiper blades
Lamp replacement
Dipped beam / daylight lamps
High beam lamps
Front direction indicators
Side lights
Xenon lamps and fog lamps
Tail lamps
License plate lamps
Interior lighting
Tire repair kit
Wheel replacement
Side direction indicators and instrument panel lighting
Spare wheel
Tires with a given direction of rotation
Starting the engine from an external power source
Towing a car
Towing another vehicle
Daily checks
Vehicle checks before driving
Engine starting
Start of movement
While driving
Determination of engine malfunctions by the condition of the 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 for Insignia A
Vehicle identification
Engine parameters
Traction and dynamic characteristics
Fuel Consumption — CO₂ Emissions
Weight characteristics of the car
Vehicle dimensions
Refueling tanks
Dashboard
Outdoor Lighting
Steering wheel adjustment
Steering wheel controls
Sound signal
Windshield wiper/washer
Windshield and headlight washer
Rear window cleaner/washer
Outdoor 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
Information 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 action of the sign «Caution, children!»
Lighting in the city
Country road lighting
Highway lighting
Lighting in adverse weather conditions
Dynamic cornering lights
Side lights
Additional lighting when reversing
Automatic high beam switching
Automatic dynamic headlight beam throw adjustment
Malfunction in system of adaptive forward lighting
Emergency light signaling
Turn and lane change signals
Front fog lights
Rear fog lights
Parking light
Reversing lights
Fogging headlights
Interior lighting
Features of the lighting system
Glove boxes
Luggage compartment
Luggage compartment cover
Cargo management system
Luggage net
Roof-mounted trunk
Information about permitted loads
Warning triangle
Travel first aid kit
Car storage
Commissioning
Disposal of a used vehicle
Car exterior care
Salon care
Vehicle check
Vehicle maintenance
Recommended fluids, lubricants and spare parts
Coolant and antifreeze
Brake and clutch fluids
Safety and tool
Labor protection during repairs
Precautions to prevent vapor or gas poisoning
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 elements of the Supplementary Restraint System (SRS)
Environmental protection
Basic set of necessary tools
Flat stylus
Micrometers
Calipers
Dial indicator
Nutrometer
Power unit
Petrol engines 1.6 l
General information
Cylinder compression check
Checking Attachment Belt Tension
Attachment Drive Belt Replacement
Cylinder head cover
Timing mechanism drive device
Checking the timing belt of the gas distribution mechanism
Replacing or adjusting the timing belt
Cylinder head device
Replacing the cylinder head
Dismantling of a head of the block of cylinders
Cleaning and checking the technical condition of the cylinder head
The device 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
Measurement of pistons and connecting rods
Removal and installation of the crankshaft
Checking the axial play of the crankshaft
Checking the radial runout of the crankshaft
Checking the clearance in the main bearings of the crankshaft
Cylinder Block Cleaning Procedure
Checking the technical condition of the cylinder block
Removal and installation of a turbocharger
Specification
Special tools and fixtures
Operating materials
Tightening torques for threaded connections
Petrol engines 2.0 l
General information
Cylinder compression check
Attachment Drive Belt Replacement
Replacing the Attachment Belt Tensioner
Removing the cylinder head cover
Installing the cylinder head cover
Gas distribution mechanism drive
Replacing the Primary Drive Chain (Camshaft Drive Chains)
Primary drive chain adjustment (camshaft drive chains)
Secondary Drive Chain Replacement (Water Pump Drive Chain and Balance Shafts)
Cylinder head device
Replacing the cylinder head
The device of the cylinder block and crank mechanism
Dismantling and assembly of a head of the block of cylinders
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 of the crankshaft
Cleaning and checking the technical condition of the crankshaft
Cleaning and checking the technical condition of the cylinder block
Turbocharger replacement
Cleaning and checking the technical condition of the turbocharger
Specification
Special tools and fixtures
Operating materials
Tightening torques for threaded connections
Engine Thread Recovery Card
Diesel engines 2.0 l
General information
Checking engine compression
Replacing the alternator drive belt, air conditioning compressor and power steering pump
Timing belt drive
Toothed belt replacement
Cylinder head device
Replacing the camshaft housing
Replacing the cylinder head
Dismantling of a head of the block of cylinders
Cleaning and checking the technical condition of the cylinder head
The device 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
Turbocharger replacement. Engines LBS/A20DTH, LBX/A20DTJ, LCD/A20DTC
Turbocharger replacement. Engine LBY/A20DTR
Specification
Special tools and fixtures
Operating materials
Tightening torques for threaded connections
Diesel engines 2.8 l
General information
Cylinder compression check
Attachment Drive Belt Replacement
Replacing the drive belt parasitic pulley
Replacing the drive belt tensioner
Cylinder head cover
Replacing the secondary timing chain
Replacing the primary timing chain
Replacing camshafts
Cylinder heads
Dismantling and assembly of a head of the block of cylinders
Cleaning and checking the technical condition of the cylinder head
Removing the crankshaft balancer
Installing the crankshaft balancer
Removing pistons with connecting rods
Cleaning and checking the technical condition of the connecting rod and piston group
Installing pistons with connecting rods group
Removing the crankshaft
Cleaning and checking the technical condition of the crankshaft
Cleaning and checking the technical condition of the cylinder block
Installing the crankshaft
Turbocharger replacement
Specification
Special tools and fixtures
Operating materials
Tightening torques for threaded connections
Engine Thread Recovery Card
Cooling system
General information
Checking the tightness of the cooling system
Checking the opening pressure of the steam valve
Thermostat check
Draining and recharging the cooling system
Draining the cooling system
Filling the Cooling System — 1.6L and 1.8L Gasoline Engines
Filling the Cooling System — 2.0L Gasoline Engines
Cooling System Charge — 2.0L Diesel Engines
Filling the Cooling System — 2.8L Gasoline Engine
Flushing the cooling system
Specification
Special tools and fixtures
Tightening torques for threaded connections
Lubrication system
Lubrication system for gasoline engines
Diesel engine lubrication system
Checking Oil Pressure — 1.6L and 1.8L Gasoline Engines
Oil Pressure Check — 2.0 and 2.8L Gasoline Engines
Oil Pressure Check — 2.0L Diesel Engines
Changing the Oil Filter — 1.6 and 1.8 L Gasoline Engines
Changing the Oil Filter — 2.0L Gasoline Engines
Changing the Oil Filter — 2.0L Diesel Engines
Changing the Oil Filter — 2.8L Gasoline Engine
Oil Pan Replacement — 1.6L and 1.8L Gasoline Engines
Oil Pan Replacement — 2.0L Gasoline Engines
Oil Pan Replacement — 2.0L Diesel Engines
Oil Pan Replacement — 2.8L Gasoline Engine
Specification
Special tools and fixtures
Operating materials
Tightening torques for threaded connections
Supply system
Power supply system for gasoline engines
Diesel engine power system
Checking the pressure in the power supply system of gasoline engines
Fuel tank leak test
Removing fuel from the tank
Fuel tank modifications with gasoline engines
Fuel tank modifications with diesel engines
Special tools and fixtures
Tightening torques for threaded connections
Engine management
General information
Electronic engine control unit
Tightening torques for threaded connections
Intake and exhaust system
General information
Air filter replacement
Removal and installation of the intake manifold — gasoline engines 1.6 and 1.8 l
Removal and installation of the intake manifold — 2.0 l gasoline engines
Removal and installation of the intake manifold — diesel engines 2.0 l
Removal and installation of the intake manifold — gasoline engine 2.8 l
Exhaust Manifold Replacement — 1.6 and 1.8 L Gasoline Engines
Exhaust Manifold Replacement — 2.0L Gasoline Engines
Exhaust Manifold Replacement — 2.0L Diesel Engines
Exhaust Manifold Replacement — 2.8L Gasoline Engine
Exhaust tract replacement
Special tools and fixtures
Tightening torques for threaded connections
Engine electrical equipment
Charging system
Engine start system
Ignition system for petrol engines
Diesel engine preheating system
Removal and installation of the negative plug of the storage battery
Replacing the battery
Generator replacement
Starter Replacement — Gasoline Engines
Starter Replacement — Diesel Engines
Replacing ignition coils
Replacing spark plugs
Checking spark plugs
Replacing glow plugs
Replacing the preheating control unit
Specification. Charging system
Special tools and fixtures
Tightening torques for threaded connections
Transmission
Clutch
General information
Pumping the clutch hydraulic drive
Clutch Position Sensor Replacement
Clutch Master Cylinder Replacement
Replacement of the pipeline of the working cylinder of coupling
Clutch Slave Cylinder Replacement
Clutch slave cylinder replacement (LDE/A16XER, 2H0/A18XER engines)
Replacing clutch discs
Specification
Special tools and fixtures
Operating materials
Tightening torques for threaded connections
Mechanical gearbox
General information
Transmission Neutral Position Sensor Calibration
Changing transmission oil in a manual transmission M32-6
Changing transmission oil in a manual transmission F40-6
Replacing a manual transmission M32-6
F40-6 Manual Transmission Replacement
Gearshift mechanism device
Replacing the knob of the gear lever
Gear Lever Replacement
Replacing shift cables
Gear shift cable adjustment
Specification
Special tools and fixtures
Tightening torques for threaded connections
Automatic gearbox
General information
Checking the level and condition of transmission oil
Checking the pressure in the lines
Checking for transmission oil leaks
Transmission oil change
Valve body replacement
Replacing the shift lever on the gearbox
Selector lever cable adjustment
Specification
Special tools and fixtures
Operating materials
Tightening torques for threaded connections
Transfer case
General information
Transfer case replacement
Transfer box installation
Specification
Special tools and fixtures
Operating materials
Tightening torques for threaded connections
Drive shafts
General information
Rear axle
Drive Shaft Replacement
Replacing the right drive shaft with an intermediate shaft
Cardan shaft replacement
Checking the oil level in the propeller shaft rear differential clutch
Replacing the working fluid of the driveshaft differential clutch
Checking the oil level in the rear final drive of the cardan shaft
Changing the oil in the rear final drive of the cardan shaft
Replacing the rear differential clutch of the propeller shaft
Replacing the clutch of the limited slip differential of the cardan shaft
Replacing the driveshaft rear differential clutch control unit
Replacing the propeller shaft rear differential clutch oil filter
Rear wheel drive shaft replacement
Special tools and fixtures
Operating materials
Tightening torques for threaded connections
Chassis
Wheel suspension
Front suspension
Rear suspension
Electronic suspension control
Wheel alignment measurement
Wheel alignment
Camber and angle of longitudinal inclination of the axis of rotation of the wheel
Rear axle turning angle
Wheel hub replacement
Replacing the racks of the anti-roll bar of the front suspension
Stabilizer bar replacement
Removing and installing GMA front suspension strut assembly
GMA Lower Arm Replacement
GMA Lower Arm Bushing Replacement
GMA Suspension Steering Knuckle Replacement
Removal and installation of a rack of a forward suspension bracket GNB assy
Replacing the steering knuckle and GNB front suspension fork
GNB Lower Suspension Arm Replacement
Replacing the upper ball joint of the front suspension GNB
Disassembly and assembly of the front suspension strut
Shock Absorber Disposal
Rear Suspension Trailing Arm Replacement
GNC Rear Suspension Spring Replacement
Replacing the GNC Suspension Control Rod
Replacing the GNC suspension trunnion
GNC Stabilizer Link Replacement
GNC Stabilizer Bar Replacement
GNC Suspension Shock Replacement
Replacing GNC Rear Upper Arm
GNC Rear Suspension Lower Arm Replacement
GNC Suspension Subframe Replacement
GNE Rear Suspension Spring Replacement
GNE Rear Suspension Lower Arm Replacement
GNE rear shock absorber replacement
GNE Suspension Stabilizer Link Replacement
GNE Suspension Anti-roll Bar Replacement
Wheel hub replacement with GNE suspension bearing
Replacing the GNE Suspension Control Rod
GNE Upper Rear Suspension Arm Replacement
GNE suspension trunnion replacement
Replacing the GNE Suspension Subframe
GNE Rear Shock Absorber Recycling
Replacing the electronic suspension control unit GNE
Replacing the GNE Front Suspension Lower Cortical Acceleration Sensor
Replacing the upper vertical acceleration sensor of the front suspension GNE
Replacing the GNE Rear Suspension Position Sensor
Wheel alignment
Special tools and fixtures
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
Stability System
Electronic brake force distribution system
Assisted emergency braking system
The system of assistance when starting on the slope
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 check of operability of components of the hydraulic brake system
Bleeding the brake system
Pedal assembly replacement
Replacing the master brake cylinder
Replacing the vacuum brake booster
Replacing the expansion tank of the brake system
Replacing the front brake pipe
Replacement of brake hoses
Replacing Modulator Valve Piping
Checking the brake pads
Replacing the front brake pads
Checking the equipment for attaching the front brake pads
Replacing the front brake caliper
Brake caliper replacement
Checking the technical condition of the brake caliper
Replacing the front brake disc
Checking the technical condition of the brake discs
Resurfacing of brake discs
Checking the rear brake pads
Replacing the rear brake pads
Checking the equipment for fastening the rear brake pads
Replacing the rear brake caliper
Replacing the rear brake caliper caliper
Checking the technical condition of the rear brake caliper
Replacing the rear brake discs
Checking the technical condition of the rear brake discs
Resurfacing front brake discs
Parking brake adjustment
Replacing the parking brake lever
Replacing the parking brake handle
Parking Brake Indicator Switch Replacement
Parking Brake Switch Replacement
Replacing the parking brake cable
Electric Parking Brake (J71)
Electronic parking brake control unit
Steering angle sensor centering
Brake Pressure Modulator Pressure Sensor Calibration
Yaw Sensor Calibration
Replacing the electronic brake control unit
Replacing the front wheel speed sensors
Replacing the rear wheel speed sensors
Yaw sensor replacement
Wheel Angle Position Sensor Replacement
Specification
Service Data
Special tools and fixtures
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
Steering wheel replacement
Replacing the upper and lower facing casings of the steering column
Replacing the steering column switch bracket
Replacing the turn signal stalk 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)
Power steering pump replacement (six-cylinder engines)
Power steering pump pulley replacement
Replacing the expansion tank of the power steering (four-cylinder engine)
Replacing the expansion tank of the power steering (six-cylinder engine)
Replacing the pressure pipe / power steering hose (four-cylinder engine)
Replacing the pressure pipe / power steering hose (six-cylinder engine)
Power Steering Return Hose Replacement (Four Cylinder Engine)
Power steering return hose replacement (six-cylinder engine)
Power steering cooler replacement
Steering gear heat shield replacement
Steering gear replacement
Replacing the anthers of the steering gear
Replacement of pipelines of a steering reducer
Replacement of internal steering rods
Replacing the steering wheel force control unit
Power steering pump specification
Special tools and fixtures
Operating materials
Tightening torques for threaded connections
Body
Exterior
General information
Front bumper device
Replacement of facing of a forward bumper
Front bumper battery replacement
Front bumper center support bracket replacement
Replacing the front bumper beam
Replacing the lower beam of the front bumper
Rear bumper device
Replacement of facing of a back bumper
Rear bumper battery replacement
Replacing the rear bumper beam
Replacing the lower brackets of the rear bumper cladding
Front fender replacement
Door replacement
Front door adjustment
Rear door adjustment
Hood replacement
Hood adjustment
Tailgate Replacement
Tailgate Adjustment
Trunk lid
Trunk lid adjustment
Replacing the fuel filler flap
Body dimensions
Interior
Dashboard Assembly Replacement
Windshield Defrost Nozzle Replacement
Replacing the upper center trim panel
Replacing the lower center trim panel
Replacement of facing of the switch of head lighting
Dashboard Spacer Replacement
Replacing the front floor console
Replacing the bezel of the ceiling reading lamp
Overhead console replacement
Arrangement of interior trim panels
Replacement of facing of thresholds of forward and back doors
Replacing the lining of the windshield pillars
Replacing the lower and upper facings of the central pillar of the body
Ceiling panel replacement
Front floor replacement
Rear floor replacement
Replacing the inner lining of the door
Door waterproofing replacement
Replacing the lining of the door frame
Special tools and fixtures
Tightening torques for threaded connections
Passive safety
General information
The device of the passive safety system
Safety instructions for working with seat belt pretensioners
Safety precautions when working with airbags
Replacing a contact disk
Alignment of a contact disk of a steering pillow of safety
Deactivation and activation of the additional passive safety system
Steering Wheel Airbag Module Replacement
Replacing the rest of the system components
Disposal of passive safety elements
Special tools and fixtures
Tightening torques for threaded connections
«Quick check» cooling procedure
Heater and air conditioner
General information
Climate control
Precautionary measures
Checking the refrigerant circuit
Checking for Refrigerant Leaks
Repair operations
Replacing the Passenger Cabin Air Filter
Specification
Special tools and fixtures
Operating materials
Tightening torques for threaded connections
Electrical equipment
Electrical circuits
General information about the electrical system
Zoning car wiring harnesses
Wire harness routing
Non-standard symbols and designations
Standard symbols and wire color designations in diagrams
Adaptive head lighting (TT2)
Anti-lock braking system and traction control
Dashboard fuse box
Gearshift lock
Steering column lock
Interior rear view mirror
High speed GMLAN bus
High Speed GMLAN CE Bus
Gas discharge headlights (TT2)
Hydraulic brakes
High beam headlights (TT4)
Rain sensor (CE1)
Wheel speed sensors
Daytime and low beam headlights (TT4)
Rear parking lights and license plate lights
Rear fuse box
Rear wiper
Egnition lock
Sound signal
Immobilizer
Backlight lamps
Local internet
Low speed GMLAN bus
Washers
Interior lighting
Front lighting
Front windscreen wipers
Heated rear window
Fuel filler door release drive
Rear window blind drive
Cigarette lighters and sockets for connecting additional equipment
Fog lights
Ground wiring
Trailer connector
Power distribution: fuses
Power Distribution: Battery Positive Bus (B+), Engine Compartment Fuse Box
Power distribution: battery positive bus (B+), fuse box, battery
Interior lighting dimming
Headlight control (TT4)
AC outlet
Door opening alarm
Door lock system
Tire pressure monitoring system
All-wheel drive system (F46)
Stabilization system
Body control system
Medium speed GMLAN bus
Parking brake
Direction indicators and brake lights
Interior lighting control
Head lighting control
Outdoor lighting control
Reversing lamp
Electronic suspension control system: sensors and actuators (F45)
Electronic suspension control system: power, weight and serial data (F45)
Electric power steering



Kadett D (1979-1984)
General information
Car care
Car body care
Underbody protection and cavity preservation
Bituminous spots on the body
Traces of insects on the body
Industrial body pollution
Car conservation
Care of polymer parts and varnish coatings
Car glass cleaning
Caring for rubber seals
Upholstery care
Maintenance
Jacking up the car
Basic and special tool
Functions of motor oil
Engine oil viscosity
Oil Change — Manual Transmission and Final Drive
Engine oil change
Annual technical inspection
Annual engine and clutch inspection
Annual inspection of the power supply system
Annual inspection of the front suspension and steering
Annual inspection of the car body
Annual inspection of brakes, tires and wheels
Annual inspection of gearbox, drive, steering
Power unit
Gasoline engines
Description and characteristics of gasoline engines
Removal and installation of the engine
Removal and installation of a gear belt
Checking and adjusting the toothed belt tension
Removal and installation of a head of the block of cylinders (OHC engine)
Replacing the camshaft housing / removing and installing the camshaft (OHC)
Removal and installation of valves (OHC engine)
OHV engine cylinder head
Removal and installation of a head of the block of cylinders (OHV)
Removal and installation of valve springs (OHV engine)
Removal and installation of valves (OHV engine)
Removal and installation of a case of the gas-distributing mechanism (OHV)
Removal and installation of the chain tensioner (OHV engine)
Checking the valve timing (OHV engine)
Checking the valve guides
Lapping valves to seats
Replacement of oil seals
Valve clearance adjustment
Checking for flatness of the mating surface of the cylinder head
Checking the surface of the cylinder block for flatness
Cylinder compression check
Starting the engine from an auxiliary source
Engine malfunctions
Lubrication system
Oil Circuit — 1.0/1.2/1.3L Engines
Engine oil consumption
Oil filter replacement
Oil pressure check
Removal and installation of the oil pan
Removal and installation of the oil pump (ONS engine)
Engine oil temperature measurement
Removal and installation of a forward epiploon of the crankshaft
Removal and installation of the oil pressure reducing valve
Malfunctions of the engine lubrication system
Cooling system
Coolant circulation
Coolant replacement
Removal and installation of a radiator
Removing and installing and checking the thermostat
Removal and installation of the pump of a cooling liquid
Cooling system malfunctions
Power system (gasoline)
Fuel System Service
Carburetor — general information
Carburetor adjustment
Malfunctions in the fuel supply system
Preheating of the intake air
Removing and installing the air filter element
Cleaning and replacing the fuel pump filter
Removal and installation of the fuel pump
Carburetor malfunctions and solutions
Removal and installation of system of release OG
Replacing the front exhaust pipe with the middle muffler
Rear muffler replacement
Carburetor Solex 35 PDSI
Solex 35 PDSI carburetor — design description
Removal and installation of the carburetor
Removal and installation of the upper part of the carburetor
Float valve check
Idle speed and CO content adjustment
Idle adjustment
Adjustment of the CO content in the exhaust gases
Checking the idle shutoff valve
Replacing the accelerator pump diaphragm
Checking and adjusting the amount of fuel of the accelerator pump
Checking and adjusting the clearance of the air (start) damper
Adjustment of draft of the air damper
Checking and adjusting the throttle valve clearance
Characteristics of the PDSI carburetor
Carburetor Varajet II
Varajet II Carburetor — Design Description
Removal and installation of the carburetor
Removal and installation of a cover of the carburettor
Throttle gap adjustment
Retaining damper adjustment (secondary chamber air damper)
Idle adjustment
Carburetor Drive Adjustment
CO content adjustment
Setting and checking the clearance of the starting air damper
Checking the opening time of the starting air damper
Starter cover adjustment
Checking and adjusting the accelerator pump
Checking and setting the fast idle speed (for a cold engine)
Checking and adjusting the fuel level in the float chamber
Damping valve installation
Characteristics of the Varajet II carburetor
Carburetor 1B1
Carburetor 1B1 — design description
Removal and installation of the carburetor
Removal and installation of a cover of the carburettor
Removing and adjusting the start cable
Carburetor throttle cable adjustment
Checking and adjusting the idle speed and CO content
Checking and adjusting the CO concentration
Installing and adjusting the starting automation cover
Starter flap clearance checks and adjustment
Checking and adjusting the injection quantity
Characteristics of the 1B1 carburetor
Fuel injection (gasoline)
LE-Jetronik Fuel Injection System — Design Description
Idle speed adjustment
Checking and adjusting the CO content
Checking the control relay
Checking the performance of the fuel pump
Removal and installation of the fuel pump
Fuel filter replacement
Check, removal and installation of injection valves (injectors)
Checking, adjusting and replacing the sensor of extreme positions of the throttle valve
Checking, removing and adjusting the air flow meter
Check, removal and installation of the temperature sensor
Checking and replacing the secondary air spool
Filter element replacement
Fuel level sensor replacement
Malfunctions of the LE-Jetronik fuel injection system
Diesel engines
Diesel engine — general information
The most important engine specifications
Working principle of diesel engine
Removal and installation of the engine
Toothed belt drive — design description
Removal and installation of a gear belt
Checking and adjusting the toothed belt tension
Removal and installation of a head of the block of cylinders
Removal and installation of valves
Diesel engine problems and how to fix them
Fuel system (diesel)
Diesel power 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 limit speed
Checking the pre-glow system
Checking the spark plugs
Removal and installation of nozzles
Idling malfunctions
Loud knocking in the engine
Checking and adjusting the injection pump start moment
Cleaning and replacing the air filter element
Fault: too much fuel consumption
Removal and installation of the vacuum pump
Checking and adjusting the valve timing
Removal and installation of the electromagnetic shut-off valve
Fault: too low engine power
Transmission
Clutch
Clutch — design description
Removal and installation of clutch
Replacing the release bearing and clutch release lever
Clutch cable replacement
Clutch adjustment
Clutch problems and how to fix them
Manual gearbox
Gearbox — general description
F16 gearbox — removal
F10 gearbox — removal
Gearbox — installation
Gear Lever — Design Description
Removal and installation of the gear lever
Switch adjustment
Chassis
Front suspension
Front suspension — design description
Removal and installation of an amortization rack
Removal and installation of a forward spring
Removal and installation of hydraulic shock absorber
Shock absorber check
Removal and installation of a power shaft
Hinge and Hinge Cover Replacement
Rear suspension
Rear suspension — design description
Removal and installation of hydraulic shock absorber (sedan)
Removal and installation of a hydraulic shock-absorber (station wagon)
Removal and installation of the stabilizer
Removing and installing rear springs (sedan)
Removal and installation of rear springs (station wagon)
Wheel bearing play adjustment
Replacement of the bearing of a nave of a back wheel
Steering
Steering — design description
Removal and installation of a steering wheel
Steering gear drive — design description
Checking and adjusting the steering play
Removal and installation of steering drafts
Removal and installation of a tip of steering draft
Brake system
Brake system — general information
Checking the condition of the friction linings
Removal and installation of brake pads
Piston installation template
Removal and installation of a brake disk
Rear brakes — design description
Friction lining thickness check
Rear brake adjustment
Removal and installation of a brake drum
Removal and installation of rear brake pads (up to 8.1983)
Removal and installation of rear brake pads (since 8.1983)
Replacement of friction linings
Removal and installation of the wheel brake cylinder
Wheel Brake Cylinder Repair
Checking and adjusting the brake system regulator
Compensation reservoir for brake fluid
Bleeding the brake system
Removal and installation of a cable of a manual brake
Handbrake adjustment
Checking the brake booster
Brake system malfunctions
Wheels and tires
Wheel alignment
Negative Toe Adjustment
Parameter values for camber and toe adjustment
Wheels and tires — general information
Wheel balancing
Wheel replacement
Tire wear
Anti-skid chains
Tire and rim sizes
Correct tire pressure (overpressure) in kPa (bar/atm)
Tire defects
Abnormal tire wear
Running in new tires
Permissible speed marking
Body
Body elements
General description of the car body
Removal and installation of a bumper
Removal and installation of a forward wing
Removal and installation of a protective lattice of a radiator
Additional installation of protective moldings
Heater — design description
Removal and installation of fresh and heated air regulator / replacement of rods
Doors and windows
Removal and installation of facing of forward doors
Removal and installation of facing of back doors (sedan)
Removal and installation of a window regulator
Removal and installation of glass of a forward door
Removal and installation of glass in the rear doors
Removal and installation of the external handle of a forward door
Removal and installation of the cylinder of the lock of a forward door
Removal and installation of a window lifter on rivets
Electrical equipment
Equipment and devices
Onboard electrical equipment — general information
Installation instructions for optional equipment
Maintenance of electrical equipment
Replacing fuses
Fuse table
On-board electrical equipment — general information
Removal and installation of the instrument panel
Checking the voltage regulator
Removal and installation of light bulbs
Removal and installation of devices
Turn signal switch and wiper switch
Removal and installation of the fan motor
Removal and installation of the screen wiper lever
Removal and installation of the wiper motor
Removal and installation of a screen wiper
Additional installation of an adjustable outside rear-view mirror
Windshield wiper rubber defects
Antenna Installation
Installing the loudspeaker on the instrument panel
Installing the radio
Lighting system
Replacing headlight bulbs
Parking light bulb replacement
Replacing the front direction indicators
Replacing taillight bulbs
Removal and installation of headlights
Headlight adjustment
Removal and installation of rear lights
Removal and installation of interior lighting lamps
Removal and installation of a lamp of illumination of license plate
Table of incandescent lamps
Power devices
Removing and installing the battery
Checking the battery
Charging the battery
Maintenance-free batteries
Battery Faults and Solutions
Generator — design description
Removal and installation of the generator
Checking and tensioning the V-belt
Removing and installing the V-belt
Replacing and checking the carbon contacts of the generator / voltage regulator
Removal and installation of a starter
Replacing the traction relay
Starter malfunctions and solutions
Ignition system
Ignition system — general information
Maintenance of the ignition system
Functions of TSZ-H,TSZ-I systems
Safety measures during the operation of the electronic ignition system
Checking the ignition coil
Capacitor check
Removal and installation of the distributor of ignition
Replacing breaker contacts
Checking and adjusting the closed angle
Ignition timing adjustment
Spark plug
Electrical circuits
Work with electrical circuits
Supplementary Wiring Diagram — Fuel Injection System
Wiring diagram I
Wiring diagram II
Wiring diagram III
Wiring diagram IV



Kadett E (1984-1995)
General information
Vehicle description
Car wheels and tires
Vehicle dimensions
Mass characteristics of cars
Conditional fuel consumption
Refueling tanks and used fuels and lubricants
Fuels and lubricants of domestic production and their foreign analogues
Body control points
Operation and maintenance
Introduction to the Cadet E Owner's Manual
Passport data of the car
Lifting and towing a car
Designation of some cars
General requirements for car repair
The instrument cluster of the car Opel «Kadett E» model «GL»
The instrument cluster of the car Opel «Kadett E» model «GSi»
The instrument cluster of the car Opel «Kadett E» models «GLS» and «OT»
Controls and instrumentation of cars Opel «Kadett E»
Engine hood
Engine start
Starting a carburetor engine
Lubrication system of a carburetor engine
Carburetor engine cooling system
Carburetor engine power system
Carburetor engine ignition system
Clutch
Manual Transmission
Automatic transmission
Front wheel drive
Steering
Front suspension
Rear suspension
Brake system
Accumulator battery
Generator
Fuses
Electronic control and measuring devices
Onboard control system
On-board computer
Ventilation and heating
OHV power unit
Engine design
Main technical characteristics
Specifications of the cylinder head
Specifications of the cylinder block
Technical characteristics of the crank mechanism
Technical characteristics of the gas distribution mechanism
Specifications of the lubrication system
Specifications of the cooling system
Power System Specifications
Specifications of the ignition system
Tightening torques of the main threaded connections, kgf.m
Check and repair
Valve clearance adjustment
Removal and installation of the distributor of system of ignition
Adjustment of a gap between contacts of the breaker of system of ignition
Setting the ignition timing
Fuel pump
The principle of operation of the Weber 32 TL carburetor
The main dosing system of the Weber 32 TL carburetor
Carburetor Throttle Starting Gap Adjustment
Oil filter
Engine work
Removing the cylinder head
Installing the cylinder head
Disassembly of the cylinder head
Checking the cylinder head
Grinding valve seats and valves
Valve guide repair
Cylinder head assembly
Removal and installation of the engine
Engine disassembly
Engine Assembly
Installing the crankshaft
Checking the diametrical clearance between the liners and the crankshaft journals
Assembling the connecting rod and piston group
Checking and installing piston rings
Installation of pistons with connecting rods in cylinders
Installing the camshaft
Installing the camshaft drive
Replacement of pushers of the gas distribution mechanism
Replacement of camshaft bearing sleeves
Checking the technical condition of the oil pump
Oil pressure check
Coolant replacement
Thermostat replacement
Water pump replacement
OHC power unit
Engine design
Main technical characteristics
Specifications 8-valve cylinder head
Specifications 16-valve cylinder head
Specifications of the cylinder block
Technical characteristics of the crank mechanism
Technical characteristics of the gas distribution mechanism of 8-valve engines
Technical characteristics of the gas distribution mechanism of the 16-valve engine
Specifications of the lubrication system
Specifications of the cooling system
Power System Specifications
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»
Specifications of the fuel injection system
Specifications of the ignition system
Technical characteristics of the digital engine management system «Motronic ML 4.1»
Technical characteristics of the fuel injection system of the Motronic M 1.5 system
Technical characteristics of the ignition system of the Motronic M 1.5 system
Technical characteristics of the digital engine management system «Motronic M 2.5»
Technical characteristics of the fuel injection system of the Motronic M 2.5 system
Technical characteristics of the ignition system of the Motronic M 2.5 system
Technical characteristics of the ignition system of engines «13N», «13S», «14NV», «16S», «18E»
Engine repair
Adjustment of gaps in the drive mechanism
Design of hydraulic pushers
The principle of operation of hydraulic pushers
Checking the technical condition of hydraulic pushers
Removing the cylinder head of 8-valve engines
Installing the cylinder head for 8-valve engines
Disassembly and assembly of the cylinder head of 8-valve engines
Removal and installation of a camshaft of 8-valve engines
The device of the gas distribution mechanism of 8-valve engines
Removal and installation of a head of cylinders of the 16-valve engine
Disassembly and assembly of the cylinder head of a 16-valve engine
The device of the gas distribution mechanism of 16-valve engines
Checking the installation of the drive of the gas distribution mechanism of the 16-valve engine
Replacement of a belt of a drive of camshafts of the 16-valve engine
Replacing the front oil seals of the camshafts of a 16-valve engine
Removal and installation of the 16-valve engine
Dismantling the 16-valve engine
Assembling a 16-valve engine
The device of the crank mechanism of a 16-valve engine
The device of the exhaust gas system
Engine suspension device
Cross and longitudinal sections of the engine
Ignition system
Non-contact ignition system device
The principle of operation of a contactless ignition system
Fully electronic ignition system
The device of the sensor-distributor ignition
Diagram for troubleshooting a non-contact ignition system
Cooling and lubrication
Lubrication system
Lubrication system device
Cooling system
Cooling system device
Supply system
Power supply system for carburetor engines
The principle of operation of the Solex 35 PDSI carburetor
Air filter device
Solex 35 PDSI carburetor adjustment and check
GM Varajet II Automatic Carburetor Launcher
Starting device with manual control of the carburetor air flap GM Varajet II
GM Varajet II carburetor idle system
GM Varajet II carburetor adjustment and check
GM Varajet II Carburetor Fast Idle Adjustment
GM Varajet II Carburettor Check and Adjustment
GM Varajet II Carburetor Manual Choke Trigger Adjustment
The principle of operation of the Pierburg 2E3 carburetor
Checking and adjusting the Pierburg 2E3 carburetor
Carburetor Pierburg 2EZ
Checking and adjusting the fuel injection system GM «Multec SPI»
Fuel injection system GM «Multec SPI»
Self-diagnostic system of fuel injection system GM «Multec SPI»
Fuel injection «LE-Jetronic»
Features of the device and principle of operation
Fuel injection system «LE-Jetronic»
Checking and adjusting the LE-Jetronic system
Checking the auxiliary air valve
Checking injection nozzles
Checking the electronic control unit
The sequence of checks when determining malfunctions of the injection system «LE-Jetronic»
Fuel injection «LE3-Jetronic»
Fuel injection system «LE3-Jetronic»
Checking and adjusting the LE3-Jetronic system
The sequence of checks when determining malfunctions of the fuel injection system «LE3-Jetronic»
Motronic ML4.1 system
Distinctive components «Motronic ML4.1» system from «LE-Jetronic»
The device of the Motronic ML4.1 system
Operating principle
Warnings. Checking and adjusting the fuel injection system
Checking and adjusting the engine idle
Self-diagnosis system
Ignition system
Motronic M1.5 system
Digital engine management system «Motronic M1.5»
Malfunctions and methods for 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 for their elimination
Transmission
Clutch
Design and specifications
Tightening torques of the main threaded connections, kgf.m
Removal and installation of clutch
Clutch device
Gearbox F10 and F13
Design and specifications
Tightening torques of the main threaded connections, kgf.m
Removal and installation of a transmission
4-speed gearbox device
Dismantling the 4-speed gearbox
Features of disassembling a 5-speed gearbox
5-speed gearbox device
Differential disassembly
Differential Assembly
Assembling the 4-speed gearbox
Gearshift and differential drive device
Assembly features of the 5-speed gearbox
Adjustment of a drive of a gear change
Removal and installation of the gear lever
Gearbox F16 and F20
Design and specifications
Tightening torques of the main threaded connections, kgf·m
Removal and installation of a transmission
Gearbox disassembly
The device of a 4-speed gearbox type «F16»
Differential disassembly
Differential Assembly
The device of the 5-speed gearbox type «F16»
Gearbox Assembly
Adjustment of a drive of a gear change
Removal and installation of the gear lever
Gearshift drive and differential gearbox type «F16»
Gearshift drive device type «F20»
Automatic gearbox
Design and specifications
Gearbox Specifications
Technical characteristics of transmission oil
Tightening torques of the main threaded connections, kgf.m
Design features and principle of operation
Torque converter
Planetary gear
Clutches
Band brake
Freewheel clutch
Output planetary gear
Removing the hydromechanical gearbox
Oil pressure check
Forced Reverse Cable Adjustment
Removal and installation of a chain of a drive
Checking the band brake
Drive unit for speedometer, band brake servo regulator, pressure accumulator and transmission brake
The device of the automatic transmission control mechanism
Possible malfunctions of the hydromechanical gearbox and their causes
Drive shafts
Design and specifications
Tightening torques for main threaded connections, kgf·m
Removal and installation of shafts of a drive of forward wheels
Replacement of hinges of shaft of a drive of forward wheels
Replacement of protective covers of hinges of shafts of a drive of wheels
Front wheel drive device
Chassis
Front suspension
Design and specifications
Technical characteristics of the stabilizer bar
Specifications of the front wheel hubs
Tightening torques of the main threaded connections, kgf.m
Removal and installation of a telescopic rack
Front suspension device
Removal and installation of front suspension springs
Removal and installation of front suspension shock absorbers
Removal and installation of a bar of the stabilizer of cross-section stability
Removal and installation of suspension arms
Replacing the ball joints of the suspension arms
Replacement of silent blocks of suspension arms
Checking and adjusting the angles of the front wheels
Front wheel bearing replacement
Adjustment of a backlash in the bearing of a nave of forward wheels
Rear suspension
Design and specifications
Tightening torques of the main threaded connections, kgf·m
Removal and installation of rear suspension springs
Removal and installation of rear suspension springs
Replacing the rear shock absorbers
Replacing the rubber bushings of the shock absorber on cars
Removal and installation of the stabilizer bar
Removal and installation of a beam of a back suspension bracket
Rear suspension device
Adjustment of a backlash in bearings of naves of back wheels
Removal and installation of rear wheel hubs on cars of all models, except for cars with a 20XE engine
Replacing rear wheel hub bearings on cars of all models, except for cars with a 20XE engine
Removal, installation and repair of rear wheel hubs on vehicles with a 20XE engine
Arrangement of the rear wheel hub of cars with the engine «20 XE»
Steering
Specifications for mechanical steering
Technical characteristics of power steering
Tightening torques of the main threaded connections, kgf.m
Removal and installation of the steering mechanism of a mechanical steering
Disassembly and assembly of the steering mechanism of mechanical steering
Removal and installation of a shaft of a mechanical steering
Checking the straight-line position of the mechanical steering
Steering device
Removal and installation of the steering mechanism of a steering with the hydraulic booster
Checking the oil pressure in the power steering system
Replacing the power steering pump drive V-belt
Replacement of sealing rings of the steering mechanism
Brake system
Design and specifications
Specifications of the brake mechanisms of the front wheels
Specifications of rear wheel drum brakes
Specifications of wheel cylinders
Specifications of rear wheel disc brakes
Specifications of the brake actuator
Specifications of the parking brake system
Specifications of anti-lock braking system
Tightening torques of the main threaded connections, kgf.m
Replacement of brake pads
Removal and installation of brake discs
Removal and installation of the ATE brake mechanism
Dismantling and assembling the brake mechanism of the front wheel brand ATE
The device of the brake mechanisms of the front wheels
Removal and installation of the brake mechanism brand Delco Moraine
Dismantling and assembly of the brake mechanism brand Delco Moraine
Removal and installation of brake drums on vehicles up to 1984 model year
Replacing the brake pads of the rear wheel drum brakes
Removal and installation of the wheel cylinder of drum brake mechanisms of back wheels
Rear wheel brake device
The device of the drum brake mechanism of the rear wheel
Replacing the brake pads of the rear wheel disc brakes
Rear wheel disc brake device
Removal and installation of a support
Parking brake adjustment
Parking brake system device
Removal and installation of the main brake cylinder of a drive of brakes
The device of the main brake cylinder and the vacuum booster of the brake drive
Removal and installation of the vacuum amplifier of a drive of brakes
Rear brake pressure regulator device for van brake drive
Removal and installation of regulators of pressure of a drive of brakes on cars with a body «hatchback» and «sedan»
Replacing the brake pressure regulator on station wagons
Replacing the Brake Pressure Regulator on Delvan and Combo Vans
Check of work of a regulator of pressure of a drive of brakes
Removal of air from the hydraulic drive of the brakes using a special installation
Removal of air from the brake hydraulic drive without special installation
The principle of operation of the anti-lock brake system
ABS device
Monitoring the operation of the ABS system
Removal and installation of the hydroblock ABS
Removal and installation of 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 the main threaded connections, kgf·m
Removal and installation of the generator
Alternator Drive V-Belt Tension Adjustment
Generator accessory drive belt tension adjustment
Disassembly and assembly of the generator
Generator device
Removal and installation of a starter
Disassembly and assembly of the starter
Starter device
Headlight adjustment
Removal and installation of the windshield wiper gearmotor
Glass cleaner device
Removal and installation of a combination of devices
Instrument cluster device
Mounting block device
Cabin heater
Electrical circuits
Wire color designation
Scheme of electrical equipment No. 1
Scheme of electrical equipment No. 2
Electrical equipment diagram No. 3
Scheme of electrical equipment No. 4
Electrical equipment diagram No. 5
Scheme of electrical equipment No. 6
Scheme of electrical equipment No. 7
Scheme of electrical equipment No. 8
Scheme of electrical equipment No. 9
Scheme of electrical equipment No. 10
Scheme of electrical equipment No. 11
Scheme of electrical equipment No. 12
Scheme of electrical equipment No. 13
Scheme of electrical equipment of cars with the engine «20XE»



Omega A (1986-1993)
General information
User manual
Car keys
Seat and steering wheel adjustments
Egnition lock
Lighting and sound signaling
Windshield wipers and washers
Dashboard
Transmission
Engine starting
Stopping the car
Temperature gauges, fuel gauges and control lamps
Instruments (arrow instrument panel)
Instruments (LCD instrument panel)
Automatic control system
On-board computer
Door control
Trunk lid, tailgate
Salon elements management
Structural body safety
Lighting devices
Windows, sunroof
Heating and ventilation control
Air conditioner control
Automatic transmission
Electronic chassis damping control
Adjusting the level of landing of the car
Manual speed control device
Brake system
Wheels and tires
Additional roof rack
Drawbar hitch
Diesel engine fuel system
Starting the engine with assistance
Electronic equipment, ignition system
Lamp replacement
Maintenance
General dimensions, weight and capacities
Identification numbers
View of the engine compartment (model 1.8 GL Sedan)
Front bottom view (1.8 GL Sedan model)
Rear bottom view (model 1.8 GL Sedan)
Recommended Lubricants and Fluids
Service Procedures (Petrol Models)
Service Procedures (Diesel Engines)
Required actions for maintenance
Engine oil level check — every 400 km
Checking the coolant level — every 400 km
Exhaust quality check — every 400 km
Checking the glow plug indicator lamp — 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
Draining water from the fuel filter — every 7500 km
Checking and adjusting the idle speed — every 10,000 km
Fuel filter change — every 10,000 km
Replacing the 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
Lubricating the thrust of the throttle lever — 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
Fuel filter change — every 30,000 km
Glow plug replacement — every 100,000 km
Coolant change — every 2 years, regardless of mileage
Changes and additions
Introduction
Specifications
Fuel and exhaust systems — 2.0 liter models
Ignition system — 1.8 liter carburetor models
Automatic transmission
Main gear and drive shafts
Brake system
Body
Electrical system
Troubleshooting
Engine
Cooling system
Fuel and exhaust systems
Clutch
Mechanical transmission
Automatic transmission
Differential and cardan shaft
Brake system
Suspension and steering
Electrical system
Power unit
Gasoline engines
Gasoline Engine Specifications
General description
Technical service
Basic operations possible with the engine in the car
Basic Operation Requiring Engine Removal
Engine removal method
Engine — removal
Engine Disassembly — General Description
Auxiliary parts of the engine — removal
Engine — complete disassembly
Pallet — removal and installation with an engine in a car
Engine mounting brackets — replacement
Cylinder head — removal and installation with an engine in a car
Toothed belt drive — replacement with the engine in the car
Engine Components — Inspection and Rebuild
Cylinder head — bulkhead
Engine — Assembly
Engine Accessories — Installation
Engine — Installation
Engine — preparation for launch after overhaul
Diesel engines
Diesel engine specifications
General description
Compression test — description
The main actions possible with the engine in the car
Basic actions requiring removal of the engine
Engine removal method
Engine — removal
Engine Disassembly — General Description
Auxiliary parts of the engine — removal
Engine — complete disassembly
Pallet — removal and installation with an engine in a car
Engine mounting brackets — replacement
Cylinder head — removal and installation (engine in a car)
Valve clearances — checking and adjusting
Engine Components — Inspection and Rebuild
Cylinder head — bulkhead
Engine — Assembly
Engine Accessories — Installation
Engine — Installation
Preheating system — description and serviceability check
Engine — preparation for the first start after a major overhaul
Cooling system
Cooling system specifications
General description
Ongoing 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
Thermal viscous cooling fan — removal and installation
Water pump — removal and installation
Alternator/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
Ongoing maintenance
Plugged adjustment screws — general description
Air filter and element — removal and installation
Fuel pump (carburetor models) — removal, inspection and installation
Fuel pump (models with fuel injection) — check, removal and installation
Fuel Filter (Fuel Injected Models) — Replacement
Fuel tank — removal and installation
Fuel level sensor — removal and installation
Diaphragm damper (engines with fuel injection) — removal and installation
Accelerator cable — removal, installation and adjustment
Fuel control pedal — removal and installation
Carburetor — description
Carburetor — idle and mixture adjustment
Carburetor — removal and installation
Carburetor — Bulkhead
Carburetor Throttle Damper (Automatic Models) — Adjusting
Carburetor — High idle adjustment
Carburetor thermostatic valve — check
Intake manifold heater element (carburetor models) — removal, inspection and installation
Fuel injection system — description
Fuel Injection System — Precautions
Fuel injection system — idle speed and mixture adjustment
Fuel Injection Throttle Switch — Check and Adjust
Components of the Bosch L3 Jetronic fuel injection system — removal and installation
Bosch Motronic ML4 fuel injection system components — removal and installation
Drive 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 — check
Fuel system — pumping
Nozzles — removal and installation
The moment of the beginning of the injection 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
Ongoing maintenance
Distributor breaker cover and distributor slider — removal and installation
Ignition timing — check
Octane plug — adjustment
Ignition coil — test, removal and installation
Inductive impulse 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
Ongoing 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 mech. transmission
Manual transmission — removal and installation
Manual transmission — disassembly into main blocks
Manual Transmission — Inspection
Secondary shaft of a manual transmission — disassembly and assembly
Manual Transmission Input Shaft — Disassembly and Assembly
Rear crankcase of a manual transmission — disassembly and assembly
Manual Transmission Main Cover — Disassembly and Assembly
Manual Transmission — Assembly
Manual transmission shift lever — removal, reassembly and installation
Mounting suspension gear lever — removal and installation
Draft of a gear change mech. gearboxes — 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 Select Lever Link — Adjustment
Automatic transmission selection lever — removal and installation
Inhibitor switch — removal and installation
Cardan shaft
Cardan Shaft Specifications
General description
Cardan shaft — removal and installation
Center bearing — replacement
Connecting discs — replacement
Final Drive Rear Cover Gasket — Replace
Drive shafts
Final Drive and Drive Shaft Specifications
General description
Technical service
Final drive mechanism — removal and installation
Silencing suspension of the final drive mechanism — replacement
Final Drive Gear Seal — Replacement
Final Drive Differential Bearing Seal — Replacement
Drive shaft — removal and installation
Rubber boots of the drive shaft and external CV joint — replacement
Chassis
Brake system
Brake Specifications
General description
Technical service
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 — pumping
Brake pipes and hoses — removal and installation
Vacuum booster — test
Booster Vacuum Hose and One-way Valve — Replacement
Vacuum booster — removal and installation
Brake pedal — removal and installation
Anti-Lock Brake System (ABS) Precautions
ABS hydraulic modulator — removal and installation
ABS electronic control unit — removal and installation
ABS wheel speed sensor — removal and installation
ABS relay — replacement
Car suspension
Suspension specifications
General description
Technical service
Front suspension strut — removal and installation
Front suspension strut — bulkhead
Lower arm front suspension — removal and installation
Front suspension lower ball joint — replacement
Front anti-roll bar — removal and installation
Front anti-roll bar — removal and installation
Swivel fist — removal and installation
Front hub and bearings — removal and installation
Front suspension cross member — removal and installation
Rear shock absorber rod — removal and installation
Rear diagonal lever — removal and installation
Rear coil spring — removal and installation
Rear anti-roll bar — removal and installation
Rear axle (assembly) — removal and installation
Rear suspension crossbar — removal and installation
Rear Suspension Crossbar 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 (No Height Adjustment) — Bulkhead
Steering Column (Height Adjustable) — Bulkhead
Steering gear — removal and installation
Steering gear — adjustment in place
Tie rods — removal and installation
Intermediate steering gear — removal and installation
Power steering pump — removal and installation
Wheel installation — check and adjustment
Wheels and tires — care and maintenance
Body
Exterior
Body Specifications
General description of the body
Technical service
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 grill — 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 tailgate window / rear window — removal and installation
Front door window — removal and installation
Rear door window — removal and installation
External 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 rugs — maintenance
Door trim panel — removal and installation
Door speaker — removal and installation
Internal door handle — removal and installation
Headrest guides — removal and installation
Seat belts — removal and installation
Seats — removal and installation
Dashboard — removal and installation
Center console — removal and installation
Heater dashboard — 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
Details of the air conditioning system — removal and installation
Electrical equipment
Power devices
Electrical system specifications
General description
Technical service
Electrical System — Precautions
Battery — removal and installation
Battery — Charging
Alternator — test in a car
Generator — removal and installation
Generator brushes and voltage regulator — removal and installation
Starter — general description
Starter — check in the car
Starter — removal and installation
Starter overhaul — general description
Traction starter relay — removal and installation (starter removal)
Starter brushes — inspection and removal
Starter — disassembly and assembly
Lighting and appliances
Fuses and relays — general description
Combined steering column switches — removal and installation
Panel switches — removal and installation
Interior lighting switch — removal and installation
Clock — removal and installation
Cigarette lighter backlight — removal and installation
Heater control switch — removal and installation
Ignition lock — removal and installation
Dashboard — 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 — directivity adjustment
Wiper blades and arms — removal and installation
Wiper motor and traction — 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
Wiring Diagrams — General Description
Symbols on electrical diagrams
Wiring diagrams for models 1987-1988 release
Wiring diagrams for models 1989-1990 release
Wiring diagrams for models 1991-1992 release
Wiring diagrams for models since 1993



Omega B (1993-1999)
General information
User manual
Instrument panel device
Pilot lamps and switches
Vehicle controls
Instrument cluster
Control indicators of a combination of devices
Car opening
Rear view mirrors
Ignition / starter switch
Manual transmission
Automatic transmission
Engine starting
Releasing the handbrake
Car parking
Multifunction display
Electronic air conditioning system
Fuses — location and replacement
Replacing lighting lamps
Lubricants and fluids
Location of elements in the engine compartment
Tips for the car owner
Buying a used car
Revealing broken 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 malfunctions of diesel engines with Bosch fuel equipment
Buying a used diesel engine
Diesel engine care
Maintenance (gasoline)
Specifications
Ongoing maintenance
After 8000 km or every 6 months
Every 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)
Specifications
Ongoing 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
Specifications
Compression test
Top dead center (TDC) piston No. 1
Camshaft cover
Crankshaft pulley
Timing belt covers
Gas distribution belt
Timing belt and sprocket tensioner
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
Specifications
Compression test
Top dead center (TDC) piston No. 1
Camshaft cover
Crankshaft pulley
Timing belt covers
Gas distribution belt
Belt tensioner, sprockets and intermediate pulleys
Camshaft 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
Specifications
Compression test
Top dead center (TDC) piston No. 1
Camshaft covers
Crankshaft pulley
Timing belt covers
Gas distribution belt
Belt tensioner, sprockets and intermediate pulleys
Camshaft seals — replacement
Camshafts and tappets
Cylinder head
Oil pan
Oil pump
Oil radiator
Flywheel and drive disc
Crankshaft seals
Engine and gearbox mounts
Repair of gasoline engines
Specifications
Compression test
Engine overhaul
Engine diagnostics with a vacuum gauge
Checking compression in the engine cylinders
Engine Overhaul — Alternatives
Auxiliary elements of the engine
Dismantling the power unit — methods and safety precautions
Removal and installation of the engine
Engine overhaul
Cylinder head and valves
Pistons and connecting rods
Crankshaft
Cylinder block
Main bearings and connecting rod bearings
Piston rings
First engine start after overhaul
Diesel engine 2.0 l
Specifications
Repair operations on the engine installed in the car
Compression pressure test
Top dead center (TDC) piston No. 1
Gas distribution 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 cooler — removal and installation
Crankshaft sealing rings
Flywheel — removal, inspection and installation
Suspension of the power unit — check
Diesel engine repair 2.0 l
2.0 liter diesel engine overhaul
Specifications
Cylinder head
Pistons and connecting rods — removal, inspection and installation
Crankshaft — removal, inspection and installation
Engine block — cleaning
Main bearings and connecting rod bearings
Engine assembly sequence during overhaul
Piston rings — installation
Operating clearances of main bearings
Operating clearances of connecting rod bearings
Starting the engine after a major overhaul
Diesel engine 2.5 l
Removal and installation of the engine
Cylinder head — removal and installation
Camshaft — removal and installation
Compression test
Multi-ribbed V-belt
Oil pan and gasket
2.5 liter diesel engine cooling system
Radiator — removal and installation
Viscous clutch fan / fan clutch
Cooling pump — removal and installation
Air blower pipe — removal and installation
Cooling and heating
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)
Specifications
Unleaded gasoline
Fuel injection systems
Air filter and air pipes
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 (engine 2.5 and 3.0 liters)
Inlet manifold — removal and installation
Exhaust manifold — removal and installation
Multi-flow air supply system
Exhaust gas exhaust system
Emission reduction
Emission Control Systems
Specifications
Emission Control Systems Test
Elements of the exhaust emission reduction system
Elements of the fuel vapor collection system
Elements of the exhaust gas recirculation system
Elements of the additional air supply system
Catalytic converter
Fuel system (diesel 2.0 l)
General information and precautions
Specifications
Air filter and air inlets
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 the maximum speed
Electrical components of the injection system
High pressure fuel pump
Fuel injection timing
Fuel injectors — removal and installation
Turbocharger — removal and installation
Inlet manifold — removal and installation
Exhaust manifold — removal and installation
Fuel system (diesel 2.5 l)
Working principle of diesel engine
Turbocharger — general information
Exhaust gas recirculation (EGR) system
Pre-heating device for diesel engines
Pre-glow system / glow plugs
Preheating relay
Removal of air from the power system
High pressure fuel pump (TNVD)
Nozzles — check, removal and installation
Checking / adjusting the start of injection pump
Inlet manifold — removal and installation
The main malfunctions of the diesel injection system
Diesel engine exhaust system
Launch system
Engine start system — general information
Specifications
Finding the source of a malfunction in the electrical system
Battery — removal and installation
Battery Charging System
Auxiliary battery connection
Alternator drive belt
Generator — removal and installation
Engine start system
Starter — removal and installation
Low oil pressure warning light switch
Oil level sensor — removal and installation
Ignition system
General information and verification
Specifications
Ignition distribution module
Ignition advance angle
Transmission
Clutch
Specifications
Hydraulic clutch release drive system
Master cylinder — removal and installation
Working cylinder — removal and installation
Clutch pedal — removal and installation
Clutch discs — removal and installation
Main malfunctions, their causes and methods of elimination
Mechanical gearbox
Specifications
Transmission oil
Gear shift mechanism — adjustment
Gear shift lever
Oil seals — replacement
Reversing light switch
Manual transmission — removal and installation
Automatic gearbox
Unlocking the shift lever
Specifications
Transmission fluid — replacement
Gear shift mechanism
Gear shift lever
Oil seals — replacement
Transmission fluid cooler
Electrical components of the transmission control system
Automatic transmission — removal and installation
Drive shafts
Specifications
Main gear
Final drive damper bushings
Final drive rear cover gasket
Epiploon of a leading gear wheel of the main transfer
Axle bearing seals
Half shaft — removal and installation
Axle boots and outer CV joint
Cardan shaft — removal and installation
Chassis
Brake system
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 camber
Lower arm front suspension
Lower control arm ball joint, front suspension
Stabilizer bar of the front suspension
Connecting links of the stabilizer bar
Stub axle — removal and installation
Front wheel hub and bearings
Front suspension crossbar
Rear shock absorber
Rear suspension arm — removal and installation
Rear suspension springs — removal and installation
Stabilizer bar of the rear suspension
Transverse rods of the rear suspension
Rear suspension height adjustment system
Rear suspension — removal and installation
Rear suspension cross member
Rear suspension crossbar mounts
Rear wheel hub and bearings
Steering
Steering wheel — removal and installation
Steering column — removal and installation
Steering lock / ignition lock
Steering gear — removal and installation
Tie rods — removal and installation
Steering arm — removal and installation
Power Steering system Pump
Wheel alignment and steering angles
Body
Exterior
Specifications
Maintenance and repair
Repair of minor body damage
Repair of significant damage to the body
Hinges and locks
Windscreen and fixed windows
Bumpers — removal and installation
Radiator grille — removal and installation
Hood and support legs — removal and installation
Hood lock cable — removal and installation
Bonnet lock spring — removal and installation
Exterior mirrors
External body elements
Interior
Seats — removal and installation
Elements of seat belts
Interior trim panels
Center console — removal and installation
Glove box — removal and installation
Dashboard — removal and installation
Doors and windows
Doors — removal and installation
Interior door trim panel
Door handles and locks
Power windows and windows — removal and installation
Rear side window (station wagon models)
Fuel tank flap lock and lock cable
Trunk lid and support legs
Trunk lid lock elements
Rear door and support legs
Elements of the rear door lock
Elements of the central locking system
Elements of electric windows
Windscreen and fixed windows
Top hatch elements
Electrical equipment
Equipment and devices
General information and precautions
Specifications
Finding the source of a malfunction in the electrical system
Fuses and relays
Switches — removal and installation
External lighting bulbs
Interior lighting bulbs
External lighting fixtures
Headlight adjustment
Instrument panel — removal and installation
Instrument panel elements
Clock / multifunction display
Lighter — removal and installation
Xenon headlight adjustment system
Horns of the sound signal
Wiper arms — removal and installation
Engine, windscreen wiper coupling mechanism
Rear window wiper motor
Windshield / rear window / headlight washers
Radio/cassette/CD player
Speakers — removal and installation
Radio antenna — removal and installation
Anti-theft alarm system and engine immobilizer
Airbag system
Elements of the airbag system
Elements of the cruise control system
Wiring diagrams (early)
Explanations for wiring diagrams
Chain index 100-1199 (early models)
Keys to Early Model Schematics
Circuit diagrams 100-199
Circuit diagrams 200-299
Circuit diagrams 300-399
Circuit diagrams 400-499
Circuit diagrams 500-599
Circuit diagrams 600-699
Circuit diagrams 700-799
Wiring diagrams (late)
Chain index 100-1699 (later models)
Keys to Late Model Schematics
Circuit diagrams 100-199
Circuit diagrams 200-299
Circuit diagrams 300-399
Circuit diagrams 400-499
Circuit diagrams 500-599
Circuit diagrams 600-699
Circuit diagrams 700-799
Circuit diagrams 800-899
Circuit diagrams 900-999



Omega B2 (1999-2003)
General information
User manual
Signal lights and button labels
Key numbers and codes
Unlocking doors
Seat adjustment
Head restraints — height and tilt adjustment, locking
Steering wheel height adjustment
Seat adjustment according to your height
Adjustment of an internal rear-view mirror
Electric outside rear-view mirrors
Ignition lock and key positions in it
Heated rear window and exterior mirrors
Cleaning foggy or icy windows
Controls and controls on the instrument panel
Switch for lighting and light signaling
Steering wheel switch of the windshield cleaner
Windscreen and headlight washers
Rear window cleaner and washer
Gear shift. Vehicles with manual transmission
Gear shift. Vehicles with automatic transmission
Engine starting. Cars with a gasoline engine
Engine starting. Diesel vehicles
Stopping and parking a car
Dashboard
Front seat passenger recognition system
Tachometer and speedometer
Coolant temperature gauge
Fuel reserve indicator
Information display
Electronic air conditioning system
Airing the cabin. Deflectors
Cabin air recirculation mode
General information about the air conditioning system
Location and purpose of the fuses
Checking the level and filling engine oil
Fuel filter. Diesel vehicles
Fluid tanks in the engine compartment
Security alarm
Maintenance
Car care
Starting the engine using a booster battery
Towing a car
Poddomkrachivanie car
Maintenance plan
Maintenance — work
Fuel filter — condensate removal/replacement
V-belt — check
Timing belt of the gas distribution mechanism — check
Coolant — check
Coolant — Concentration Check
Exhaust system — visual leak test
Air Filter Replacement Element — Replacement
Spark plugs — removal, inspection and installation
Gearbox and final drive
Brakes. Tires. wheels
Brake Fluid — Level Check
Brake Fluid — Change
Wheels and tires
Front axle and steering
Body. Salon equipment
Troubleshooting
Determination of engine malfunctions and their elimination
Determination of malfunctions of the engine lubrication system and their elimination
Determination of malfunctions of the engine cooling system and their elimination
Determination of malfunctions of the gasoline injection system and their elimination
Determination of malfunctions of the diesel engine power system and their elimination
Determination of malfunctions of the brake system and their elimination
Clutch Fault Identification and Troubleshooting
Identifying Battery Faults and Troubleshooting
List of starter malfunctions and their elimination
Identifying Generator Faults and Troubleshooting
Determination of malfunctions of a screen wiper and their elimination
Power unit
Petrol 4-cylinder
Specifications of gasoline 4-cylinder engines
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
Toothed drive belt covers — removal and installation
Toothed drive belt — removal and installation
Sprockets, tensioner and timing belt 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, reassembly and installation
Crankshaft balancer block — removal, installation and adjustment
Flywheel / Drive Disc — Removal, Inspection and Installation
Crankshaft seals — replacement
Engine / transmission mounts — inspection and replacement
Petrol 6-cylinder
Specifications of gasoline 6-cylinder engines
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
Toothed drive belt covers — removal and installation
Toothed drive belt — removal and installation
Sprockets, tensioner and toothed 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, reassembly 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 — Build Sequence
Piston rings — installation
Crankshaft — setting and checking the operating clearance of the main bearing
Piston/Connecting Rod Assemblies — Installing and Checking the Connecting Rod Bearing Running Clearance
Engine — preparation for launch after a bulkhead
Diesel engines 2.0 l
2.0 liter diesel engine specifications
Engine — removal and installation
Cylinder head cover — removal and installation
TDC of the piston of the cylinder No. 1 — installation
Cylinder head — removal and installation
Cylinder head — bulkhead
Camshaft — removal and installation
Vacuum pump — removal and installation
Timing cover — 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
Vibration damping unit — removal and installation
Auxiliary drive ribbed 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 the piston of the cylinder No. 1 — installation
Cylinder head — removal and installation
Cylinder head — bulkhead
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
Auxiliary drive ribbed 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, Refilling 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 resistances — removal and installation
Air distribution damper diaphragm valve — removal and installation
Interior blower motor — removal and installation
Air conditioner
Injection system (gasoline)
General information about the fuel injection system
Fuel injectors — check, removal and installation
Lambda probe — removal and installation
Fuel system (diesel)
Working principle of diesel engine
Preheater — checking, removing and installing glow plugs
Relay block preheating — removal and installation
Fuel cut-off valve — check, removal and installation
High pressure fuel lines and injectors — removal and installation
Start of injection pump supply — check and adjustment
Intake manifold — removal and installation
Fuel system
General description of the fuel system
Fuel pump — removal and installation
Fuel gauge — 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
System of release of the fulfilled gases — 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 — check and adjustment
Transmission
Clutch
Clutch Specifications
General description of clutch
Clutch hydraulic system — bleeding
Master cylinder — removal and installation
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
Shift Rod — Adjustment
Shift rod — removal and installation
Oil seals — replacement
Reversing light switch — service check, 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
Draft of switching of modes of the movement — adjustment
Draft of switching of a mode of movement — removal and installation
Assembly of the lever of a choice of a mode of movement — removal and installation
Oil 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 final drive and drive shafts
Final drive unit — removal and installation
Final drive unit — filling and checking the oil level
Damper bushings of the final drive unit — replacement
Final drive rear cover gasket — replacement
Main gear oil seal — replacement
Differential bearing seal — replacement
Drive shaft — removal and installation
Rubber protective covers of the drive shaft and its external CV joint — replacement
Cardan shaft — removal and installation
The central bearing of the cardan shaft — replacement
Elastic joints of the cardan shaft — replacement
Chassis
Brake system
Brake Specifications
General description of the braking system
Front wheel brake pads — check, removal and installation
Rear wheel brake pads — check and replace
Front wheel brake caliper — removal, reassembly and installation
Rear wheel brake caliper — removal, reassembly and installation
Brake disc — check, removal and installation
Parking brake pads — 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 — pumping
Brake hoses — removal and installation
Vacuum brake booster — check, removal and installation
Vacuum booster hose and its one-way valve — replacement
Brake pedal — removal and installation
ABS and traction control system — general description
ABS and traction control system — removing and installing components
Car suspension
Suspension specifications
General description of the suspension
Front suspension strut — removal and installation
Front wheel camber — adjustment
Lower suspension arm — removal and installation
Front suspension lower ball joint — replacement
Front anti-roll bar — removal and installation
Sheer draft front anti-roll bar — removal and installation
Swivel fist — removal and installation
Front wheel hub and bearings — removal and installation
Underframe — removal and installation
Rear shock absorber — removal and installation
Rear diagonal lever — removal and installation
Rear leaf spring — removal and installation
Rear anti-roll bar — removal and installation
Reactive rod rear suspension — removal and installation
Rear suspension stiffness control system — removing and installing components
Rear suspension assembly — removal and installation
Rear suspension crossbar — removal and installation
Rear cross bar mounts — replacement
Hub and rear wheel 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
Tie rods — removal and installation
Pendulum lever — removal and installation
Power steering pump — removal and installation
Wheel Alignment — Check and Adjust
Body
Body elements
General description of the body
Front bumper — removal and installation
Front bumper pad — removal and installation
Front cross member — 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 fitting
Door upholstery — removal and installation
Door glass — removal, installation and adjustment
Door handles — removal and installation
Door lock — removal and installation
Center console — removal and installation
Tailgate — removal and installation
Electrical equipment
Equipment and devices
Light Bulb Check
Checking electric motors
Light bulb and motor switches — check
Switch sensors — check
Relay — check
Turn signal breaker — check
Wiper motor — check
Rear window heater — check
Stoplight — check
Central locking device
Battery — removal and installation
Generator — device
Starter — removal and installation
Lighting fixtures — lamp replacement
Instrument panel — removal and installation
Warning lights on the instrument panel — replacement
Electrical circuits
Reading electrical diagrams
Scheme 1. Vehicles with Y22DTH engine
Diagram 2. Vehicles with Y25DT engine
Scheme 3. Cars with the Y25DT engine (addition to scheme 2)
Scheme 4. Cars with the Z22XE engine
Scheme 5. Cars with the Z22XE engine (addition to scheme 4)
Diagram 6. Vehicles with Y26SE/Y32SE engine
Scheme 7. Vehicles with Y26SE/Y32SE engine (supplement to Scheme 6)
Scheme 8. Cooling and ventilation system. Vehicles with Y22DTH engine
Scheme 9. Cooling system. Vehicles with Y25DT engine
Scheme 10. Cooling and ventilation system. Vehicles with Y26SE/Y32SE engine
Scheme 11. Cooling system. Vehicles with Z22XE engine
Diagram 12. Vehicles with Y25DT engine and automatic transmission
Diagram 13. Cars with an automatic transmission and an automatic transmission switch
Diagram 14. Anti-lock braking system (ABS)
Diagram 15. ABS and ESP
Diagram 16. Vehicles with ABS and traction control system
Scheme 17. Climate control
Diagram 18. Airbags
Scheme 19. Central lock
Scheme 20. Power windows
Scheme 21. Instrument panel
Scheme 22. Drawbar, reversing lights, fog lights...
Scheme 23. Parking lights, brake lights, direction indicators
Diagram 24. Horn, glass cleaner (without rain sensor), headlight washer



Vectra A (1988-1995, petrol)
General information
User manual
Your car key
Steering wheel height adjustment
Seat adjustment
Safety belt
Adjustment of rear-view mirrors
Ignition switch
Dashboard Description
Indicator lamps in the instrument cluster
Manual Transmission
Automatic transmission
Checks before leaving
Starting engines
Installing the car in the parking lot
Instrument description
Pilot lamps
Liquid crystal display
Power-on control check
On-board computer
Passenger safety
Safety accessories
Seat belt operation
External lighting
Interior lighting
Windows doors
Sliding sunroof
Heating and ventilation system
The device and control of the air conditioner
Automatic transmission control
Maintenance
Vehicle dimensions and weight
Lubricants and fluids
Service Specifications
Vehicle identification
Weekly checks
Engine oil level
Coolant level
Washer fluid level
Brake fluid level
Power steering fluid level
View of the engine compartment model 1.6 L 1989 (engine 16 SV)
View of the engine compartment of the 1991 Cavalier 3L (C16 NZ engine)
View of the engine compartment model 2.0 SRi 1989 (engine 20 SEH)
View of the engine compartment of a 1990 2000 GSI (20 XEJ engine)
Maintenance Schedule
General description of maintenance
Intensive service
Engine oil and filter — change
Hoses — checking the condition and tightness of their fasteners
Steering and suspension — check
Checking the protective cover of the drive shaft
Checking the transmission fluid level
Inspection and cleaning of the radiator
Idle and mixture adjustment
Throttle link service
Exhaust system check
Wiring check
Ignition advance angle
Brake Fluid Replacement
Checking the brake pads
Checking the handbrake linkage
Power steering fluid check
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 the door lock key — replacement
Road test
Coolant replacement
Air filter element — replacement
Inlet Air Temperature Control Check (Carburetor Models Only)
Fuel filter replacement
Spark plug replacement (SOHC engines)
Distributor breaker cover and checking high voltage wires
Checking the clutch cable
Checking the manual transmission fluid
Automatic transmission check
Replacing the toothed drive belt
Spark plug replacement (DOHC engines)
Transmission Fluid Replacement
Power unit
SOHC engine
Single Overhead Cam Engine Specifications
General description of the 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
Engine disassembly and assembly — general description
Toothed drive belt and sprockets (without automatic tensioner) — removal, installation and adjustment
Toothed drive belt and tensioner (models 1.4 and 1.6 l, except C16NZ2) — removal, installation and adjustment
Timing Belt Cover Opening, 1.4L and 1.6L Models — General Description
Toothed drive belt and tensioner (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, overhaul dimensions for C16NZ2, 1.8 and 2.0 liter models — 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
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
Preparation for launch after overhaul
Engine Troubleshooting
DOHC engine
General characteristics of the DOHC engine
Engine — removal and installation
Double overhead cam engine specifications
Engine/Transmission Brackets — Replacement
Toothed drive belt, sprockets, tensioner pulley and intermediate pulley — removal, installation and adjustment
Toothed drive belt with automatic adjuster — 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 cooler — removal and installation
Cooling and ventilation
Cooling and Ventilation Specifications
General description of the cooling and ventilation system
Cooling System — Fluid Drain
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 — check 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)
Specifications of the carburetor power system
General description of the carburetor power system
Fuel System — Precautions
Air filter — removal and installation
Inlet air temperature control — description and verification
Fuel pump — check
Fuel pump — removal and installation
Fuel tank — removal, inspection and installation
Fuel level sensor block — removal and installation
Fuel vapor separator (models 1.6 and 1.8 liters) — removal and installation
Gas pedal — removal and installation
Throttle cable — removal, installation and adjustment
Carburetor — general description
Carburetor — removal, reassembly and installation
Idle speed and mixture — adjustment
Needle and float — removal, inspection and installation
Secondary Throttle Valve Vacuum Diaphragm — Inspection, Removal and Installation
Economizer valve diaphragm — removal and installation
Accelerator pump — check, removal and installation
Automatic air damper unit — removal, installation and adjustment
Vacuum automatic choke pull-down blocks — removal, installation and adjustment
Carburetor filter — removal and installation
Throttle damper (automatic transmission models) — adjustment
Throttle position sensor (models with automatic transmission) — removal and installation
Idle speed increase valve
Idle shut-off valve (1.8 liter models) — description and verification
Intake manifold — removal and installation
Fuel system (injector)
Power Injection Specifications
General description of the injection power system
Fuel Injection System — Precautions
System check — general description
Air filter — removal and installation
Air block — removal and installation
Air temperature control — description and verification
Air temperature sensor (late models) — removal and installation
Fuel System Depressurization — General Description
Fuel filter (models with a fuel priming pump) — removal and installation
Fuel filter (models with a fuel priming pump) — removal and installation
Fuel 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
Sensor in the fuel tank — removal and installation
Fuel flow damper — removal and installation
Gas cable — removal, installation and adjustment
Idle mixture — check and adjust
Fuel pressure regulator — removal and installation
Idle speed regulator — removal and installation
Throttle position sensor — removal and installation
Throttle valve potentiometer — removal and installation
Air flow meter (if equipped) — removal and installation
Air mass meter (if equipped) — removal and installation
Air flow mass tape meter — 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 valve 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 (engine with one overhead camshaft without Multec) — removal and installation
Intake manifold (single overhead camshaft engine with Multec) — removal and installation
Intake manifold (models with two overhead camshafts) — removal and installation
Exhaust converter
Exhaust converter specifications
Emissions management systems — general description
Exhaust Gas Reburning (EGR) System — General Description
EGR valve (Models with Multec system) — testing, removal and installation
Exhaust gas recirculation valve (Simtec system) — inspection, removal and installation
Exhaust gas recirculation unit (X16 SZ models) — removal and installation
Emission Control Pump Assembly (Simtec System) — Removal and Installation
The shut-off valve of the toxicity neutralization system — removal, inspection and installation
Emission control system shut-off valve — removal and installation
Emission Control Tubing and One-way Valve — Removal and Installation
Catalytic Converter — Description and Precautions
Charcoal filter — removal and installation
Oxygen sensor (models with a catalytic converter) — removal and installation
Exhaust manifold — removal and installation
Exhaust system — check, removal and installation
Troubleshooting the fuel and exhaust systems
Transmission
Clutch
Clutch Specifications
General description of clutch
Clutch cable — removal and installation
Clutch cable — adjustment
Clutch pedal — removal and installation
Clutch (engine and transmission are in the engine compartment) — removal, inspection and installation
Clutch (transmission removed) — removal and installation
Release bearing and lever — removal and installation
Clutch Troubleshooting
Mechanical gearbox
Manual Transmission Specifications
General description of mechanical transmission
Gear selector link — adjustment
Assembly of a casing of the lever of a gear change — removal and installation
Gear selector link — removal and installation
Gear shift lever — removal and installation
Protective cover of the gear lever — 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
The switch of lanterns of a backing — removal and installation
Troubleshooting a mechanical transmission
Automatic gearbox
Automatic transmission specifications
General description of automatic transmission
Transmission Fluid — Change
Downshift mechanism — adjustment
Downshift mechanism — removal and installation
Starter lock — removal and installation
Shift cable — adjustment
Gearshift cable — removal and installation
The lever of a choice of a mode of movement — removal and installation
Central console — removal and installation
Submode switches — removal and installation
Electronic control unit (ECU) — removal and installation
Driving Mode Select 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 transmission
Drive shafts
Drive Shaft Specifications
General description of drive shafts
Drive shaft — removal and installation
Intermediate shaft — removal, reassembly and installation
Drive shaft CV joint — replacement
SHRUS protective cover — replacement
Troubleshooting Drive Shafts
Chassis
Brake system
Brake Specifications
General description of the braking system
Anti-lock braking system (ABS) — general description
Brake hydraulic system — pumping
Front brake pads — inspection, removal and installation
Rear disc brake pads — inspection, removal and installation
Rear brake pads (drum brakes) — inspection, removal and installation
Hand brake pads (rear disc brakes) — inspection, removal and installation
Front brake caliper — removal, reassembly and installation
Rear disc brake caliper — removal, reassembly 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 support shield — removal and installation
Front brake disc guard — removal and installation
Master cylinder — removal and installation
Master Cylinder (Non-ABS Models) — Bulkhead
Master Cylinder (Models with ABS) — General Description
Vacuum booster — description and verification of operation
Vacuum booster — removal and installation
ABS hydraulic modulator — removal and installation
ABS sensor mounted on the wheel — removal and installation
ABS control unit — removal and installation
ABS relay (ABS-2E only) — removal and installation
Pressure control 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
Troubleshooting the brake system
Car suspension
Suspension specifications
General description of the suspension
Front wheel bearing — replacement
Underframe — removal and installation
Front suspension strut — removal, reassembly and installation
Lower arm front suspension — removal and installation
Bushings of the lower arm of the front suspension — replacement
The 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 (Single Overhead Cam Models) — Adjustment
Rear Wheel Bearing (Single Overhead Cam Models Before Mid 1993) — Replace
Hub and rear wheel bearings (since mid-1993) — removal and installation
Rear wheel hub (models with one overhead camshaft) — removal and installation
Rear shock absorber — removal and installation
Rear shock absorber rubber pads — replacement
Rear Suspension Spindle Spring (Single Overhead Camshaft (SOHC) Models) — Removal and Installation
Rear Suspension Trailing Arm Assembly (Single Overhead Camshaft (SOHC) Models) — Removal and Installation
Rear Anti-roll Bar (Single Overhead Cam Models) — Removal and Installation
Rear Suspension Trailing Arm Bushings (Single Overhead Cam Models) — Replacement
Rear suspension stub axle (models with one overhead camshaft) — removal and installation
Rear suspension stiffness control system — adjustment
Components of the rear suspension stiffness control system — removal and installation
Rear Wheel Bearing (Double Cam Models) — Replace
Rear wheel hub (models with two overhead camshafts) — removal and installation
Coil spring rear suspension (models with two overhead camshafts) — removal and installation
Rear Suspension Assembly — Removal and Installation (Double Overhead Cam Models)
Diagonal Rear Suspension Arm (Dual Cam Models) — Removal and Installation
Rear suspension cross member (models with two overhead camshafts) — removal and installation
Rear Anti-roll Bar (Dual Cam Models) — Removal and Installation
Troubleshooting Suspension and Steering
Steering
Steering Specifications
Steering wheel — removal and installation
Steering wheel — centering
Elastic coupling of a shaft of the steering mechanism — replacement
Steering column — removal and installation
Steering column — bulkhead
Steering damper — removal and installation
Steering gear guards — replacement
Assembly of the steering mechanism (without amplifier) — removal, reassembly and installation
Assembly of the steering mechanism (with amplifier) — removal, reassembly and installation
Power steering hydraulic line — bleeding
Power steering pump — removal and installation
Power steering hydraulic reservoir — removal and installation
Power steering hydraulic fluid cooling pipes (where used) — removal and installation
Tie rod end — removal and installation
Tie rod — removal and installation
Front Wheel Alignment — General Specifications
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 — bulkhead
Ignition coil — removal, inspection and installation
Breaker cover and distributor slider — 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 — check and adjustment
Ignition Timing — Adjusting for Unleaded Gasoline
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 (C20 XE engine) — removal and installation
Troubleshooting the electrical system
Equipment and devices
Electrical system specifications
General description and precautions
Troubleshooting the electrical system — general description
Fuses and Relays — General Description
Ignition lock — removal and installation
Lighting / turn signal switch — removal and installation
Washer / wiper switch — removal and installation
Dashboard switches — removal and installation
Electric control of the external mirror — removal and installation
Sunroof power switch — removal and installation
The switch for lighting the car interior, which turns on when the doors are opened — removal and installation
Luggage compartment lighting switch — removal and installation
Stoplight switch — removal and installation
The switch of a control lamp of a manual brake — removal and installation
The switch of a control lamp of pressure of oil — removal and installation
Cigarette lighter backlight — removal and installation
Clock — removal and installation
Heated front seats — general description
Dashboard — removal and installation
Dashboard components — removal and installation
On-board computer components — removal and installation
Control system components — removal and installation
Sound signal (s) — removal and installation
Interior lamp — removal and installation
Lights in the car — replacement
Headlight unit — removal and installation
Headlight range adjustment motor — removal and installation
Headlights — adjustment
Dimmer headlight system — general characteristics, removal and installation
Front turn signal lamp — removal and installation
Side repeater lamp — removal and installation
Front fog lamp — removal, installation and adjustment
Rear light unit — removal and installation
License plate light — removal and installation
External incandescent lamps — replacement
Wiper blades — replacement
Wiper arms — removal and installation
Washer jets — removal and installation
Wiper motor and traction — removal and installation
Rear door wiper motor, opening up — removal and installation
Headlamp wiper motor — removal and installation
Washer reservoir — removal and installation
Washer pump — removal and installation
One-way headlight washer fluid valve — removal and installation
Power window components — removal and installation
Electric window lifter control — programming
Components of the central blocking of doors — removal and installation
Antenna — removal and installation
Antenna with electrical control — removal and installation
Loudspeakers — removal and installation
Radio — removal and installation
Sunroof engine — removal and installation
Speedometer drive cable — removal and installation
Anti-theft alarm — general characteristics
Anti-theft alarm components — removal and installation
Air bag — general characteristics
Airbag unit, driver's side — removal and installation
Steering wheel (with airbag) — removal and installation
Airbag connection block — removal and installation
Airbag unit, passenger side — removal and installation
Bracket, passenger airbag unit — removing and installing
Airbag control unit — removal and installation
Electrical circuits
Wiring Diagrams — General Specifications
Explanation of abbreviations used in wiring diagrams
Wiring diagram for models from 1989
Wiring diagram key for models since 1989
Wiring diagram for models from 1991
Key to wiring diagrams for models since 1991
Wiring diagram for models from 1992
Wiring diagram key for models since 1992



Vectra A (1988-1995)
Power unit
Engine repair
Engine Specifications
Removal and installation of the engine
Removal and installation of a gear belt
Checking and adjusting the toothed belt tension
Installing the toothed belt tensioner
Removal and installation of the vacuum pump
Removal and installation of a head of cylinders
Checking the cylinder head and cylinder block for straightness
Replacing the camshaft housing. Removal and installation of a camshaft
Checking and adjusting the valve timing
Cleaning the oil separator of the camshaft housing cover
Checking and adjusting valve clearances
Removal and installation of valves
Replacement of valve stem seals
Valve grinding
Lapping of valves
Checking clearance in valve guides
Checking the valve guides
Compression test
Removing, installing and tensioning the V-belt
Removing, checking, installing and tensioning the V-ribbed belt
Visual search for oil leaks
Checking the V-belt
Towing a car
Engine malfunctions
Ignition system
General information
Safety measures when working with electronic ignition systems
Checking the ignition coil