Opel ASTRA H 2004 User manual

1
O P E L A S T R A H
S E R V I C E M A N U A L
http://www.autoprospect.ru –Google translation

2
Table of Contents
OPEL ASTRA H (2004 and 2006 editions)............................................................................ 8
1. Operation and maintenance of vehicles ......................................................................... 8
1.1. General ................................................................................................................................... 8
Identification of the vehicle........................................................................................................................... 8
Keys, door locks, sunroof, anti-theft system ............................................................................................... 12
Power windows ........................................................................................................................................... 19
1.2. Controls and combination devices ..................................................................................... 22
Combination of devices and light detectors................................................................................................. 22
Information display ..................................................................................................................................... 40
Wipers and washers..................................................................................................................................... 53
1.3. Air conditioner and heater ................................................................................................. 57
Heating and ventilation with air conditioning ............................................................................................. 57
Electronic climate control system................................................................................................................ 57
Automatic mode electronic climate control................................................................................................. 60
1.4. Salon Equipment ................................................................................................................. 67
Lamps indoor lighting ................................................................................................................................. 67
Interior rearview mirror ............................................................................................................................... 68
Outside mirrors............................................................................................................................................ 69
Steering wheel ............................................................................................................................................. 70
Cigarette lighter plug and power outlet ....................................................................................................... 71
Ashtrays....................................................................................................................................................... 72
Folding tables .............................................................................................................................................. 73
Front box kit ................................................................................................................................................ 73
Glove compartment in front armrest............................................................................................................ 74
Compartment for glasses ............................................................................................................................. 74
Sun visors .................................................................................................................................................... 74
Seats ............................................................................................................................................................ 74
1.5. Passive safety........................................................................................................................ 90
Seatbelts....................................................................................................................................................... 90
Three-way security system .......................................................................................................................... 91
System of airbags «Opel Full Size»............................................................................................................. 93
1.6. Driving and car maintenance ............................................................................................. 95
Start Engine ................................................................................................................................................. 95
Easytronic transmission............................................................................................................................... 95
Driving a car with automatic transmission .................................................................................................. 98
Trailer coupling, riding with trailer ........................................................................................................... 101
Installation of new tires ............................................................................................................................. 106
Condition of tires, rims state...................................................................................................................... 108
Start the engine by using an auxiliary start cable ...................................................................................... 110
Spare wheel ............................................................................................................................................... 112
Replacement wheel.................................................................................................................................... 114
Towing....................................................................................................................................................... 116
Tire repair kit............................................................................................................................................. 118
Motor Oil................................................................................................................................................... 121
Coolant ...................................................................................................................................................... 121
Brake fluid................................................................................................................................................. 122
Replacement lamps.................................................................................................................................... 123
Electrical equipment.................................................................................................................................. 135
1.7. Tables.................................................................................................................................. 137
Table 1.1 Specifications of engines ........................................................................................................... 137
Table 1.2 Gas volumes and operational materials used............................................................................. 137
2. Engine............................................................................................................................ 137
2.1. New petrol engine Z 18 XER DOHC-I ............................................................................ 137
General ...................................................................................................................................................... 137
Adjustable stars camshaft .......................................................................................................................... 139
The principle of controlled camshaft sprockets......................................................................................... 140
Rack and belting........................................................................................................................................ 143
Poly-V belt ................................................................................................................................................ 143
Cylinder head ............................................................................................................................................ 144
Crankshaft and Pistons .............................................................................................................................. 145
Rear crankshaft oil seal with the sensor .................................................................................................... 145
Intake manifold.......................................................................................................................................... 148
Contour grease gasoline engine Z 18 XER DOHC-I................................................................................. 148

3
Oil cooler module ...................................................................................................................................... 149
Sump.......................................................................................................................................................... 149
Module thermostat petrol engine Z 18 XER DOHC-I............................................................................... 149
Simtec 75.1 electronic control module petrol Z 18 XER DOHC-I............................................................ 150
2.2. Petrol engines - general inspection procedures............................................................... 151
Checking the pressure loss in the engine (1,4-1,6 l).................................................................................. 151
Checking the pressure loss in the engine (1,8 l) ........................................................................................ 156
Checking the pressure loss in the engine (2,0 l) ........................................................................................ 160
Checking compression (1,4-1,8 liter engines) ........................................................................................... 164
Check compression (engine 2.0 l) ............................................................................................................. 166
Checking the engine oil pressure (engine 2.0 liters).................................................................................. 168
Check tightness of the engine (CO content in the cooling system) ........................................................... 168
Measurement of oil.................................................................................................................................... 169
Check tension Poly-V belt (engine 2.0 l)................................................................................................... 170
Checking the synchronization of the timing mechanism (motor 2,0 l)...................................................... 170
Adjusting the tension of the toothed belt (engine 2.0 l)............................................................................. 172
Checking the tension of the toothed belt (engine 2.0 l) ............................................................................. 174
Replacing the front lower lid toothed belt (engine 2.0 l)........................................................................... 178
Replacing the toothed belt (engine 2.0 liters)............................................................................................ 179
2.3. Removing and installing the power unit.......................................................................... 183
General and safety by disconnecting power unit ....................................................................................... 183
Removing sealant ...................................................................................................................................... 184
Removing and installing the power unit (engine 1.4 l).............................................................................. 185
Removing and installing the power unit (engine 2.0 l).............................................................................. 202
2.4. The mechanical part of the engine ................................................................................... 219
Removing and installing the flywheel (engine 1.4 liters) .......................................................................... 219
Removing and installing the flywheel (engine 2.0 liters) .......................................................................... 220
Replacing the rear flange of the crankshaft ............................................................................................... 221
Replacing the valve stems seals (installed cylinder head) ......................................................................... 223
Removing and installing the crankshaft (engine 1.4 liters) ....................................................................... 228
Checking the axial free motion of the crankshaft ...................................................................................... 244
Removing and installing cylinder head (engine 2.0 l) ............................................................................... 245
Removing and installing cylinder head (engine 1,4-1,6 l)......................................................................... 248
2.5. Inspection, and repair operations components of the mechanical part of the engine . 257
Checking the gap in the connecting rod bearings ...................................................................................... 257
Checking the gap in the connecting rod bearings ...................................................................................... 258
Replace connecting rod bearings............................................................................................................... 259
Replacing piston rings ............................................................................................................................... 260
Replacing the piston rod with.................................................................................................................... 262
2.6. Cooling................................................................................................................................ 265
Filling and removing air from the cooling system..................................................................................... 265
Checking the tightness of the cooling system............................................................................................ 266
Replacing the auxiliary electric fan (2.0 liter engines).............................................................................. 266
Replacing the radiator (2.0 liter engines) .................................................................................................. 269
Removal and installation of coolant pump ................................................................................................ 272
Replacing the intercooler........................................................................................................................... 273
2.7. The system of fuel injection gasoline engines.................................................................. 273
Removing and installing fuel injectors ...................................................................................................... 273
Replacing the fuel line pressure (High pressure pump - pressure chamber).............................................. 276
Fuel Pump Module .................................................................................................................................... 278
Replacement module dosage ..................................................................................................................... 280
Replacing the fuel pressure regulator ........................................................................................................ 282
Replacing the damping body fuel return ................................................................................................... 283
Replacing the fuel level sensor.................................................................................................................. 284
Fuel Tank................................................................................................................................................... 287
Replacing the tube fuel filler (petrol engines) ........................................................................................... 288
Vapor Fuel System .................................................................................................................................... 294
Replacing the front vent tube..................................................................................................................... 295
Removing and installing tanks with activated charcoal............................................................................. 296
Removing and installing the sensor mass air flow..................................................................................... 297
Replacing boost pressure sensor (Z 20 LEH) ............................................................................................ 297
Removing and installing the thermostat housing (engine 2.0 l) ................................................................ 298
Exhaust system (Z 14 XEP, Z 14 XEL, Z 16 XEP)................................................................................... 300
Exhaust system (Z18 XE).......................................................................................................................... 300
Exhaust system (Z 20 LEL)....................................................................................................................... 300

4
Replacing a refrigerator exhaust gas recirculation (2.0 liter engine) ......................................................... 301
2.8. Lubrication......................................................................................................................... 305
Replacing the oil pump (1.4 l)................................................................................................................... 305
2.9. Tables.................................................................................................................................. 317
Table 2.1 Specifications petrol engine Z 18 XER DOHC-I ...................................................................... 317
Table 2.2 Validation and tuning values - DOHC-I (engine volume 1.4 liters).......................................... 317
Table 2.3 Validation and tuning values - DOHC-I (engine volume 1.6 liters).......................................... 317
Table 2.4 Validation and tuning values - DOHC-I (engine volume 1.8 liters).......................................... 317
Table 2.5 Validation and tuning values - DOHC-I (engine capacity of 2,0 l) ........................................... 318
Table 2.6 Poly-V belt - valve gear (engine volume 1.4 liters)................................................................... 318
Table 2.7 Poly-V belt - valve gear (engine volume 1.6 liters)................................................................... 318
Table 2.8 Poly-V belt - valve gear (engine volume 1.8 liters)................................................................... 318
Table 2.9 Poly-V belt - valve gear (engine capacity of 2,0 l).................................................................... 318
Table 2.10 Specifications (engine volume 1.4 liters) ................................................................................ 319
Table 2.11 Specifications (engine volume 1.6 liters) ................................................................................ 319
Table 2.12 Specifications (engine volume 1.8 liters) ................................................................................ 319
Table 2.13 Specifications (engine capacity of 2,0 l).................................................................................. 320
Table 2.14 toothed belt (engine volume 1.6 liters) .................................................................................... 320
Table 2.15 toothed belt (engine volume 1.8 liters) .................................................................................... 320
Table 2.16 Recommended tightening torques threaded............................................................................. 320
Table 2.17 Cooling system (engine 1.4 l).................................................................................................. 322
Table 2.18 Cooling system (engine 1.6 l).................................................................................................. 322
Table 2.19 Cooling system (engine 1.8 l).................................................................................................. 322
Table 2.20 Cooling system (engine 2.0 l).................................................................................................. 323
Table 2.21 Lubrication system (1.4 liter engines) ..................................................................................... 323
Table 2.22 Lubrication (Engine 1,6 l) ....................................................................................................... 323
Table 2.23 Lubrication system (1.8 liter engines) ..................................................................................... 324
Table 2.24 Lubrication system (2.0 liter engines) ..................................................................................... 324
3. Transmission................................................................................................................. 325
3.1. Strength .............................................................................................................................. 325
General ...................................................................................................................................................... 325
The flow of hydraulic clutch (gearbox - F13 / F17 + / F23 / M20 / M32)................................................. 325
Removal, inspection and installation of hard plates and the driven clutch plate (without SAC)............... 326
Removing and installing the piping and discharge hose coupling (gear - F13 / F17 / F17 + / F23 / M20 /
M32) .......................................................................................................................................................... 332
Replacing the clutch pedal......................................................................................................................... 335
3.2. Manual transmission ......................................................................................................... 337
General ...................................................................................................................................................... 337
Gears and gear lever .................................................................................................................................. 337
Check transmission oil level (gearbox M20 / M32) .................................................................................. 338
Check transmission oil level (gearbox F13) .............................................................................................. 340
Removing and installing transmission (F13) ............................................................................................. 340
Transmission, removing and installing on the engine (dismantled) .......................................................... 344
Replacing the transmission housing (gearbox F13)................................................................................... 349
Removing and installing the rear cover gearbox (F 13) ............................................................................ 350
Removal and assembly of the differential (gearbox F13).......................................................................... 359
Removal and installation of the main shaft (gearbox F 13)....................................................................... 364
3.3. Automatic transmission .................................................................................................... 365
General ...................................................................................................................................................... 365
Torque ....................................................................................................................................................... 365
Main gear................................................................................................................................................... 365
Adjust the cable selector switch automatic transmission........................................................................... 366
3.4. Propulsion mechanism ...................................................................................................... 366
General ...................................................................................................................................................... 366
Measurement of radial and lateral runout of the bearing wheels............................................................... 367
Measurement oblique gap block bearing................................................................................................... 368
Removing and installing shaft wheel......................................................................................................... 369
Replacing the internal velocity joints ........................................................................................................ 372
Replacing the external velocity joints........................................................................................................ 374
Disassembly outer constant velocity joints................................................................................................ 375
3.5. Tables.................................................................................................................................. 376
Table 3.1 Potential problems of adhesion, their causes and solutions....................................................... 376
Table 3.2 Possible malfunctions of the INC, their causes and solutions ................................................... 377
Table 3.3 Volume of transmission oil........................................................................................................ 377
Table 3.4 Troubleshooting the drive wheels, their causes and solutions ................................................... 378

5
4. Chassis........................................................................................................................... 378
4.1. General ............................................................................................................................... 378
Building front axle..................................................................................................................................... 378
Rear axle.................................................................................................................................................... 379
Damping sleeve ......................................................................................................................................... 379
Shock Absorber - rear axle ........................................................................................................................ 380
Spring rack with springs of the all-clear.................................................................................................... 381
Spring rack ................................................................................................................................................ 382
Stabilizer / swivel arm............................................................................................................................... 383
Continuous Damping Control (CDC)........................................................................................................ 383
4.2. Wheels and tires................................................................................................................. 385
General ...................................................................................................................................................... 385
4.3. Front suspension................................................................................................................ 389
Adjusting the front suspension .................................................................................................................. 389
Difference Base chassis............................................................................................................................. 391
Offset wheels............................................................................................................................................. 392
Removal and installation of arm suspension ............................................................................................. 393
Removing and installing racks CDC spring with shock absorbers............................................................ 394
Replacing the front damping arm bushings ............................................................................................... 396
Replacing the spring supporting tube rack ................................................................................................ 398
Replacement Stabilizer.............................................................................................................................. 400
Replacing the rotary lever.......................................................................................................................... 401
4.4. Rear suspension ................................................................................................................. 402
Elastic beam rear suspension, Astra-G, Astra-H, Zafira - rear axle........................................................... 402
Removing and installing wheel bearing .................................................................................................... 403
4.5. Tables.................................................................................................................................. 404
Table 4.1 Potential problems, their causes and solutions .......................................................................... 404
Table 4.2 Recommended tightening torques - front suspension, wheels and tires .................................... 407
Table 4.3 Options for design of the rear axle ............................................................................................ 408
Table 4.4 Recommended values tightening torques - rear axle, rear suspension....................................... 408
Table 4.5 Angles adjustment wheels, Opel Astra-H 2006......................................................................... 409
Table 4.6 Values of the wheels for the Zafira - B 2006............................................................................. 410
Table 4.7 Potential problems, their causes and solutions .......................................................................... 410
5. Steering Gear ................................................................................................................ 411
5.1. General ............................................................................................................................... 411
Principle of operation EHPS...................................................................................................................... 411
The visual differences between the systems, TRW and ZF....................................................................... 411
Principle of operation - EHPS ZF.............................................................................................................. 411
Wiring harness connector electrohydraulic module .................................................................................. 412
Casing steering column ............................................................................................................................. 413
Steering Gear / tie rods.............................................................................................................................. 413
5.2. Preliminary checks ............................................................................................................ 413
Check wheel play ...................................................................................................................................... 413
Checking the efforts of the steering wheel ................................................................................................ 414
The flow of power steering........................................................................................................................ 414
Check tie-rod ends and seals ..................................................................................................................... 415
Check constant velocity joints................................................................................................................... 415
Check power steering leak......................................................................................................................... 416
Check level of hydraulic fluid hydraulic ................................................................................................... 416
Filling and removal of air from the hydraulic system................................................................................ 417
5.3. Steering Gear ..................................................................................................................... 418
Replacing the steering column module (CIM) .......................................................................................... 418
Replacing the steering column .................................................................................................................. 419
Replacing the steering mechanism (ZF) .................................................................................................... 424
Replacement Tie rod.................................................................................................................................. 426
Replacing the tie rod.................................................................................................................................. 427
Replacing the steering mechanism (TRW)................................................................................................ 428
Replacing the covers on the steering mechanism ...................................................................................... 430
Replacement of pipelines hydraulic steering system with amplifier (ZF) ................................................. 431
5.4. Tables.................................................................................................................................. 433
Table 5.1 Recommended values of the moments ...................................................................................... 433
Table 5.2 Technical data of hydraulic steering.......................................................................................... 433
Table 5.3 Potential problems, their causes and solutions (Power steering) ............................................... 434
Table 5.4 Elements of a EHPS .................................................................................................................. 435
Table 5.5 Pin - wiring harness connector with a 5-pin (X1) (TRW) ......................................................... 435

6
Table 5.6 Pin - wiring harness connector 2-pin (X2) (ZF) ........................................................................ 435
Table 5.7 Pin - wiring harness connector 3-pin (ZF)................................................................................. 435
Table 5.8 Change of the slats is achieved through the use of different axial joints................................... 435
Table 5.9 Structures of axial joints tie rod................................................................................................. 435
6. Brakes............................................................................................................................ 436
6.1. General ............................................................................................................................... 436
Front brakes............................................................................................................................................... 436
Rear brakes ................................................................................................................................................ 436
Power Brakes............................................................................................................................................. 436
Brake line .................................................................................................................................................. 436
The main brake cylinder............................................................................................................................ 437
-Lock braking system ESP MK60 ............................................................................................................. 439
6.2. General test procedures .................................................................................................... 442
Checking and adjustment of the brake system........................................................................................... 442
Check brake fluid level in the cistern hydraulic braking system ............................................................... 443
Removal of air from the hydraulic braking system ................................................................................... 443
Brake hoses................................................................................................................................................ 444
6.3. Operation adjustment and replacement of the brake system........................................ 444
Adjusting the parking brake system .......................................................................................................... 444
Replacing the brake pedal.......................................................................................................................... 445
Removing and installing front brake hoses................................................................................................ 448
Replacing brake pipes................................................................................................................................ 450
Replacing the tank hydraulic brake ........................................................................................................... 451
Removing and installing brake booster vacuum line ................................................................................. 453
Replacing the control unit ABS (ESP MK60)........................................................................................... 454
Removing and installing brake caliper front wheel ................................................................................... 456
Removing and installing brake shoes lining the front wheel..................................................................... 457
Removing and installing protective casing brake front wheel................................................................... 459
Replacing the brake disc front wheel......................................................................................................... 461
Removing and installing rear wheel brake shield...................................................................................... 462
Removing and installing rear wheel brake caliper..................................................................................... 462
Removing and installing brake pads rear wheel ........................................................................................ 465
Adjust drum brake mechanism .................................................................................................................. 468
Replacing brake pads disc brake rear wheel.............................................................................................. 468
6.4. Tables.................................................................................................................................. 472
Table 6.1 Specifications front brake mechanism....................................................................................... 472
Table 6.2 Specifications rear drum brake mechanism ............................................................................... 473
Table 6.3 Specifications rear brake mechanism ........................................................................................ 473
Table 6.4 Recommended tightening torques values of threaded connections ........................................... 474
Table 6.5 Potential problems, their causes and solutions .......................................................................... 474
Table 6.6 versions of systems installed in vehicles Astra-H...................................................................... 476
Table 6.7 Pin connector ABS control unit................................................................................................. 476
Table 6.8 Pin assignment connector yaw angular velocity sensor............................................................. 476
7. On-board electrical ...................................................................................................... 477
7.1. General ............................................................................................................................... 477
Principle of CAN....................................................................................................................................... 477
Safety......................................................................................................................................................... 477
Check for voltage ...................................................................................................................................... 477
Search of the short circuit.......................................................................................................................... 477
Check serviceability of earth ..................................................................................................................... 477
Checks in the absence of breakage ............................................................................................................ 477
Wires, fuses and relays .............................................................................................................................. 478
Battery ....................................................................................................................................................... 479
7.2. System power ..................................................................................................................... 483
Generator ................................................................................................................................................... 483
Starter ........................................................................................................................................................ 484
7.3. On-board electrical............................................................................................................ 485
Removing and installing windshield washer nozzles ................................................................................ 485
Removing and installing rear window washer nozzles.............................................................................. 485
Removing and installing faroomyvateley .................................................................................................. 485
Removing and installing the tank / pump for washer fluid........................................................................ 486
Removing and installing front wiper levers............................................................................................... 487
Removing and installing the electric motor cleaners windscreen.............................................................. 488
Removing and installing rear window wiper motor .................................................................................. 488
Removing and installing a rain sensor....................................................................................................... 489

7
Removing and installing the instrument cluster ........................................................................................ 489
Removing and installing the information display...................................................................................... 490
Removing and installing outdoor lighting panel switches / lighting devices............................................. 490
Removing and installing the module gearshift paddles ............................................................................. 491
Removing and installing the block switches console section of dashboard............................................... 491
Removing and installing the switch of the winter driving mode ............................................................... 492
Removing and installing switches, electric windows front door ............................................................... 492
Removing and installing switches, electric windows rear door................................................................. 493
Removing and installing panels remote control switches on the steering wheel....................................... 493
Removing and installing sensor-switch hood (model with anti-theft system)........................................... 494
Removing and installing the sensor-back of the door lock switch ............................................................ 495
Removing and installing speakers ............................................................................................................. 496
Removing and installing the outdoor antenna ........................................................................................... 497
7.4. Tables.................................................................................................................................. 498
Table 7.1 Generator (Bosch) ..................................................................................................................... 498
Table 7.2 Starter (Valeo) ........................................................................................................................... 498
8. Body............................................................................................................................... 499
8.1. Design Features.................................................................................................................. 499
Central and door locks............................................................................................................................... 499
8.2. Suspended elements........................................................................................................... 499
Removal and installation of body linings (moldings)................................................................................ 499
Laths in the back of the door ..................................................................................................................... 499
Removing and installing fairing lattice...................................................................................................... 499
Removing and installing wheel arch protection ........................................................................................ 500
Removing and installing the front bumper / bumper moldings ................................................................. 500
Removing and installing decorative radiator grille.................................................................................... 502
Removing and installing front wings......................................................................................................... 502
Removal, installation and adjustment of the hood..................................................................................... 504
Removing and installing transmission cable release hood latch lock ........................................................ 504
Removal, installation and adjustment of the back of the door................................................................... 505
Removing and installing door lining the back of....................................................................................... 506
Removing and installing lock the door back of ......................................................................................... 507
Removal, installation and adjustment of the side doors ............................................................................ 507
Removing and installing lock side doors................................................................................................... 508
Removing and installing exterior side door handles.................................................................................. 508
Removing and installing the base outside door handles ............................................................................ 509
Removing and installing upholstery, side door ......................................................................................... 510
Care for car body....................................................................................................................................... 510
9. Electrical Circuits......................................................................................................... 512
9.1. The designations used on electrical circuits .................................................................... 512
9.2. The cooling system of engine (engines Z14XEP, Z16XEP, Z18XE and Z17DTL) ...... 516
9.3. Front and rear steloochistiteli / rain sensor / headlamp washers.................................. 516
9.4. Windowlifter ...................................................................................................................... 516
9.5. Switch stop-signalov/Vyklyuchatel reversing lamps / switches Control outdoor lighting
/ lighting of the dashboard............................................................................................................ 517
9.6. The rear combination lamps / Podssvetka license plate / brake light upper level ....... 517
9.7. Headlamps (except Xenon) / Fog lights ........................................................................... 517
9.8. Domestic interior lighting / PTO socket / cigarette lighter / Lighting bogazhnogo
Branch............................................................................................................................................ 518

8
OPEL ASTRA H (2004 and 2006 editions)
Issue serial Opel Astra began in February 2004. The car remains front-wheel drive.
Campaign was launched in a model with five-door hatchback. Later appears three-door and station
wagon version. For the new Opel Astra to develop two new engines, and are taken from the previous
most recent engines, thereby obtaining a line of six engines, continues a series Ecotec and meet Euro
4 standards. To start the proposed petrol engines 1.4 TWINPORT (90 hp), 1.6 TWINPORT (105 hp),
1.8 (125 hp) and 2.0 Turbo (170 hp), as well as two diesel engines volume of 1.7 (80 and 100 hp)
equipped with a turbo and fuel system type "Common Rail".
From June 2004 to these engines added two turbo unit with a system of "Common Rail"
volume of 1.9 liter capacity of 120 and 150 hp These modern diesels on the dynamics are not inferior
to their petrol counterparts. For example, aster with a motor of 150 hp zero to 100 km / h in 8.9
seconds. Not all petrol engine has the momentum. Moreover, the Astra engine has a maximum
speed of 210 km / hour, and spends 100 km. less than 6 liters of fuel. Among other things, new
engines tailored to the mistakes of the past models, they do not require fuel additives and as an option
can be supplied with a special filter fuel that does not require any maintenance throughout the lifetime.
Naturally, both engines are equipped with the latest models of catalysts, which give almost no way out
all the toxic components: CO, HC and even reduce emissions of soot. New diesel engines are
manufactured at the plant of the group in Pratola Serra (Italy), and since the spring of 2005 will be
released yet, and at the factory in Kaiserslautern (Kaiserslautern).
"The third generation Opel Astra car reflects mainly the emotional side and the direction of the
new design style of the company Opel. The exterior design of the car is harmoniously complemented
by its inner nature. The lounge is dominated by smooth and free surface. High quality materials used
are organically combined with the high level design of the internal finishing the car "- said the head of
design department, Martin Smith (Martin Smith). Decorative bend on the hood smoothly inside the
passenger compartment of elegantly designed central console. Cabin were increased compared with
the previous model Astra. Length increased by approximately 14, the height and width of 2 to 4
centimeters.
1. Operation and maintenance of vehicles
1.1. General
Identification of the vehicle
Typical plate
Fig. 1.1. Location type plate
Typical plaque installed on the frame right front door (see Figure 1.1).

9
Fig. 1.2. Data on the type label: 1 -
the country of manufacture; 2 -
permit number; 3 - Vehicle
identification number 4 - a
permissible total weight, 5 - a
permissible total weight of the
trailer, 6 - the maximum permissible
load on the front axle, 7 - maximum
permissible load on rear axle, 8 -
Individual vehicle data or data
specific to the country
ID
Fig. 1.3. ID number, located on the
floor of the car
ID number of the car knocked on the floor on the right side under the cover between the front door
and the seat (Figure 1.3).
Fig. 1.4. ID number, located on the
dashboard
ID number of the car and knocked on the dashboard (see Figure 1.4).

10
Engine number
Fig. 1.5. Engine number (volume
1.4 l)
Identification and engine number stamped on the left side of the engine, the crankcase (Fig. 1.5, 1.6,
1.7, 1.8).
Fig. 1.6. Engine number (volume
1.6 l)
Fig. 1.7. Engine number (volume
1.8 l)

11
Fig. 1.8. Engine number (volume
2.0 l)
Gas tank components and systems. Recommended maintenance materials.
Fuel consumption, CO
To determine the fuel consumption since 1996, the Instruction 80 / 1268 / EWG with the latest
changes in 1999 / 100 / EG.
Instruction takes into account actual traffic conditions: driving in the city is estimated by a factor of
approximately 1 / 3, and riding outside the city - by a factor of about 2 / 3 (fuel consumption in town
and country). This takes into account cold start and acceleration phase.
In addition, part of the instruction is an indication of CO2 emissions.
From these data can not be concluded how much fuel a vehicle consumes each.
In determining the fuel economy standard for 1999 / 100 / EG takes into account its own weight of
car, is also established in this standard. Additional special equipment vehicle may slightly increase
the mass and, together with that, fuel consumption and CO2 emissions.
Type, properties and volumes of working fluids
The use of leaded gasoline and the abuse of additives to the fuel can lead to failure of the catalytic
converter exhaust gases to meet the requirements exhaust emissions and engine failure. On diesel
models in any case, do not use additives for winter operation, increase the fluidity of the fuel. When
non-compliance with these requirements in the event of engine failure warranty of the manufacturer of
this vehicle do not apply.
Recommended fuel
Gasoline engines
Use unleaded gasoline with an octane number not less than 95 (on the research method).
Diesel engine
Use diesel fuel with a cetane number of not less than 50.
Depending on the ambient temperature operate the car on diesel fuel summer or winter varieties.
- At temperatures above -7 ° C - summer grade fuel
- At temperatures below -7 ° C - winter grade of fuel
NOTICE
Do not fill the car with fuel intended for domestic heating boilers, gasoline or any flammable
liquids, except for diesel fuel. Using the wrong fuel engine was severely damaged.
Do not fill the car with diesel fuel year-old class, if the ambient temperature is below -7 ° C.
When cooling in the summer fuel-intensive fall of wax crystals that clog the fuel filter. This
engine can stay or to work intermittently.
In the absence of unleaded fuel grade "super", you can use fuel with octane number 91, to avoid high
loads on the engine and full vehicle load and driving in the mountains with a trailer or a high load -
while decreasing power and torque of the engine. Regulator detonation, depending on the type of fuel
filled (the octane number) automatically adjusts the ignition system.
NOTE
Engines, adjusted at the factory to run on gasoline with an octane number of AI-95 can be
freely used and gasoline AI-98, but it will not increase efficiency or improve the performance
properties of the car.

12
Recommendations for the choice of the viscosity of motor oil (petrol engines)
Fig. 1.9. Table prevailing ambient
temperature in the period until the
next replacement of engine oil
Recommended to use motor oil with a viscosity of 5W-30, in the absence of the oil run out the
scheme with the prevailing environmental temperature.
Refrigerant air conditioning systems
Air-conditioning systems at the car is recharged with refrigerant HFC-134a (R-134a) or a similar
material operational, fully equivalent to the specified properties. The use of another refrigerant will
result in serious damage to the air conditioning system and the need for complete replacement of the
system.
Is not recommended to release the refrigerant into the atmosphere. The refrigerant HFC-134a (R-
134a) used in cars, no adverse effects on the ozone layer of the atmosphere. However, entering the
atmosphere of the refrigerant can be a small contribution to global warming.
Coolant type
Must use only the red (dark orange), not containing silicate antifreeze recommended for use by Opel,
with the number 19 40 650 / 09 194 431 on the label. With prolonged use of anti-freeze can change
the color to yellow. This does not affect the properties of the coolant, so it can be used until the next
scheduled MOT.
NOTICE
Never use a cooling system for antifreeze / antifreeze green-blue color, with the content of
silicate. We do not recommend adding any additives to coolant (including the sealing of the
system and eliminate small leaks).
Keys, door locks, sunroof, anti-theft system
Switches
Fig. 1.10. Folding key with remote
uprevleniem
The car can be equipped with remote control door locks. In this case, the one key for all locks (Figure
1.10).
The key is an integral part of the electronic locking system start-up of the engine. Included with the
master key is supplied spare.
It is recommended to keep a spare key in a safe place, such as at home.

13
Key with folding beard
To expand the key, press the button. In order to lay down a key, press the same button and fix his
beard till a key clicks (see Fig. 1.10).
Lock the doors from opening children
Use of blocking children from opening in all cases when they are in the car. Failure to do so can lead
to injuries or accidents. Adequately inform their passengers.
Fig. 1.11. Locking rear door lock
In order to lock the door, turn the lever to lock the back door key or a screwdriver from a vertical
position to horizontal (Fig. 1.11).
Remote Device
Fig. 1.12. Buttons on the remote
control door locks
The device is built into the remote control key (Figure 1.12).
The remote system controls the central locking device, mechanical anti-theft devices and anti-theft
alarm.
In addition, in vehicles with electronic control system controls the windows on all doors.
Device remote control has a range of about 3 m. In order to use them, send a remote control device
on the car.
NOTE
In the range of the remote system can affect the surrounding environment.
Handle the remote control carefully. Do not expose to moisture and high temperatures, avoid using
unnecessarily.
Indication of operation of the device running power for emergency light signal.
Write and call the individual units
car with the remote control device
When locking the car through the remote control device remembers the current settings climate
control and lighting dashboard. The settings are stored by different remote control devices, are
restored by using the appropriate remote control device.

14
Malfunction of remote device
If the control of central locking device using remote control devices is not possible, the cause of
failure may be as follows:
- Exceeded the operating range of the remote control device;
- Battery voltage of the remote control is too low;
- Multiple, following one after another attempt to use the remote control device outside the range of a
vehicle (eg, distance to the vehicle is too high, resulting in a remote control device ceases to be
recognized);
- An overload of the central locking device as a result of frequent, repeated exposure (power supply
device, briefly suspended);
- Imposition of radio waves due to the presence of external high-power radio.
Replacing the battery of the remote control
If the operating range of the remote control decreases, replace the battery.
Fig. 1.13. Replacing the battery of
the remote control
Open the remote control device (Figure 1.13).
Replace the battery, while adhering to the sequence of assembling parts.
Synchronizing the remote control device
After replacing the battery door to unlock the car the usual way. Insert the key in the ignition, with
automatic synchronization occurs remote control device.
Remote door locking device
Fig. 1.14. Key lock car doors
Click on the button of the remote control, as shown in Figure 1.14, with the door locks automatically
closed.
Lock with a mechanical protective device
Fig. 1.15. Lock the door locks

15
All doors must be closed. Not later than 15 seconds after the re-lock, press the remote control
device, as shown in Figure 1.15.
Locks all doors locked from the opening.
If the ignition is switched on, you must open and close the driver's door, so the car could again block.
NOTICE
Do not block castles, if there are people in the car. Not be released from inside.
Unlock the door remote device
Fig. 1.16. Key to unlock car doors
Press the remote control device, as shown in Figure 1.16.
Unlocking and locking the door from the inside
In order to lock or unlock the doors from the inside, press the central locking device Located on
the middle console of the dashboard (see Figure 1.17).
Fig. 1.17. Key unlocking and
locking the car doors from inside
When the key is inserted in the ignition, lock the car can be used only if all doors are closed.
NOTICE
When the mechanical anti-theft device to unlock the door of this key is impossible.
NOTE
When closure of driver's door central locking device does not work.
For locking the door from the inside (for example, to prevent undesirable penetration of the
interior strangers), press the central locking device on the middle console.
After unlocking the driver's door in the usual way (using the key) unlocked all the doors.
Locked central door locking device can be opened from the inside by pulling the handle on the inside
of the door. Simultaneously unlocked and the central locking device.
Locked doors are automatically unlocked when the accident (in cases of damage to the car, to assist
the outside), in addition, the hazard lights. The key in this should be in the ignition.
LED in the key central locking device burns approximately 2 minutes after locking.
Faulty devices or unlock the door lock
Fig. 1.18. Destviya when
malfunction unlock doors

16
To resolve this issue devices to unlock doors, turn the key in the lock driver's door all the way forward.
Then turn it back into the upright position and remove (Figure 1.18).
When you open the driver's door unlocked all the doors. To deactivate the device anti-theft alarm turn
on the ignition.
To resolve this issue device locking, front passenger door open, then close the driver's door and
press the central locking device on the middle console. Central locking device will be locked all the
doors. Close the door front passenger.
Faulty central locking device
Unlock.
Turn the key in the lock driver's door forward until it stops. Turn the key back and remove it. Other
doors can be unlocked from the inside by pulling the handles on the inside of the door (it is not
possible with earlier engagement of the device). Trunk and cover the fuel tank thus remain locked. to
turn off the device anti-theft alarm, turn on the ignition.
Locking.
Fig. 1.19. Removal of the central
locking device malfunction
Insert the key into the hole on the inside of the door, above the lock, and cock the lock push up
tangible click, then close the door (Fig. 1.19).
Repeat for all other doors. Driver's door can be locked also on the outside with a key. Unlocked the
lid of the fuel tank lock is impossible.
Closing and opening windows with remote control
In cars with electronically controlled window box, you can open or close all the doors from the outside.
Fig. 1.20. Opening and closing
windows from the outside
To do this, press the corresponding button on the remote control, until all the windows would not open
or be closed completely (Figure 1.20).
Overloading power
For too often, repeatedly turned on and off the remote control system power windows central locking
device can be briefly interrupted. However, after a while its functions are restored.

17
Unlocking and locking luggage
Fig. 1.21. Lock opening trunk
In order to unlock the trunk lock, press the appropriate button on the remote control device (Figure
1.21).
Fig. 1.22. Opening trunk
Trunk unlocked with the central lock and can be opened by pressing the button under the bar for the
capture (Figure 1.22).
Fig. 1.23. Locking luggage lock
In order to secure the lock luggage, press the appropriate button on the remote control device (Figure
1.23).
Fig. 1.24. Closing the trunk
To close the trunk, use the handle on the inside of the back of the door (Fig. 1.24).
NOTICE
Do not go with fully or partially open rear door, for example, the transport of bulky cargo, as
well as in the salon will be exposed to toxic exhaust gases.
Mounting accessories on the back of the door increases its mass. As a result, the excessive
weight of the rear door is not kept in the open position.

18
Alarm
The unit antitheft alarm controls:
- Doors, trunk, hood;
- Lounge car;
- The slope of the vehicle, such as when lifting;
- The ignition.
Fig. 1.25. The inclusion of anti-
theft alarm
In order for anti-theft system has joined, should be closed all doors, windows, sunroof and hood. Not
later than 15 seconds after locking the re-press the corresponding key remote control device (Figure
1.25).
If the ignition is switched on, you must open and close the driver's door to be able to activate the
device anti-theft alarm.
Without the inclusion of control functions and tilt the car interior
Close the trunk and hood.
Click on the button the console on the roof (Figure 1.26).
Fig. 1.26. Key partial disabling
anti-theft system
Close the door.
The device anti-theft alarm. After about 10 with the device (without the control cabin and the
inclination of the car) is activated. LED on the center console will flash to turn off the device.
Fig. 1.27. Deactivating the partial
deactivation of anti-theft system
To disable the partial deactivation of anti-theft system, click the corresponding button on the remote
control or turn on the ignition (Figure 1.27).
When a failure of the remote control, open the car key. Turn the key in the lock all the way forward,
return it to vertical position and remove.
If you open the driver's door of alarm, disable the device anti-theft alarm, switched on the ignition.
NOTE
When the device anti-theft alarms might trigger a sound (beep) alarm or light (emergency light
signaling).

19
Opening and closing the hood
Fig. 1.28. Handle opening hood
To open the hood, pull the handle to unlock the hood from the driver's espoused under the dashboard
(see Figure 1.28).
Castle is unlocked, and the hood will open slightly. Return the handle to its original position.
Fig. 1.29. Opening bonnet
At the bottom of the hood latch handle is - then it up and open the hood (Fig. 1.29).
NOTE
Be careful: the mud or snow, located on the hood, when opened, can fall on the windscreen
and clog the air intake.
Hood is automatically kept in the open position. To close the hood, pull it down and give it slammed
shut.
Check the fixation of the hood, pulling it over the front edge. If the hood is not, repeat the previous
operation.
Power windows
Electronic control window
Electronic control window work when the ignition key.
In addition, the functions of windows continue to work within 5 minutes after the ignition is turned off
and within 5 minutes when you turn the ignition key to position 1.
When you open the driver's door using the function becomes impossible.
Central Control Panel window
Fig. 1.30. Opening bonnet
Central Control Panel window is located on the driver's door (Fig. 1.30).

20
The front keys are designed to control the glass on the doors of the driver and front passenger. Rear
keys open and close the glass rear door. Additional control buttons are located on the front passenger
door and rear door panels.
For the gradual movement of the glass, briefly press the forward or backward. To automatically open
or close hold the keys pressed so far as is necessary.
Safety function
In the case of resistance during the automatic closing of glass above the middle of the window
movement immediately stopped and the window re-opens.
If tugogo progress, for example due to the presence of frost, repeatedly press the key corresponding
to the window until it closes.
Lock opening rear windows
To lock, press the switch between the rear buttons on the handle of the driver's door (Fig. 1.31).
Fig. 1.31. Key lock rear windows
If you press the switch forward (see red box) - glass rear doors are blocked.
If you press the switch back (see green box) - glass rear door unlocked.
Faulty windows
If the automatic opening and closing windows is not possible, an electronic management system
windows must be activated. To do this, close the doors, turn on the ignition and open the windows.
Then close the window and hold not less than 5 seconds.
NOTE
The procedure is repeated for each window separately.
Panoramic glass
Fig. 1.32. Opening panoramic
glass
To open the panoramic windows, turn the knob to the right and slide back into the right position lining
the ceiling (Figure 1.32).
Fig. 1.33. Closing the panoramic
glass