Contents

To your Opel / Vauxhall Astra

• Safety first!
• Introduction
• Emergency troubleshooting
• Replacing a wheel
• Leak detection
• Towing
• Weekly checks
• Checks under the hood of a car
• Tire condition and air pressure
• Windshield wiper blades
• Battery
• Electrical systems
• Working fluids and lubricants
• Tire pressure

Operating manual

• Dashboard
• Lighting
• Climate control

Regular maintenance

• General information
• Regular maintenance
• Changing engine oil and filter
• Working fluids
• Checking the brakes
• Checking the chassis
• Checking the tightening torque of the wheel bolts
• Lubrication of canopies and locks
• Checking electrical systems
• Checks during the trip

Repair procedures without removing the engine from the engine compartment - car models
equipped with a 1.4 l engine

• General information
• Compression check
• Cylinder head cover - removal and installation
• Valve timing - checking and adjusting
• Crankshaft pulley - removal and installation
• Timing chain and cover - removal and installation
• Timing chain tensioner - removal, inspection and installation
• Camshaft sprockets - removal and installation
• Camshafts, hydraulic compensators and rocker arms - removal and installation
• Cylinder head - removal and installation
• Oil pan and oil pressure pipe - removal and installation
• Oil pump - removal, checking and adjustment
• Crankshaft oil seals - replacement
• Flywheel - removal, inspection and installation
• Engine / gearbox mounts - check and replacement

Repair procedures without removing the engine from the engine compartment - gasoline engines
volume 1.6 l

• General information
• Compression check
• Cylinder head cover
• Timing chain and cover
• Cylinder head
• Engine / gearbox mounts - check and replacement

Repair procedures without removing the engine from the engine compartment - gasoline engines
volume 1.8 l

• General information
• Compression check - general information
• Top dead center for piston of cylinder No. 1
• Cylinder head cover - removal and installation
• Crankshaft pulley - removal and installation
• Timing belt covers - removal and installation
• Timing belt - removal and installation
• Sprockets, tensioner and timing belt parasitic pulley - removal and installation
• VVT oil control valves (Z18XER engines) - removal and installation
• Camshaft seals - replacement
• Valve clearance (Z18XER engines) - checking and adjustment
• Camshafts and pushers - removal, inspection and installation
• Cylinder head - removal and installation
• Oil pan - removal and installation
• Oil pump - removal, overhaul and installation
• Crankshaft oil seals - replacement
• Flywheel / clutch drive disc - removal, inspection and installation
• Engine / gearbox mounts - check and replacement

Removing the engine from the engine compartment and overhaul procedures

• General information
• Engine overhaul
• Removing the engine
• Cylinder head
• Cylinder block

Cooling system, heater and air conditioning

• General information and precautions
• Cooling system
• Heater and ventilation system
• Air conditioning system

Power supply and exhaust system

• General information and precautions
• Air filter assembly and air ducts
• Accelerator pedal / accelerator pedal position sensor
• Fuel injection system
• Exhaust system

Emission control systems

• General information
• Emission control systems (petrol engines)
• Catalytic converter

Starting and charging systems

• General information and precautions
• Battery
• Charging system
• Generator
• Starting system

Ignition system

• General information
• Ignition module
• Knock sensor

Clutch

• General information
• Hydraulic clutch system
• Clutch cylinder
• Clutch pedal
• Clutch assembly

Manual transmission

• General information
• Gear shift mechanism
• Manual transmission

Automatic transmission

• General information
• Shift cable
• Selector lever
• Electrical components of the transmission control system
• Automatic transmission

Easytronic transmission

• General information
• Selector lever
• Gear shift module
• Easytronic transmission

Drive shafts

• General information
• Drive shafts
• Drive shaft boots

Brake system

• General information
• Hydraulic system
• Brake pads and brake caliper
• Disc brake
• Drum brake
• Brake cylinder
• Brake pedal and vacuum booster
• Parking brake lever
• Anti-lock braking system (ABS) and traction control

Suspension and steering

• General information
• Front suspension
• Rear suspension
• Steering wheel
• Steering column
• Steering gear
• Hydraulic power steering system
• Adjusting the installation angles and steering angle

Body structure and components

• General information
• Maintenance
• Bumper, hood and pillars
• Doors
• Luke
• External body components
• Seats
• Center console
• Interior trim panels

Electrical equipment and electrical systems

• General information
• Detecting faults in the electrical system
• Fuses and relays
• Lamps
• Dashboard
• Windshield wipers
• Electronic steering column module
• Audio system
• Anti-theft system
• Components of the heated seat system
• Airbag system
• Electrical diagrams

Applications

• Dimensions and weight
• Vehicle identification numbers
• General repair procedures
• Lifting a car using a jack, support points
• Disconnecting the negative terminal of the battery
• Tools and devices
• Checking the technical condition of the car
• Fault detection
• Glossary

Useful tips for car owners

• Replacing the air filter in a 1.3 l diesel engine
• Replacing rear shock absorbers
• Replacement of rear springs
• Changing oil and oil filter in a diesel engine
• Replacing the rear wheel bearing
• Replacing the front wheel bearing
• Replacing the cabin filter
• Replacing the fuel filter in a 1.3 l diesel engine
• Removing, installing and disassembling the front shock absorber strut