Opel Agila User manual

Participant’s Handout
LAAS07
V 1.0
Aftersales Training
Opel Agila
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Table of Contents
1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . General introduction of the Opel Agila _______4
2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Body and Safety features ______13
3. . . . . . . . . . . . . . . . . . . . . . . . . . . Heating, ventilation and air-conditioning ______23
4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Suspension ______41
5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brakes ______47
6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engines ______55
7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . European On Board Diagnosis ______71
8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission and clutch ______97
9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steering _____101
10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electricalsystems _____111
11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service _____129
Topic Page

4
The Agila is a Sub-S model, which
means that the Agila is placed just
below the Corsa (S-car) in the Opel
car line.
Thereis only one bodyversionof
the Agila available with three
differentmodelvariants:
- Base(model-code F68)
- Comfort(model-codeL68)
- Elegance(model-code P68)
1.1 Introduction
For the model year 2000½, Opel
introduces the new Agila, a car that
belongstothe so-called Mini People
Carrier segment. With this vehicle
Opel is the first European car
manufacturer ever to built a Mini
PeopleCarrier. The Opel Agilais
born out of a corporation with
Suzuki, but Opel made his own
specificmodificationstomeet their
qualitystandardsand give the Agila
itsownexpression. The Agila isbuilt
in the Gliwice plant in Poland and is
available as right hand drive as well
as left hand drive.
1. General introduction of the Opel Agila

5
Z10XE
F12 - 4.39
Z12XE
F12 - 4.11
1
2
3
4
5
R
1
2
3
4
5
R
1
2
3
4
5
R
Comfort:
- Electricallyadjustablemirrors
- Electronicpower steering
- Airconditioning(optional)
- Powerwindows(optional)
Performance:
The Agila is available with two
differentengines:
- 1.0 litre 12V engine (Z10XE) with
58Hp
- 1.2 litre 16V engine (Z12XE) with
75Hp
The Agila comes with a 5-speed
manualtransmission(F12)only.
1.2 Car features
Activesafety:
- Mc Pherson front wheel suspen-
sion
- ElectronicPower Steering
- Anti-lockbrakes (optional)
Passivesafety:
- Headrestsavailable on allseats
- 3-point seatbelt on all seats
- Pyrotechnicalpre-tensionersfor
the front seat belts
- Body structure
- Drivers airbag (standard)
codriversairbag(optional)
- Third brake light

6
TheZ- emission standsforthe
internaldefinitionof the compliance
to Euro IV emission regulations, that
willbe effective by 2005.
Someengine features:
- Doubleoxygensensor
- Drive by wire (E-gas)
- Return-lessfuel system
- Catalytic converter welded to
exhaustmanifold
- Plasticintake manifolds forboth
engines
- Maintenancefree direct ignition
system
- Maintenance free camshaft
drive
1.0litre engine Z10XE
1.2litre engine Z12XE

7
1.3 Dimensions and weights
Thedifferentdimensionsof the Agila
are shown in the picture below.
The Agila has a turning circle of 10.6
m from wall to wall.
The luggage compartment has a
volumeof 248 litres behindthe
second seat row. With the second
seat row folded down, the volume
ofthe luggage compartment
increasesto 597 litre.
Dimensions of the Agila in mm

8
Weight of the Agila:
Z10XE: 975 Kg (987 Kg with AC)
Z12XE:990 Kg (1002Kgwith AC)
Permissiblegrossvehicleweightof
theAgila:
Z10XE1325 Kg (1325 Kg with AC)
Z12XE1340 Kg (1340 Kg with AC)
Themaximum roof loadfortheAgila
is30Kg.
The fuel tank has a capacity of 41
Litre.
1.4 Models
Asmentioned before, theAgilais
availableinthree different model
variants, each with their own
specificequipmentlevel:
Theequipmentlevels indicated here
arebased on theEuropeanspecifi-
cations and may vary from country
to country.
AgilaBase:
- Electricpower steering
- Driver airbag and seatbelt pre
tensioners
- Powermirrors
AgilaComfort:
- Paintedfront and rearpanelling
- Tintedwindows
- Loadcompartment cover
- Wheelcovers
AgilaElegance
- 14’’light alloy wheels
- Frontfoglights
- BlackB-pillar
Furthermorethefollowingoptions
areavailable:
- Centraldoorlocking
- Powerwindows
- Passengerairbag
- Air-conditioning
- Anti lock brakes
- Manualsunroof
- RadioCAR 2001, 2003,2005

9
1.5 VehicleIdentification
TheVIN (Vehicle Identification
Number)can be explainedusingthe
followingtable:
VIN-number
Digits
W 1 Definedcode for manufacturer ofvehicle:
O 2 WOL = ADAM OPEL AG
L3
O 4 GMcode for manufacturer:zero(orspecificallydefined letter)
H 5 GM code for vehicle type:
S = Corsa, Combo, Tigra H = Agila
T = Astra, Zafira E = Speedster
J = Vectra V = Omega
A 6 Modeldesignation which indicates theversionofthemodel:
G for Astra-G, A for Agila-A, B for Corsa-B etc.
F 7 GM code forbodystyle
68
89
Y 10 Model Year: W = 98, X = 99, Y =00
G 11 Manufacturingplant:
1=Rüsselsheim 2 = Bochum 3 = Azambuja
4 =Zaragoza 5 = Antwerp II 6 = Opel Eisenach
7 = Luton 8 = Ellesmere Port
B = Bertone D = Chin Chuang, Taiwan
F = Zamalek, Egypt G = Gliwice, Poland
H = Halol, India J = Bekasi, Indonesia
N = Norwich S =Szentgotthard,Hungary
P = Warszawa, Poland Z = Izmir, Turkey
0 12 Serialnumber:
1 13 14915thvehicleofmodelyear2000
414
915
116
517

10
1.6 Interior
Thanksto its body shape,Agila
offersa generous interior space.
TheAgiladesignprovidesmaximum
interior space vs. the small exterior
size. The height of the Agila offers
maximumheadroom.
Heightadjustableheadrests on the
front seats are standard. The rear
seats are placed a little higher than
the front seats to create more leg
space and a good all around view.
Therear seat features50/50split
and two-seater capacity.
Someinterior features:
- Storage tray below the instru-
ment on the drivers side.
- Storage tray below the instru-
ment panel on the passenger
side.
- Glovebox with openlid.
- Large front door pockets for the
driverand passenger.
- Cupholder on centralfloor
console.
- Slidingtrays below driver and
passengerseat.
- Storage unit with cup holder for
rearpassengers on centralfloor
console.
50/50split rear seat
- Map pocket on the back of the
front seat.
- Large pockets on rear doors.
- Full-size spare wheel in cargo
floor.
Forthe Agila three differentfabric
coloursareavailable.

11
On the rear window a centre high
mountedstoplightis installed.
The size of the tyres of the Agila is
155/65R14.Currentlyonlypro-
ducedby the manufacturers Kleber
andMichelin. Alloy rims (6spoke
design)are available as anoption
onlyin combination withlargertyre
size165/60R14.
Alloyrim
TheAgila will beavailablein10
exteriorcolours, seven of these
exteriorcolours are two-coat
metallic/micapaints.
1.7 Exterior
TheAgila has the followingfeatures
related to the exterior.
TheAgila front design ischaracter-
isedby its large headlampswith
integratedsideblinkers(orange
bulbs).Thegrille is integrated into
the front panelling as well as the
(optional)foglights.
TheAgilais available with roofrailing
aswell as glued sidemouldings.The
electricallyadjustableoutsidemirrors
arefoldable.
Foldable outside mirrors

12
1.8 Accessories
The listed items below are some of
the accessories to compliment the
factoryoptions:
• Centralarmrest
• Towinghitch
• Foglights
• Opel FIX child seat
• Bootstorage box
• Lowprofile base carrier
• Opeli-line interior andexterior
accessories
• Sunroof
Opeli-line exterior spoiler Sport Interior

13
2.1 Body equipment
2.1.1 Bonnet
The bonnet is connected to the
bodywithtwo scissor-type hinges.
Withthese two scissor-type hinges
itis possible toadjustthebonnet
perfectly to the body work.
Scissor-typehinges
2.1.2 Wings
To remove the front wings, the front
bumper and wheel arches must be
removedfrom the body.Thefront
wings are connected to the body
with several screws as shown in the
picturebelow.
2. Body and Safety features

14
K 0048
1
2
1
3
4
13
2.1.3 Front/rear doors
To increase the passive safety level
ofthe Agila the doorsareequipped
with side impact door bars. It is not
allowed to adjust or replace these
door bars. The hinges are welded to
to the body.
1. Hinges
2. Check link
3. Connector
4. Side impact doorbeam
2.1.4 Trunk lid
Twodampers support the trunklid
with opening and closing. The trunk
lidcan be adjustedbyreplacingthe
strike plate. The strike plate must
be adjusted in such a way that the
rubberstoppers have apreload.
1. Trunk lid hinge
2. Mounting points dampers
3. Rubber stoppers
4. Strike plate

15
2.1.5 Bumpers
To reduce repair costs in the event
of a collision the front and rear
members are connected with nuts
to the chassis, when the front or
rear member is removed, parts
mounted behind the bars are easy
accessible.
1. Front member
2. Self-lockingnut
Afterevery disassembly of thefront
or rear bar new self-locking nuts
must be used.
1. Rear member
2. Self-locking nut

16
2.1.6 Side windows
TheAgila will beavailablewith
manualoperatedwindows and
optionalwithelectricallyoperated
windows. Electricallyoperated
windows are only available on the
frontdoors. The manual operated
windows of the front and rear doors
aresimilar.
1. Fixing points electricallyoper-
atedwindows
2. Fixing points manualoperated
windows
3. Catch nut
2.1.7 Outside rear-view mirror
Electricallycontrolledoutsidemirrors
arestandard on allmodelvariants.
Themirror glass is clippedontothe
adjustingmechanism.To remove
theoutside mirror, thedoorpanel
on the inside must be removed. The
outsidemirror is fixed tothedoor
with three screws.
1. Switch for left or right outside
mirror
2. Multi switch formirroradjust-
ment
3. Fixing points

17
2.1.8 Outside/Windows
Thefront windscreen, thesmallside
windows and the rear window are
allglued to thebody.Thefront
windowhaspositioners to adjust the
windowinthe right position.
Forthe Agila isasunroofavailable
asanoption. This sunroof issimilar
to the sunroof available for the
Astra-G.The body mouldings onthe
Agila are glued and can be removed
by heating them with a hairdryer.

18
2.1.9 Roof railing
Onthe standard equipped Agilaa
roofrailing is only availableasan
option.With all other modelvariants
theroof railing is standard.Theroof
railingis fixed ontheroofwith four
nuts.Themaximumroofloadis
30Kg.
2.1.10 Inside
TheAgilaisstandard equipped with
two headrests on the front seats
and optional two headrests on the
rear seats. All headrests are height
adjustableand can beremoved.
Underneathboth driver and passen-
ger seat a storage box is installed.
2.2 Safety Features
2.2.1 Freewheelinglockcylin-
ders
The front doors and the trunk lid are
equippedwithfreewheelinglock
cylinders.Thesefreewheeling lock
cylinders prevent the car from theft
and protect the lock against dam-
age when the correct key is not
used.The working principalofthe
freewheelinglock cylinders arethe
same, but the lock in detail is
differentfrom the freewheeling lock
cylinders used on the e.g. Astra-G.
2.2.2 Airbag system
The new Agila comes standard with
a drivers airbag and seat belt
pretensioners.Apassengersairbag
isavailable as anoption.The airbag
unitsof the driverandpassenger
are similar to the units used for the
driverand passenger ofthe
Astra-G.
Thecontrol unit ismanufacturedby
Siemens and is placed between the
two front seats as always with Opel.
Because side airbags are not
availablefor the Agilathecontrol
Roofrailing

19
module can handle max. four
squibs.Twofor the front airbags
and two for the seatbelt
pretensioners.
Thecontrol unit isserviceablewith
the TECH II. The data list contains
thefollowingparameters:
• System voltage (V)
• Power reserve (V)
• Airbagloops
• Airbagconfiguration
• Pretensionerconfiguration
• Driverairbag squib circuit
(Ohms)
• Passengerairbag squib circuit
(Ohms)
• Driverpretensioner squib circuit
(Ohms)
• Passengerpretensionersquib
circuit(Ohms)
In the event of a rearend collision
the seatbelt pretensioners can be
activated.
The control unit must be replaced
after 1 airbag ignition or after 3
ignitionsof the safetybeltpreten-
sioners.Thepretensioners must be
replaced after each activation.
2.2.3 Seatbeltpretensioner
Theknownseatbelt pretensioners
from Opel are all located at the lock
of the safety belt. The pretensioners
on the safety belts of the Agila are
located in the retractor gear. The
workingprincipalof these seatbelt
pretensionersis not very differentto
a seatbelt pretensioner located at
the lock of a safety belt.
But because the retractor is a
rotatinggear the constructionis
verydifferent.
ControlUnit
As written before the working
principaloftheseatbelt pretensioner
of the Agila is similar to the known
seatbeltpretensioners. So there is
alsoa pyrotechnical load.That
means that al the safety precau-
tions must be taken very serious.
Seatbeltpretensioner
In this pretensioner the safety belt is
tensioned by turning the axle on
which the belt is wrapped. So in
case of a frontal accident the
retractor gear is driven by the
pyrotechnicalloadand tensions the
safety belt which makes that the
occupantis protected.

20
How is the energy of the pyrotech-
nical load brought to the axle of the
retractorgear?
Theenergy of thepyrotechnicalload
is not brought to the retractor by a
cable like all other seatbelt pre-
tensioners Opel uses. The manufac-
turer(Autoliv) of this seatbelt
pretensioner invented a new way for
thisenergytransmission.
Thepyrotechnical load is locatedin
the top of a bent iron pipe. In this
iron pipe are also 14 balls, kept in
place on one side by a smal piston
and at the other side by a security
pin.
1. Retractor gear in the shape of
the balls
If the car is involved in a frontal
accidentand the deceleration
reaches the set values which
makes sure that the seatbelt
pretensionersare ignited. Nowthe
pyrotechnicalload, which is located
in the top of the bended iron pipe,
willexpand and forces allbulletsin
the same direction: out of the iron
pipe. The security pin will break and
releasethe balls outoftheirposition.
When the balls move out of the
tube, they drive a special gear
which is mounted on the axle of the
retractor right after the iron pipe.
This retractor gear has the shape of
the balls and that contributes to a
maximumenergytransmission. So
now the retractor axle rotates and
makes sure that the safety belt is
pulledinto the retractormechanism.
At the end of the activation the belt
isblockedin the pulled position.
1. Bent iron pipe with pyrotechni-
calload and 14ballsinside