Vauxhall 2010 Astra User manual

Contents
LIVING WITH YOUR VAUXHALL ASTRAlZAFIRA
Safety first! Page
0-5
Introduction Page
0-6
Roadside Repairs
If your car won't start Page
0-7
Jump starting Page
0-8
Wheel changing
Identifying leaks Page
0-10
Towing Page
0-10
Weekly Checks .
Introduction Page 0-11
Underbonnet check points Page 0-11
Engine oil level Page
0-12
Coolant level Page
0-13
Brake (and clutch) fluid level Page
0-13
Tyre condition and pressure Page
0-14
Screen washer fluid level Page· 0-15
Power steering fluid level Page
0-15
Wiper blades Page 0-16
Battery Page
0-16
Electrical systems Page
0-17
Lubricants and fluids
Page
0-18
Tyre pressures Page
0-18
MAINTENANCE
Routine Maintenance and Servicing
Vauxhall Astra/Zafira models Page 1-1
Servicing specifications Page
1-2
Maintenance schedule Page
1-3
Maintenance procedures

REPAIRS AND OVERHAUL
Engine and Associated Systems
SOHC petrol engine in-car engine repair procedures
DOHC petrol engine in-car engine repair procedures
Engine removal and overhaul procedures
Cooling, heating and air conditioning systems
Fuel and exhaust systems
Emission control systems
Starting and charging systems
Ignition system
Transmission
Clutch
Manual transmission
Automatic transmission
Driveshafts
Brakes and suspension
Braking system
Suspension and steering
Body equipment
Bodywork and fittings
Body electrical system
Wiring Diagrams
Vauxhall Astra
Vauxhall Zafira
REFERENCE
Dimensions and weights
Conversion factors
Buying spare parts
Vehicle identification
General repair procedures
Jacking and vehicle support
Disconnecting the battery
Tools and working facilities
MOT test checks
Fault finding.
Glossary of technical terms
Index
~ Contents
Page 2A-1
Page
28-1
Page 2C-1
Page 3-1
Page 4A-1
Page 48-1
Page 5A-1
Page 58-1
Page 6-1
Page 78-1
Page 8-1
Page 9-1
Page 10-1
Page 11-1
Page 12-1
Page 12-26
Page 12-46
Page REF-1
Page REF-2
Page REF-3
Page REF-3
Page REF-4
Page REF-5
Page REF-5
Page REF -6
Page REF-8
Page REF-12
Page REF-21
Page REF-26

0-4 Advanced Driving
Advanced driving
Many people see the words 'advanced
driving' and believe that it won't interest them
or that it is a style of driving beyond their own
abilities. Nothing could be further from the
truth.
Advanced driving is straightforward
safe, sensible driving -the sort of driving we
should all
do every time we get behind the
wheel.
An average of 10 people are killed every day
on UK roads and 870 more are injured, some
seriously. Lives are ruined daily, usually
because
somebody did something stupid.
Something like 95% of all accidents are due
to human error, mostly driver failure.
Sometimes we make genuine mistakes -
everyone does. Sometimes we have lapses of
concentration. Sometimes we deliberately
take risks.
For many people, the process
of 'learning to
drive'
doesn't go much further than learning
how to pass the driving test because of a
common belief that good drivers are made by
'experience'.
Learning to
drive by 'experience' teaches
three driving skills:
o Quick reactions. (Whoops, that was
close!)
o Good handling skills. (Horn, swerve,
brake, horn).
o Reliance on vehicle technology. (Great
stuff this ASS, stop in
no distance even in
the wet...)
Drivers whose skills are 'experience based'
generally have a lot
of near misses and the
odd accident. The results can be seen every
day in our courts and our hospital casualty
departments.
Advanced drivers have learnt
to control the
risks by controlling the position and speed
of
~heir . vehicle. They avoid accidents and near
misses, even if the drivers around them make
mistakes.
The key skills
of advanced driving are
concentration, effective all-round
observation, anticipation and planning.
When good vehicle handling is added to
these skills, all driving situations can be
approached and negotiated in a safe,
methodical way, leaving nothing to chance.
Concentration means applying your mind to
safe driving,
completely excluding anything
that's not relevant. Driving
is usually the most
dangerous activity that most
of us undertake
in our daily routines. It deserves our full
attention.
Observation means not just looking, but
seeing and seeking out the information found
in the driving environment.
Anticipation means asking yourself what is
happening, what you can reasonably expect
to happen and
what could happen
unexpectedly. (One of the commonest words
used
in compiling accident reports is
'suddenly'
.)
Planning is the link between seeing
something and taking the appropriate
action. For many drivers, planning is the
missing link.
If you want to become a safer and more skilful
driver and you want to enjoy your driving more,
contact the Institute of Advanced Motorists at
www.iam.org.uk, phone [phone],
or
write to lAM House, 510 Chiswick High Road,
London W4 5RG for
an information pack.

Is
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11
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Working on your car can be dangerous.
This page shows just some of the potential
risks and hazards, with the aim of creating a
safety-conscious attitude.
General hazards
Scalding
• Don't remove the radiator or expansion
tank cap while the engine is hot.
• Engine oil, automatic transmission fluid or
power steering fluid may also be dangerously
hot if the engine has recently been running.
Burning
• Beware of burns from the exhaust system
and from any part of the engine. Brake discs
and drums can also be extremely hot
immediately after use.
Crushing
\)
venture
under a car which
is only supported by a jack.
• Take care if loosening or tightening high-
torque nuts when the vehicle is
on stands.
Initial loosening and final tightening should be
done with the wheels
on the ground.
Fire
• Fuel is highly flammable; fuel vapour is
explosive.
• Don't let fuel spill onto a hot engine.
• Do not smoke or allow naked lights
(including pilot lights) anywhere near a
vehicle being worked on. Also beware of
creating sparks
(electrically or by use of tools).
•
Fuel vapour is heavier than air, so don't
work on the fuel system with the vehicle over
an inspection pit.
• Another cause
of fire is an electrical
overload or short-circuit.
fake care when
repairing or modifying the vehicle wiring.
• Keep a fire extinguisher handy, of a type
suitable for use on fuel and electrical fires.
Electric shock
• Ignition HT
voltage can be
dangerous,
especially
to r- .f
people with heart .f
problems or a ./
pacemaker. Don't ./
work on or near the ) ~
ignition system with f I 1 ( ) "\ '" .
the engine running or ) J \ ~ '\
the ignition switched on .
• Mainsvoltage is also dangerous. Make
sure that any mains-operated equipment
is
correctly earthed. Mains power points should
be protected by a residual current device
(RCD) circuitbreaker.
Fume or gas intoxication
• Exhaust fumes are
poisonous; they often
contain carbon
monoxide, which is
rapidly fatal if inhaled.
Never run the
engine
in a
confined space
such
as a garage
with the doors shut:
•
Fuel vapour is also
poisonous,
as are the vapours from some
cleaning solvents and paint thinners.
Poisonous or irritant substances
• Avoid skin contact with battery acid and
with any fuel, fluid or lubricant, especially
antifreeze, brake hydraulic fluid and Diesel
fuel. Don't syphon them by mouth. If such a
substance is swallowed or gets into the eyes,
seek medical advice.
• Prolonged contact with used engine oil can
cause skin cancer. Wear gloves or use a
barrier cream if necessary. Change out of oil-
soaked clothes and do not keep oily rags
in
your pocket.
• Air conditioning refrigerant forms a
poisonous gas if exposed to a naked flame
(including a cigarette). It can also cause skin
burns
on contact.
Asbestos
• Asbestos dust can cause cancer if inhaled
or swallowed. Asbestos may be found
in
gaskets and in brake and clutch linings.
When dealing with such components it is
safest to assume that they contain asbestos.
R emember ...
DO
• Do use eye protection when using power
tools, and when working under
the vehicle.
• Do wear gloves
or use barriercream to
protect your hands when necessa ry.
• Do get someone to check periodically
that all
Is well when working alone on the
vehicle.
• Do keep loose clothing
an d 10l'\ g hairwell
out of the way
of moving mechanical parts.
• Do remove ri ngs, wristwatch etc, before
working on the vehicle -especially the
electrical system.
• Do ensure that
any lifting or jacking
equipment has a safe working load rating
adequate Ior the job.
Safety First! 0-5
Special hazards
Hydrofluoric acid
• This extremely corrosive acid is formed
when certain types of synthetic rubber, found
in some O-rings, oil seals, fuel hoses etc,
are
exposed to temperatures above 400' C. The
rubber changes into a charred or sticky
substance containing the acid. Once formep,
the acid remains dangerous foryears. If it
gets onto the skin, it may
be necessary to
amputate the limb concemed.
• When dealing with a vehicle which has
suffered a fire, or with components salvaged
from such a vehicle, wear protective gloves
and discard them after use.
The battery
• Batteries contain sulphuric acid, which
attacks clothing, eyes and skin. Take care
when topping-up or carrying the battery.
• The hydrogen gas given off by the battery
is highly explosive. Never cause a spark or
allow a naked light nearby. Be careful when
connecting and disconnecting battery
chargers or jump leads.
Air bags
• Air bags can cause injury if they go off
aCCidentally. Take care when removing the
steering wheel and/or facia. Special storage
instructions may apply.
Diesel injection equipment
• Diesel injection pumps supply fuel at very
high pressure. Take care when working on
the fuel injectors and fuel pipes.
A Warning:
Never expose the hands,
, face
or any other part of the body
• to injector spray; the fuel can
penetrate the skin with potentially fatal
results. .
DON'T
• D on't attempt to lift a heavy compoRent
which may be beyond your capability -get
aSSistance.
• Don't
ruS/:l to finish a job, or take
unverified short outs.
• Don't use ill-fitting tools which may slip
and cause injury.
• Don't leave tools
or parts lying around
where someone can
tlip OVer them. Mop
up oil and fuel spills at once.
•
Don't allow children or pets to play In or
near a vehicle being worked on,

0-6 In tr oduction
The Vauxhall Astra-G model was introduced
in the UK in February 1998 as a replacement
for the previous Astra, the 'F' model. It
was
available in Saloon, Hatchback and Estate
versions with 1.4, 1.6, 1.8 and 2.0 litre petrol
engines. The 1.6 litre engines are
in either 8-
valve or 16-valve form, and the 1-4, 1.8 and
2.0 litre engines are 16-valve. Models may be
fitted with a five-speed manual transmission or
four-speed automatic transmission mounted
on the left-hand side of the engine.
All models have front-wheel-drive with fully-
independent front suspension, and
semi-in-
dependent rear suspension with a torsion
beam and trailing arms.
Electro/Hydraulic
power steering (PAS) is
fitted as standard
to all models, whilst Anti-
Lqck Braking (ABS)
is available as an option.
The Zafira range
was launched in June
1999, available with 1.6 and 1.8 litre DOHC
16V petrol engines. Whilst the Zafira shares
the same drive train and suspension as the
. Astra, the
body is that of a Multi Personnel
Vehicle (MPV). Not only does the Zafira have
7
seats arranged in three rows, it quickly
converts to a spacious load carrier -thanks to
the 'Flex 7' system, which allows the rear
seats
to fold completely flat into the floor
giving an uninterrupted load space.
Both models have a full-sized driver's side
airbag fitted as standard, and side impact air-
bags available as
an option. Passenger's side
airbags
became standard equipment from
January 1999. Cruise control is available as
an
option on certain models.
In February 2000, the Astra was also
available with a 2.2 litre petrol engine, whilst
in
October 2000 a 2.0 litre turbocharged petrol
version was introduced. These
two engines,
along with the various diesel engines fitted
to
the Astra and Zafira range, are not covered in
this manual.
For the home mechanic, the Vauxhall Astral
Zafira is a straightforward vehicle
to maintain
and repair since design features have been
incorporated to reduce the actual cost of
ownership to a minimum , and most of the
items requiring frequent attention are easily
accessible.
Your Vauxhall' Astra
and Zafira manual
The aim of this manual is to help you get the
best value from your vehicle. It can
do so' in
several ways. It can help you decide what
work must be done'(even should you choose
to get it done by a garage), provide
informatio'n on routine maintenance and
servicing, and
'\Jive a logical course of action
and
diagnosis when randqm faults occu r.
However, it is
hoped that you will use the
manual
by tackling the work yourself. On
simpler jobs, it may even be quicker than
booking the car into a garage and going there
tw ice, to leave and collect it. Perhaps most
important, a lot of money can .be saved by
avoiding the costs a garage must charge to
cover its labour and overheads.
The manual has drawings and descriptions
to show the function of the various com-
ponents, so that their layout can be
understood. Then the tasks are described and
photographed in a clear step-by-step
sequence.
References to the 'left' or 'right' are
in the
sense
of a person in the driver's seat, facing
forward.
Acknowledgements
Certain illustrations are the copyright of
Vau x hall Motors Limited, and are used with their
permission. Thanks
are also due to Draper Tools
Limited, who provided some
of the workshop
tools, and to all those people at Sparkford who
helped
in the production of this manual.
We take great pride in the accuracy of
information given in this manual, but
vehicle
manufacturers make alterations
and design changes during the production
run of a particular vehicle of which they do
not inform us. No liability can,be accepted
by
the authors or publishers for loss,
damage or injury caused by any errors in, .
or omissions from, the information given.
Project vehicles
The main vehicle used in the preparation of
this manual, and which appears in many of the
photographic sequences, was a Zafira fitted
with a 1.8 litre engine. Other vehicles used
included 1.6 litre SOHC and DOHC models.
Vauxhall Zafira

The foHowing pages are intended to help in dealing with
common roadside emergencies and breakdowns. You will find
more detailed fault finding information at the
back of the
manual, and repair information in the main chapters.
Ifyour car won't start
an d the starter motor
doesn't tu
rn
o If it's a model with automatic transmission, make sure the
selector is
in P or N. .
o Open the bonnet and make sure that the battery terminals
are clean and tight.
o Switch on the headlights and try to start the engine. If the
headlights go very dim when you're trying to start, the
battery
is probably flat. Get out of trouble by jump starting
(see next page) using a friend's car.
Roadside repairs 0-7
If your car won't start
even though the starter
motor turns as normal
o Is there fuel in the tank?
o Is there moisture on electrical components under the
bonnet? Switch off the ignition, then wipe off any obvious
dampness with a dry cloth. Spray a water-repellent aerosol
product (WD-40 or equiva'lent)
on ignition and fuel system
electrical connectors like those shown
in the photos.
Pay special attention to the ignition coil wiring connector
and HT leads.
ACheck the condition and security of the
battery connections. . BCheck the engine wiring
harne:ss at the
left-hand rear
Of the engine compart-
ment. CCheck the wiring to the
DIS ignition
. module
(1 .6 engine).
Check that electrical connections are secure (with the ignition switched off) and spray them
with a water dispersant spray like WD-40 if you suspect a problem due to damp.
DCheck the wiring to the airflow meter
(1.8 engine).
ERemove the engine top cover, and
check the wiring for the ignition coils
(1.8 engine).

0-8 Roadside repairs
Jump starting
When jump-starting a car using a
booster battery, observe the following
precautions:
v Before connecting the booster
battery, make sure that the ignition
is
switched off.
V Ensure that all electrical equipment
(lights, heater, wipers, etc)
is
switched off.
V Take note of any speCial precautions
printed on the battery case.
Connect one end of the red jump lead to
the positive (+) terminal of the flat
battery
-----------,
V Make sure that the booster battery is
the same voltage as the discharged
one
in the vehicle.
V If the battery is being jump-started
from the battery
in another vehicle,
the
two vehicles MUST NOT TOUCH
each other.
V Make sure that the transmission is in
neutral (or PARK, in the case of
automatic transmission).
Connect the other end of the red lead to
the positive (+) terminal of the booster
battery. r
----
I
I
I
I
I
I
•
•
••
I
I
•
•
I
I
1"'-
.... -----------------------------~
Ii'~ Jump s~rting will get yau out
_ 1-.1 Oftf"P. uble, bur you must correct
HIN •I whatevermade thebattery go
na' in the first pl8Cf3, There are
three possibil it ies:
1
The batteryhas been drained by
repeated attempts fCJ start , or by
leaving the lights on.
2
The chargingsystem Is nof working
property (attemiltor drlvebelt slack
or broken, altemator Wiring fault or
altemator itselffaulty).
3 The battery itself is
at fQult
(electrolyte low,
Qr battery wom out).
Connect the other end of the black jump
lead to a bolt or bracket on the engine
block, well away from the battery, on the
vehicle
to be started.
5 Make sure that the jump leads will not
come into contact with the fan, drive-
belts or other moving parts
of the
engine.
6 Start the engine using the booster
battery and run
it at idle speed. Switch
on the lights, rear window demister and
heater blower motor, then disconnect
the jump leads
in the reverse order of
connection. Turn off the lights etc.

Wheel changing
Some of the details shown here wi ll vary
according
to model. For instance, the location
ofthe spare wheel and
lack is not the same on
all cars. However, the basic principles apply
to all vehicles.
Preparation
o When a puncture occurs, stop as soon as
it is safe to
do so.
~ Park on firm level ground, if possible,
and well out
of the way of other traffic.
::J Use hazard warning lights if necessary.
Changing the wheel
1 On Astra
models the jack and wheel
brace are stowed under the spare wheel
beneath the luggage compartment floor.
On Zafira models they are beneath a cover at
the rear
of the luggage compartment floor.
4 All
models have depressions in the sill
vertical web, which indicate the points at
which the jack head
is to be attached. On
Astra models, the depressions are concealed
by flaps
in the outer sill bodywork. Prise out
the flaps
to access the jacking points.
Position the jack head under the jacking point
and
make sure that the slot in the head
engages correctly with the vertical web of the
sill. Turn the handle until the base
of the jack
touches the ground then make sure
that the
base is located directly below the sill'. Raise
the vehicle until
the wheel is clear of the
ground. If the tyre is flat make sure
that the
vehicle is raised sufficiently to allow the spare
wheel to be fitted.
. ---=- - -
~------------
Road s ide repair s 0-9
Warning: Do not change a wheel in a situation where you risk being hit by
another vehicle. On busy roads, try to stop in a lay-by ora gateway. Be wary of
passing traffic while changing the wheel - it is easy to become distracted by
thejob
in hand.
D If you have one, use a warning triangle to
alert other drivers of your presence.
D Apply the handbrake and engage first or
reverse gear (or Park on models with
automatic transmission).
2 The spare wheel is beneath a cover in the
luggage
compartment on Astra models.
Raise the cover, remove the screw and
lift out the spare wheel. Place it
beneat~ the
sill as a precaution against the jack failing. On
Zafira models, the spare wheel Is under the
rear of the vehicle. Lift the rear
of the luggage
compartment floor, and slacken the bolt
in the
floor, using
the wheel brace. Un hook the
catch, lower the spare, and detach the cable.
The spare can
now .be lifted out.
5 Remove the bolts and
lift the wheel from
the vehicle. Place it beneath
the sill in
place
of the spare as a precautior
against the jack failing. Fit the spare wheel
and tighten the
bolts moderately with the
wheel brace.
Finally...
D Remove the wheel chocks.
[J Chock the wheel diagonally opposite the
one bei
ng removed - a couple of large
stones will do for this.
D 'If the ground is soft, use a flat piece of
wood to spread the load under the jack.
3 On
models with steel wheels, use the
speci
al tool to pull the wheel trim from
the wheel.
On models with alloy wheels,
use the screwdriver provided inserted at the
wheel bolt holes, to prise off the trim. Where
an anti-theft device is fitted, use the tool
provided to remove the trim. Loosen each
wheel bolt by half a turn.
6 Lower the vehicle to the ground, then
finally tighten
the wheel bolts in a
diagonal sequence. Refit the wheel trim.
Note that the wheel bolts should be tightened
to the specified torque at the earliest
opportunity.
D Stow the jack and tools
in the .correct locations in the.car.
D Check the tyre pressure on the wheel just fitted. If it is low, or if you don't have a pressure
gauge with you, drive slowly to the.nearest garage and inflate·the tyre to the right pressure.
D Have the damaged tyre or wheel repaired as soon as possible.

0-10 ·Roadside repairs
Identifying leaks
Puddles on the garage floor or drive, or
obvious wetness under ·the bonnet or
underneath the car, suggest a leak that needs
investigating. It can sometimes be difficult to
decide where the leak is coming from,
especially if the engine bay is very
dirty
already. Leaking oil or fluid can also be blown
rearwards
by the passage of air underthe car,
giving a false impression
of where the
problem lies.
Sump oil
Engine oil may leak from the drain plug...
Antifreeze
Leaking antifreeze often leaves a crystalline
deposit like this.
Towing
When all else fails, you may find yourself
having
to get a tow home - or of course you
may be helping somebody else. Long-distance
recovery should only be done by a garage or
breakdown service. For shorter distances,
DIY
towing using another car is easy ehough, but
observe the following points:
o A towing eye is provided with the warning
The towing eye has a left-hand thread
Warning: Most automotive
ot1s
and fluids are poisonous. Wash
them
off skin, and change out
of contaminated clothing,
without delay.
Oil from filter
. .. or from the base of the oil filter.
Brake fluid
A leak occurring at a wheel is almost
certainly brake fluid.
triangle
in the luggage compartment.
o To fit the towing eye, prise the cover from
the
front bumper, then screw in the towing
eye anti-clockwise
as far as it will go using the
handle
of the wheel brace to turn the eye.
Note that the towing eye has a left-hand
thread (see illustration). A rear towing
eye is
provided beneath the rear of the vehicle.
o Use a proper tow-rope -they are not
expensive. The vehicle being towed must
display
an ON TOW sign in its rear window.
o Always turn the ignition key to the 'on'
position when the vehicle is being towed, so
that the steering lock is released, and that the
direction indicator and brake lights will work.
o Before being towed, release the handbrake
and·select neutral
on the transmission.
ra;
The smell of a fluid l ea king
_ from
the c ar may prollfde a
HINT clue to what's leaking. Some
fluIds ,re- dlstlncfflle/y coIourvd.
It may help to clean the car carefully
and to park it over so me clean p ap er
ollemight as an aid to lo cating t he
source of the leak,
Remember that some leaks mey onl y
occur while the engine
Is runnfng.
Gearbox oil can leak from
the seals at the
inboard ends of the driveshafts.
Power steering fluid
Power steering fluid may leak from the pipe
connectors
on the steering rack.
o On models with automatic transmission,
only
tow with the vehicle facing forwards, at
less than 50 mph, and no further than 60 miles.
If
in doubt, do not tow, or transmission
damage may result.
o Note that greater-than-usual pedal
pressure will be required
to operate the
brakes, since the vacuum servo unit is only
operational with the engine running.
o The driver of the car being towed must keep
the tow-rope taut at
all times to avoid snatching.
o Make sure that both drivers know the route
before setting off.
o Only drive at moderate speeds and keep
.the
distance towed to a minimum. Drive ·
smoothly and allow plenty
of time for slowing
down at junctions.

In troduction
There are some very simple checks which
need only take a few minutes to carry out, but
which could save you a lot
of inconvenience
and expense.
These Weekly checks require .no great skill or
special tools, and
the small amount of time
they take to perform could prove to be very
well spent, for example;
o Keeping an eye on tyre condition and
pressures, will
not only help to stop them
wearing out prematurely, but could also save
your life.
o Many breakdowns are caused by electrical
problems. Battery-related faults are particularly
common, and a quick check on a regular basis
will often prevent the majority of these.
Underbonnet check pOints
Wee kly checks 0-11
o If your car develops a brake fluid leak, the
first time you might know about it is when
your brakes don't work properly. Checking
the level regularly will give advance warning of
this kind of problem.
o If the oil or coolant levels run low, the cost
of repairing any engine damage will be far
greater than fixing the leak, for example.
~ 1.6 litre SOHC
A Engine oil level dipstick
B Engine oil filler cap
C Coolant reservoir (expansion
tank)
D Brake
and clutch fluid
reservoir
E Washer fluid reservoir
F Battery
G Powersteering fluid reservoir
~ 1.4 & 1.6 litre
DO He
A Engine oil level dipstick
B Engine oil filler cap
C Coolant reservoir (expansion
tank)
D Brake and clutch fluid
reservoir
E Washer fluid reservoir
F Battery
G Power steering fiuid reservoir

0·12 Weekly checks
Engine oil level
Before you start
V' Make sure that your car is on level ground.
V' Check the oil level before the car is driven,
or
at least 5 minutes after the engine has been
switched off.
If the. 011 ;s chec k ed
H
•• NT Immediately affe r driving the
vehIcle, some of the 011 will
remain In the upper engine
compone.nts , resulting in an inaClClurate
reading on the dipstick!
The correct oil
Modem engines place great demands on their
oil. It
is very important that the correct oil for
your car
is used (see Lubricants and fluids).
Car Care
elf you have to add oil frequently, you should
check whether you have any oil leaks. Place
some clean
paper under the car overnight,
and check for stains in the morning. If there
are no leaks, the engine'may be burning oil.
e Always maintain the level between the
upper and lower dipstick marks (see photo 3) .
If ·the level is
too low severe engine damage
may
occur . Oil seal failure may result if the
engine is overfilled by adding too much oil.
1 The dipstick is located on the front
of the
engine (see Underbonnet Check Points
for exact location). Withdraw the dipstick.
3 Note
the oil level on the end of the
dipstick , which should be between the
upper (MAX) mark and lower (MIN) mark.
Approximately 1.0 litre
of oil will raise the level
from the lower mark to the upper mark.
. ~ 1.8 litre OOHe
A Engine oil level dipstick
B Engine oil filler cap
C Coolant reservoir (expansion
tank)
D Brake
and clutch fluid
reservoir
E Washer fluid reservoir
F Battery
~
Powersteering fluid reservoir
4 Oil is added through the filler cap. Rotate
the cap
through a quarter-turn anti-
clockwise and withdraw it. Top-up the
level. A funnel may help
to reduce spillage.
Add the oil slowly, checking the level
on the
dipstick often. Do not overfill.

Coolant level
A
Warning: DO NOT attempt to
remove the expansion tank
pressure cap when the engine
is hot, as there is a very great
risk of scalding. Do not leave
open containers of coolant
about, as it is poisonous.
1 The
coolant level varies with the
temperature of the engine. When the
engine is cold, the coolant level should
be slightly above the KALT/COLD mark on the
SId e of the tank. When the engine is hot, the
~ e l will rise.
Warning:
•
Brake fluid can harm your
eyes and damage painted
surfaces, so use extreme
caution when handling and
pouring it.
•
Do not use fluid that has
been standing open for some
time, as it absorbs moisture
from the air, which can cause a
dangerous loss of braking
effectiveness.
1 The MAX and MIN marks are indicated on
the front
of the reservoir. The fluid level
must be kept between the marks at all
limes.
Note: On Zafira models, first remove
the plastic water deflector from
in front of the
windscreen
Car Care
• With a sealed-type cooling system, adding
coolant should not be necessary on a regular
basis. If frequent topping-up is required, it is
likely there is a leak. Check the radiator, all
hoses and joint faces for signs
of staining or
wetness, and rectify as necessary.
2 If topping-up is necessary,
wait until the
engine is cold. Slowly unscrew the
expansion tank cap, to release any
pressure present
in the cooling system, and
remove it. .
, on leftel ground.
=
.
Malee sure tflat YOf/r car Is
HiNT · The fluid level in the
reservoir will drop sng htly as
the bra#Ce pads weardown, but the 'Md
level must never be aI/owed to drop
below the MIN mark.
2 If
topping - up is necessary, first wipe
clean the area around the filler cap to
prevent dirt entering the hydraulic
system.
Weekly checks 0-13
• It is important that antifreeze is used in the
cooling system all year round, not just during
the winter months.
Don't top-up with water
alone, as
the antifreeze will become too
diluted.
3 Add a mixture of water and antifreeze
to
the expansion tank until the coolant is up
to the MAX level mark. Refit the cap and
tighten it securely.
Safety First!
• If the reserVoir requires repeated topping-
up this is an indication of a fluid leak
somewhere in the system, which should be
investigated immediately.
•
If a leak is suspected, the car should not be
driven until the braking system has been
checked. Never take any risks where brakes
are concerned.
3
' Carefully add fluid, taking care not
to spill
it onto the surrounding components, Use
only the specified fluid; mixing different
types can cause damage
to the system. After
topping-up
to the correct level, securely refit
the cap and wipe off any spilt fluid.

0-14 Weekly checks
Tyre condition and pressure
It is very important that tyres are in good
condition, and at the correct pressure -having
atyre failure at any speed is high
Iy dangerous.
Tyre wear is influenced by driving style -harsh
braking and acceleration,
or fast cornering,
will all
produce more rapid tyre wear. As a
general rule, the
front tyres wear out faster
than the rears. Interchanging the tyres from
front to rear ("rotating" the tyres) may result
in
more even wear. However, if this is
completely effective, you may have the
expense of replacing all four tyres at once!
Remove any nails or stones embedded
in the
tread before they penetrate the tyre to cause
deflation.
If removal of a nail does reveal that
1 Tread Depth -visual check
The original tyres have tread wear safety
.bands
(B), which will appear when the tread
depth reaches approximately 1.6 mm . The
band
positions are indicated by a triangular
mark on the tyre sidewall
(A).
the tyre has been punctured, refit the nail so
that its point
of penetration is marked. Then
immediately change the wheel, and have the
tyre repaired by a tyre dealer.
Regularlycheck the tyres for damage in the
form of cuts or bulges, especially in the
sidewalls. Periodically remove the wheelS,
and clean any dirt or mud from the inside and
outside surfaces. Examine the wheel rims for
signs
of rusting, corrosion or'other damage.
Light alloy wheels are easily
damaged by
"kerbing" whilst parking; steel wheels may
also become dented or buckled. A new wheel
is very often the only way to overcome severe
damage.
2 Tread Depth - manual check
Alternatively, tread wear can be
monitored with a simple, inexpensive device
known as a tread depth indicator gauge.
Tyre tread wear patterns
Underinflation (w~ar on both sides)
Under-inflation will cause overheating of the
tyre, because the tyre will flex too much, and
the tread will not sit correctly on the road
surface. This will cause a loss of grip and
excessive wear, not
to mention the danger of
sudden tyre failure due
to heat build-up.
Check
and adjustpressures
Incorrect wheel camber (wear on one side)
Repair or renew suspension parts
Hard cornering
Reduce speed!
Overinflati on
Over-inflation will cause rapid wear of the
centre part of the tyre tread, coupled with
reduced grip, harsher ride: and the danger of
shock damage occurring
in the tyre casing.
Check
and adjustpressures
If you sometimes have to inflate your car's
tyres to the
higher pressures specified for
maximum load or sustained highspeed, don't
forget to reduce the pressur~s to normal
afterwards.
New tyres should be balanced when they are
fitted,
but it may become necessary to re-
balance them as they wear,
or if the balance
weights fitted
to the wheel rim should fall off.
Unbalanced tyres will wear more quickly, as
will the steering and suspension components.
Wheel
imbalance is normally signified by
vibration, particularly at a certain speed
(typically around 50 mph). If this vibration is
felt only fhrough the steering, then it is likely
that just the front wheels need balancing. If,
however,
the vibration is felt through the
whole car, the rear wheels could be out of
balance. Wheel balancing should be carried
out by a tyre dealer or garage.
3 Tyre Pressu re Check
Check the tyre pressures regularly with
the tyres cold. Do not adjust the tyre
pressures immediately aft~r the vehicle has
been used, or
an inaccurate setting will result.
Front tyres may wear unevenly as a result of
wheel misalignment.
Most tyre dealers and
garages can
check and adjust the wheel
alignment (or "tracking") for a modest charge.
Incorrect camber or castor
Repair or renew suspension parts
Malfunctioning suspension
Repair or renew suspension parts
Unbalanced wheel
Balance tyres
IncolTect toe setting
Adjust front wheel alignment
No te: The feathered edge of the tread which
typifies toe wear
is best checked by feel.
I

Screen washer fluid level
Screenwash additives not only keep the
winscreen clean during foul weather, they also
prevent the washer system freezing in cold
weather -which
is when you are likely to need it
most. Don't top up using plain water
as the
screenwash will become
too diluted, and will
Weekly checks 0-15
freeze during cold weather. On no accountuse
coolant
antifreeze in the washer system -
this could discolour ordamage paintwork.
1 The reservoir for the windscreen and rear
window (where applicable) washer
systems is located
on the front left-hand
side of the engine compartment.
If topping-up
is necessary, open the cap.
2 When
topping-up the reservoir(s) a
screenwash additive should be added in
the quantities recommended
on the bottle.
Power steering fluid level
Before you start
..... Park the vehicle on level ground.
..... With the engine idling, turn the steering
wheel
slowly from lock to lock 2 or 3 times
an d set the front wheels at the straight-ahead
position, then stop the engine.
1 The
power steering fluid reservoir is
located
on RHD vehicles on the left-hand
side of the engine compartment between
t
il e transmission and the bulkhead. On LHD
vehicles, the reservoir is located between the
engine and bulkhead on the right-hand side
of
the engine compartment. The fluid level
should be checked with the engine stopped.
Note: 01') Zafira models, first remove the
plastic
water deflector from in front of the
windscreen.
For the c heck to be accurate,
the steering mu st not be
turned once fhe engine has
been stopped .
2 Unscrew the filler
cap from the top of the
reservoir.
On TRW manufactured units,
the dipstick is incorporated into the filler
cap, whilst Delphi manufactured units have
the dipstick incorporated into the filter
immediately below the filler cap. Wipe
all fluid
from the
dipstick with a clean rag. Refit the
dipstick, then remove it again. Note the fluid
level
on the dipstick.
Safety First!
• The need for frequent topping-up indicates
a leak, which should be investigated
immediately.
3 When the engine is cold, the fluid level
should be between the upper and lower
marks on the
dipstick . Top up the fluid
level using the specified type of fluid (do not
overfill the reservoir), then refit and tighten the
filler cap.

0-16 Weekly checks
Wiper blades
1 Check the condition
of the wiper blades;
if they are cracked
or show any signs of
deterioration,
or if the glass swept area is
smeared, renew them. Wiper blades should
be renewed annually.
2 To remove a
wiper blade, pull the arm
fully away from the glass until it
locks .
Swivel the blade· through 90°, then
squeeze
the locking clip , and detach the
blade from the arm. When fitting the new
blade, make sure
that the blade locks
securely into
the arm, and that the blade is
orientated correctly.
Battery
Caution: Before carrying out any work on
the vehicle battery,
read the precautions
given in 'Safety first!'
at the start of this
manual.
V Make sure that the battery tray is in good
condition , and that the clamp is tight.
Corrosion
on the tray, retaining clamp and the
battery itself can be removed with a solution
of water and baking soda. Thoroughly rinse
all
cleaned areas with water. Any metal parts
damaged by corrosion should be covered
with a zinc-based primer, then painted.
V Periodically (approximately every three
months),
check the charge condition of the
battery
as described in Chapter 5A.
V If the battery is flat, and you need to jump
start your vehicle, see Roadside Repairs.
Batt ery corrosion ca n be k ep t to a
minimum by app ly ing a layer of
petroleum jelly to the clamps an d
terminals
after they are reconnected.
The battery is located on
the left-hand
side of the engine compartment. Unclip
the fabric cover from the top of the
battery (if fitted) for access to the terminals.
The exterior
of the battery should be
inspected periodically for damage such as a
cracked case or cover.
3 If corrosion (white, fluffy deposits) is
evident, remove
the cables from the
battery terminals, clean them with a small
wire brush, then refit them. Automotive stores
sell a tool for cleaning the battery post
.. .
2 Check the tightness
of battery clamps (A)
to ensure good electrical connections .
You should
not be able to move them.
Also
check each cable (8) for cracks and
frayed conductors.

Electrical systems
tI' Check all external lights and the horn. Refer
to the appropriate Sections of Chapter 12 for
details
if any of the circuits are found to be
inoperative.
1 If a single
indicator light, stop-light or
headlight has failed, it is likely that a bulb
has blown and will need
to be replaced.
Refer to Chapter 12
for details. If both stop- .
lights have failed, it is possible that the switch
has failed (see Chapter
9).
-
-
-~-
tl'Visually check all accessible wIring
connectors, harnesses and retaining clips for
$ecurity, and for signs
of chafing or damage.
2
If more than one indicator light or
headlight has failed, it is likely that either
a fuse has blown
or that there is a fault in
the circuit (see Chapter 12). On Zafira models,
the main fuses are located beneath a cover on
the driver's side of the facia between the
steering column and the drivers' door . Pull out
and remove
the cover, then pull out the
bottom of the fusebox. On Astra models, the
main fuses are
located next to the steering
column behind the storage compartment.
Open the compartment, squeeze the lugs at
each side, pull the compartment down
to its
full extent and detach it. Remove the fixing
screws and
remove the storage compartment
frame, then pull
out the bottom of the
fusebox. Additional fuses and relays are
located in the left-hand side of the engine
compartment.
Weekly chec ks 0-17
;;
If you need to c heck your
_ bra ke lights and Ind icators
HINT •.maided, ba ck up to a wall or
garage door an d operatethe
IIg"t$. The reflectedlightshould show if
theyare working propet'Jy,
3 To replace a blown fuse, remove it, where
applicable, using
the plastic tool
provided. Fit a new fuse of the same
rating, available from car accessory shops. It
is important that you find the reason that the
fuse
blew (see Electrical fault finding in
Chapter 12).

0-18 Lubricants, fluids & tyre pressures
Lubricants and fluids
Engine ... ..... . . .......... . . .... .... , ...... .... .. . Multigrade engine oil, viscosity SAE 5W/40, 10W/40 or
15W/40, to ACEA A2-96 or A3-96
Cooling system .. . ....... .. ............. .. .. ... . . . . . Vauxhall Anti-Freeze GM L 1301
Manual gearbox ... .... . .... . . .... ......... . . . . . ... .
Automatic transmission . ...... .. ...... . ....... . ..... .
Power steering reservoir .... .... .. . ........ ..... .... .
Brake and clutch fluid reservoir ... ... ...... . . . ..... . . .
Gear oil, Vauxhall part number 09 120 541 or 09 540 998
Automatic transmission oil, Vauxhall part number
09117946
Special steering fluid, Vauxhall part number 90 544 116
Hydraulic fluid
to SAE J1703, DOT 4
Choosing your engine oil
Engines need oil, not only to lubricate moving
parts and minimise wear, but also
to
maximise power output and to improve fuel
economy.
HOW ENGINE OIL WORKS
. •
Beating friction
Without oil, the moving surfaces inside your
engine will rub together, heat up and melt,
quickly causing the engine
to seize. Engine oil
creates a film which separates these moving
parts, preventing wear and heat build-up.
• Cooling hot-spots
Temperatures inside the engine can exceed
10000
C. The engine oil circulates and acts as
a coolant, transferring heat from the hot-spots
to the sump.
• Cleaning the engine internally
Good quality engine oils clean the inside of
your .engine, collecting and dispersing
combustion depos i ts and controlling them
until they are trapped by the oil filter
or flushed
out at oil change.
Tyre pressures (cold)
OIL CARE -FOLLOW THE CODE
To handle and dispose of used engine oil
safely, always:
OIL CARE
9;
Avoid skin contact
with used engine oi/.
Repeated or prolonged
contact can be harmful.
Dispose of us . ed oil
and empty packs in a
responsible manner in an
authorised disposal site.
D J I I I .! I J • I Call 0800 663366 to find
0800 66 33 66 the one nearest to you.
..... oIlb ••• " •• • _.uk Never tip oil down drains
or onto the ground.
Note: Pressures apply to original-equipment tyres, and may vary if any other make or type of tyre is fitted; check with the tyre
manufacturer
or supplier for correctpressures if necessary. The pressures are given on the inside of the fuel filler flap.
Astra
All models except 2.0 litre engine (all tyre sizes):
Up to 3 persons
............ . ................. .. ..... • ...
Fullload ... .... ..... . ...... . . .. ... .•. .. ....... . . .. .. ...
2.0 litre engine models:
195/60 tyres: •
Up to 3 persons . . . .
... . . .. .. . .. . ......... ... ..... . . .. .
Full load
... ' " ... . . ....... . .. . . . . . . ...... . ..... .•.. .. . . .
205/50 tyres:
Up to 3 persons .... .... ... ... .. . .. . ... ; .. . . ........ . . .
Full load
.... '. ..... . ...... . .. . .. ..... .... . ... .. ... .... .
Zafira
All tyre sizes:
Up to 3 persons
.. . ....... ... ..... . ..... . ... ... ... . .... , ..
Fullload ... . ... .. ........ .. ..... . . . .. .......... .. .. . .. .
Front
Rear
2.2 bar
(32 psi) 1.9 bar (28 psi)
2.4 bar
(35 psi) 2.81bar
(41 psi)
2.2 bar
(32 psi) 1.9 bar (28 psi)
2.3 bar
(33 psi) 2.8 bar (41 psi)
2.3 bar
(33 psi) 2.0 bar (29 psi)
2.5 bar
(36 psi) 2.9 bar
(42 psi)
2.2 bar
(32 psi) 2.2 bar (32 psi)
2.6 bar
(38 psi) 3.0 bar
(44 psi)

Chapter 1
Routine maintenance and servicing
Contents
Air cleaner element renewal ........ .... . . . ... . .......• .... . 22
Automatic transmission fluid level check . . . .. .............. .. 21
Au x il iary drivebelt check and renewal . . . . . . . . . . . . . . . . . . . . . . . . 5
Body corrosion check . . ............ .... ..... . ... .. ... . ... 9
Brake (and clutch) fluid renewal . .... .. . ... . ..... . . .. . . . . ... 26
Coolant renewal ............. ... ............ . . . . .. . . . .... 28
Electrical systems check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 7
Engine oil and filter renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 4
Exhaust emission check ' .. .. ....... .. . .. . . . . ......... .. : .. 6
Front brake pad and disc check ............ . . ... . .. . .. . ... . to
Fuel filter renewal . .. .. . .. ... ...... .. . . . .. . . ...... . .. .. ... 23
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
Handbrake adjustment check . .. .. .. ... .... . .... ... .. .. .... 12
Headlight beam alignment check .: .. .. .. . ..... . . ... .. ... ... 8
Degrees of difficulty
Hinge and lock lubrication .. ... . .. ... .. . ....... . ... .... . . .. 18
Hose and fluid leak check ... . . ...... . . . . .. . ... . . .. . .. . .. .. 13
Pollen filter renewal ....... . . .. .............. .. .. . ... . . . .. 16
Rear brake pad and disc check .. . ..... . . . . ... . .. ........ . .. 11
Rear brake shoe and drum check ....... .... . .... ......... .. 19
Rear suspension level control system check ...... . . ......... . 15
Regular maintenance
... .. .. ........... .. . , . • . . . . ~ . . . . . . .. 2
Remote control battery renewal .. . . . .. .... .. . ...•...... . .. . 27
Road test ...... .. . ....... .. . ...... . .. .. . ..... ...... .... 17
Service indicator reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3
Spark plug renewal and ignition system check .. . . . .. .. ... .. ... 24
Suspension, steering and driveshaft gaiter check .. .. ... . ... ... . 20
Timing belt renewal . . ... . ... ............ . ........ . ... .... 25
Wheel bolt tightness check ... ......... . . .. . . . . . • .......... 14
Easy, suitable for
novice with little
experience
~ Fai1y easy, suitable ~
~ for beginner with ~
~ some experience ~
Fairty difficult, ~
suitable forcompetent ~
DIY mechanic ~
Difficult, suitable for ~
experienced DIY ~
mechanic ~
Very difficult, ~
suitable for expert DIY ~
or professional ~

1-2 Servicing specifications
Lubricants and fluids. ..... ..... .... ................... Refer to Weekly checks on page 0-18
Capacities
Engine oil
Including oil filter:
1.4 litre engines .
... ..... .. .... .. . . ... ... . . . . . ... ... .. .. . .
1.6 litre:
SOHC with air conditioning
... ... . . .. . . .... . . . . . .. ... .... .
All other engines
......... . . .. ... ..... . . .. . . . . . . . . . .... .
1.8 and 2.0 litre engines
..... ............ . .... . . ... . .. . •.. .
Difference between MIN and MAX on dipstick . .
.... .. ... . .. . .. .. .
Cooling system
Astra models:
1
A litre engine ................................... . . . .. . .
1.6 litre SOHC engine
....... ... . . . . . . . . . .... . .... .. .. . ... .
1.6 litre DOHC engine
...... .. ... : ... •.. . .... . .. . . .. .......
1 .8 litre engine . . . ......... . .. . ... .. .. . ... .... . . .. . . . . .. .
2.0 litre engine
..... .. . . . . .. .. . ...... . .. ..... . ....... .. . . .
Zafira models:
1.6 litre engine
..... .. . . . .
1.8 litre engine
Transmission
Manual transmission:
3.
25 litres
3.5 litres
3.25 litres
4.25 litres
1.0 litre
Without air conditioning
6.3 litres
5.9 litres
6.3 litres
6.3 litres
7.0 litres
6.3 litres
6.5 litres
All except 2.0 litre engine
.. ... . . . ...... . . .... . .. .. . .. ...... 1.6 litres
2.0 litre engine .
... . ................ . ...... ... .. .. .. . . .... 1.8 litres
Automatic transmission
(at fluid change) ..... . . . . ... ...... ... . .. 4.0 litres
Washer fluid reservoir
Without headlight washers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . . 2.3 litres
With headlight washers
....... • . .. ... .. .. . .. . . • . . .... . ...... 4.5 litres
Fuel tank
Astra models . . . ..... • ...... . . . . ..... . .. . . . . ..... . .........
Zafira models
Cooling system
Antifreeze mixture:
52 litres
58 litres
50% antifreeze
.. ... .. .. . ... . .. .... ... ..... .. . ..... .. .. .. Protection down to -37°C
55% antifreeze
.. .. ........... . . . . . .. .. :......... .. . .. ... Protection down to -45°C
Note: Refer to antifreeze manufacturer for latest recommendations.
Ignition system
Spark plugs: . Type
All engines ...•. . . ... .... .. ' " " . . . . , .. .. . . ... . .... , .... . Bosch FLR 8 LD+U
Brakes
Friction material minimum thickness:
Front and rear brake pads
.... ... ... ... .• ........ . . . . . . ....
2.0 mm
Rear brake shoes
., ........... . . .. .... ........ . . . .. . 1.0mm
Torque wrench settings
Nm
Engine oil filter (spin-on canister type) ........ .... . . . ......... . . 15
Engine oil filter housing cap (element type) . ... . ......... . ...... . 15
Engine oil filter housing-to-block.bolt (element type) ... .. ... . ... . . .
45
Ignition module retaining screws .... . ... . . ........ .. . . .. . . ... . 8
Roadwheel bolts
.. .. . ............ .. .. ..... . . .... . . . . .. ... . . 110
Spark plugs ...
.. .. . . .. . . . . .. . . .... . . . . .. ... ...... . . .. .. .. . 25
Sump drain plug:
SOHC engines:
Models without air conditioning (pressed-steel sump)
........ . . 55
Models with air conditioning (alloy sump) .. . .......... . . . ... .
45
DOHC engines:
1.4, 1.6 and 1.8 engines:
Inner Torx type (rubber seal ring) .
.. . ... ........ . . .. . . .. . 14
Hexagon type (metal seal ring) .
.. .. . ... ..... ....... . ... . 45
2.0 litre engine ...... . . . . .. . .......... . . . ... . . ........ . .
10
With air conditioning
6.6 litres
6.2 litres
6.6 litres
6.6 litres
7
.2 litres
6.6 litres
6.8 litres
Electrode gap
1.0mm
Ibfft
11
11
33
6
81
18
41
33
10
33
7

Maintenance schedule 1-3
Maintenance schedule
1 The maintenance intervals in th is manual perform some of these procedures more more frequent maintenance intervals are
recommended.a
re provided with the assumption that you, often. We encourage frequent maintenance,
not the dealer, will be carrying out the work. because .it enhances the efficiency, 3
Wh en the vehicle is new, it should be
serviced by a factory-authorised dealer
servict;!
department, in order to preserve the factory
warranty.
These are the minimum maintenance intervals performance and resale.value of your vehicle.
re commended by us for vehicles driven daily. 2 If the vehicle is driven in dusty areas, used
If you wish to keep
your vehicle in peak to tow a trailer, or driven frequently at slow
condition at all times, you may wish to speeds (idling
in traffiC) or on short joumeys,
Every 5000 miles (7500 km) or
6 months, w hi chever comes fir st
o Renew the eligine oil and filter (Section 4)
Note: Vauxhall recommend that the engineoil and filter ate changed
ev ery 10 000 mIles ( 15000 kin) or 12 montl1S . However. of( and filter
c han g es are good for theengine end we recommend that the 0 /1 and
filter are
re newed mot e ffaquentl y. ~s p ecI8/ly if the vehiCle is used cm
s lot of short joumeys.
Every 10 000 miles (15 000 km) or
12 months, w
hi chever comes first
::J Check the co ndition and tension of the auxiliary
drivebelts (Se
cti on st
Q Exhaust emission test (Section 6)
o Check the operation of a ll electrIcal systems
(Se ctien 7)
::J Ch eck and Ifnecessary adjust the headlight beam
alignment
(S ection 8)*
=:J Che ck the bo dy and underbody for corrosion
prot ection (Seotion 9)*
:J Ch eck the front br ake p ads and discs for wear
(S ection 1 0)
~ Ch eck therear brake pads and dIScs (where
applicabl
e) for wear (Section 11)
o Ch ec k and if necessary adjust the handbrake
(Section 12)'
o Check a ll components, pipes and hoses for fluid
leaks (Section
~ 3,.
o Che ck the roadwheel bolts are tightened to the
sp ecified t or que (S eotion 14)
o Check the rear sl)spension level control system
(Section 15)
:J Ren ew the pollen filter (Section 16)
Note: If th e vehicle is us ed in dusty conditions. the pollen flIter
should be renewed more freq
ue ntlv.
:J Carry o ut a road test (Seotlon 17)
• On vehi cl es c overi ng ahi g/ )m il ea ge (more than 20 000 ml/e$/30 000 km
aI'l nuall y) car ry out the ite ms marl<e<i with af! astens){ every 20 000 miles
(30000 k m).
Every 20 000 miles (30 000 km) or
2 years, whichever comes first
Lubricate all door loc ks and hinges, doo r stops,
bonnet la
ck and release, and tailga te lo ck and
hin
ges (Section 18)
o Check the rear brake shoes and drums (where
applicable) f
or wear (Section 19)
o Check the steering and suspension co mponents
for con dit ion and security (Section 20)
o Check the condition of the drlvesha ft gaiters
(S
ec tion 20)
Check
the au tQ matic transmission fluid level
(S ection 21)
Every 40 000 m il es (60 000 km) or
4 years, whichever comes first
o Renew th e air clean er element (Sec tl on 22)
Renew the fuel f
il ter (Section 23)
o Re n ew the sp ark plugs and check the ignition
system (Section
24 )
o Renew the timing belt (Section 25)
Note: Aithough the norme1 interval for tIming b8It renewslIS 80 000 m iles
(120 000 krrV or 8 yeiJl"S, it is strongly recom(Tlflnded that the intef1lalls
halved to 40 000 m l/S$ (60 000 km) or 4 years on veh, cles whIch a re
subjected to intensive use, le. maInly sIIort Journeys or a lotof stop-start
driving. The aCIJJal belt renewal Interval is therefore very much uP to the
Individual awner. bur bear In mInd that severe engine damage will res ult
if the belt b reaJ<s .
Every 2 years, re ga rd less of mileage
o Renew the brake (and clutch) fluid (Se ct ion 26)
o Ren ew th e remote control batteries (Section 27)
U Renew
the coo lant (Section 28)