Table Of Contents - Opel 1991 Astra Workshop Manual

Table of Contents

Definition Of Procedures3
Lifting Points For Lifting Equipment3
Safety Notice4
Maintenance, Body And Chassis Sheet Metal Parts5
Table Of Contents6
Body And Chassis Sheet Metal Parts - General Instructions8
Safety Measures9
Body Repair Using Cementing9
Legend For Welding Operations11
Welding Seams11
Plug Spot Welding12
Stitch Seam Spot Welding12
Full Seam12
Body Dimension Chart13
Body Dimension Table19
Trim Panels, Trim Panel Parts, Spoiler20
Front Panelling - Remove And Install20
Front Panelling - Replace21
Radiator Grille - Remove And Install22
Wheel Well Inner Panelling - Remove And Install22
Cowl Panel - Remove And Install23
Outer B Pillar Panel - Remove And Install24
Rear Panelling - Remove And Install (Kadett)24
Rear Panelling - Remove And Install (Astra)25
Rear Spoiler - Remove And Install (Kadett)25
Rear Spoiler - Remove And Install (Kadett 200Is And 200Ts)26
Rear Spoiler - Install (Astra)27
Tailgage Trim Strip - Remove And Install (Kadett 200Is And 200Ts)29
Sheet Metal Parts - Bolted30
Wing - Remove And Install30
Bonnet, Bonnet Functioning Parts - Remove And Install31
Bonnet Hinge - Replace32
Tailgate - Remove And Install33
Luggage Compartment Lid - Remove And Install (Astra)34
Hinge Bow, Luggage Compartment Lid - Replace (Astra)34
Sheet Metal Parts - Welded36
Front Member (Radiator Crossmember) - Replace/Replace Partially36
Front Member Centre - Replace37
Air Deflector Panel Assembly - Replace Partially38
Side Bracket For Front Panelling - Replace39
Front Wheel Well - Replace Completely39
Wheel Well And Front Frame Side Member - Replace Partially40
Control Arm Brace - Front Frame Side Member - Replace41
A Pillar - Replace41
B Pillar - Replace43
Door Still Panelling, Replace44
Outer Panelling, Door - Replace45
Outer Panelling, Tailgate - Replace45
Rear Quarter Panel - Replace (Kadett)47
Separation Points, Welding Information, Attaching Parts To Be Removed47
Rear Quarter Panel, Replace (Astra)48
Rear Quarter Panel - Replace Partially (Astra)49
Rear Section Of Inner Rear Quarter Panel - Replace Partially (Kadett)50
Rear Section Of Inner Rear Quarter Panel - Replace Partially (Astra)51
Lower Rear End Panel - Replace Completely (Kadett)53
Lower Rear End Panel - Replace Partially (Kadett)54
Lower Rear End Panel - Replace Completely (Astra)54
Lower Rear End Panel - Replace Partially (Astra)55
Rear Side Member Ends, Replace Both (Kadett)56
Rear Side Member Ends, Replace (Astra)57
Roof Panelling - Replace (Kadett)58
Roof Panelling - Replace (Astra)59
Special Service Tools60
Paint63
Paint - General Information64
Negative Influences On Vehicle Paint65
Paint Repairs66
Procedure For Paint Repairs67
Vehicle Identification Plate68
Painting Of Plastic Parts68
Explanation Of Time Allowance Painting Stages I, Ii And Iii69
Body Equipment71
Glass, Window Guides, Window Winders73
Windscreen - Remove And Install Or Replace73
Tailgate Screen - Remove And Install Or Replace (Kadett)75
Rear Screen - Remove And Install Or Replace (Astra)77
Retaining Plate For Rear View Mirror, Service Cement79
Front Door Sash Window (Manual/Electric Actuation) Remove And Install80
Rear Door Sash Window Remove And Install81
Front Door Window Actuation (Manual) - Remove And Install81
Front Door Window Actuation (Electric) - Remove And Install82
Rear Door Window Actuation - Remove And Install83
Door Upper Window Guide Remove And Install83
Rear Quarter Window - Remove And Install84
Trim Mouldings, Letterings, Fittings, Hinges85
Front Door Outer Handle - Remove And Install85
Front Door Lock Cylinder - Remove And Install85
Front Door Lock - Remove And Install86
Rear Door Outside Handle - Remove And Install86
Rear Door Lock - Remove And Install87
Tailgate Outside Handle (Kadett) - Remove And Install87
Luggage Compartment Lid Outside Handle (Atra) - Remove And Install87
Tailgate Lock Cylinder (Kadett) - Remove And Install88
Luggage Compartment Lid Lock Cylinder (Astra) - Remove And Install88
Tailgate Lock - Remove And Install88
Luggage Compartment Lock (Astra) - Remove And Install89
Glove Compartment Lid Lock Cylinder - Remove And Install89
Tailgate Hinge - Remove And Install90
Side Protective Trim Strips - Replace90
Roof Cover Strip - Remove And Install91
Seats, Upholstery, Inner Panelling92
Front Door Inner Panelling - Remove And Install92
Rear Door Inner Panelling - Remove And Install92
Rubber Door Seal - Remove And Install Or Replace93
Still Panelling Seal - Remove And Install94
Front Seat - Remove And Install95
Belt Lock Tensioner - Remove And Install Or Replace96
Front Seat Backrests - Remove And Install98
Rear Seat - Remove And Install99
Rear Seat Backrest - Remove And Install99
Headrest Guide Sleeve - Remove And Install100
Rear Seat Headrest - Service Install101
Upholstery Cover For Front Seat - Remove And Install Or Replace101
Upholstery Cover For Front Seat Backrest - Remove And Install/Replace102
Upholstery Cover For Rear Seat - Remove And Install Or Replace103
Upholstery Cover For Rear Seat Backrest - Remove And Install/Replace103
Upholstery Cover For Armrest - Remove And Install Or Replace104
Moulded Headlining - Remove And Install Or Replace105
Instrument Panel Padding - Remove And Install105
Centre Console - Remove And Install107
A Pillar Upper Panelling - Disconnect And Connect107
B Pillar Panelling (Kadett) - Remove And Install107
C/D Pillar Panelling Remove And Install108
Sill Panelling, Front Disconnect And Connect109
Sill Panelling, Rear - Remove And Install109
Rear End Panel Shelf (Astra) - Remove And Install110
Rear Quarter Panelling, Rear (Kadett) - Remove And Install110
Rear Quarter Panelling, Rear Section (Astra) - Remove And Install110
Rear Wheel Well Panelling (Astra) - Remove And Install111
Rear End Lower Panelling - Remove And Install111
Tailgate Panelling - Remove And Install112
Seat Belt, Front - Remove And Install Or Replace113
Seat Belt, Rear - Remove And Install Or Replace114
Body Equipment: Recommended Torque Values119
Heating And Ventilation121
Air Conditioning122
Arrangement Of Components For Mixed Air Heating124
Ventilation Nozzle Inset - Remove And Install125
Ventilation Nozzle Housing - Remove And Install (Driver's Side)125
Ventilation Nozzle Housing, - Remove And Install (Passenger Side)126
Cover, Centre, - Remove And Install127
Heating Operating Unit - Remove And Install130
Mixed Air Flap Between Cable - Replace131
Bowden Cable For Upper Air Distribution - Replace131
Bowden Cable For Lower Air Distribution - Replace132
Heater Core - Remove And Install134
Heater Core (Air Conditioning) - Remove And Install135
Air Distribution Housing - Remove And Install137
Fan Motor - Remove And Install139
Fan Housing - Remove And Install139
Fan Motor Series Resistor - Replace140
Mixed Air/Ac Switch - Remove And Install140
Switch For Fan/Heated Rear Screen - Remove And Install141
Mixed Air Actuation Vacuum Unit - Replace141
Air Conditioning - General Instructions For The Repair And Storage142
Safety Regulations For Handling Refrigerant143
Air Conditioning Arrangement144
Air Distribution In Vehicle145
Air Conditioning Operating Controls146
Adjusting The Cooling Functions146
Maximum Cooling146
Normal Cooling146
Air Cooling With Temperature Levels147
Demisting And De-Icing Window Panes147
Glove Compartment Refrigeration147
Refrigerant Circuit148
Description Of Refrigerant Circuit149
Compressor150
Circuit Diagram - Compressor151
Compressor Lubricant152
Design Of Compressor152
Displacement Variation153
Performance Control And Functioning Of Control Valve154
High/Low Performance Requirement155
Condenser156
Accumulator157
Operation Of Harrison Accumulator/Dehydrator157
Orifice Valve158
Evaporator158
Air Distribution In Air Distribution Case159
Booster Fan160
Service Connections161
Moisture In Refrigerant Circuit161
Lead Detection In Refrigerant Circuit162
Air Conditioning, Drain Inspection163
Air Conditioning, Drain Install, Connect, Remove, Disconnect165
Air Conditioning, Evacuate And Charge166
Accumulator - Remove And Install167
Condenser - Remove And Install Accumulator - Replace167
Booster Fan - Remove And Install170
Evaporator - Remove And Install170
Pipes And Hoses172
Pipe And Hose Lines - Remove And Install172
Location Of Switches173
Triple Switch174
Terminal Assignment174
Low/Low Pressure Safety Switch174
Motronic Switch - Engine Speed Increase Switch174
Switch System Block Diagram175
Coolant Temperature Switch - Replace176
Triple Switch - Replace176
Motronic Switch - Replace176
Compressor - Remove And Install176
Compressor Clutch - Replace180
Compressor Pulley Assembly - Replace181
Compressor Safety Valve - Replace182
Compressor Control Valve - Replace182
Valve - Glove Compartment Cooling - Replace183
Heating And Ventilation - Technical Data187
Frame, Front Wheel Susp. Wheels And Tyres189
Frame - General Information190
General Notes For Underbody Repair190
Quick Measure Method191
Instructions For Use Of Checking And Straightening Bench Systems193
Underbody Dimensional Chart - View From Below194
Left Side Member - On Front Axle Body With Short Outrigger195
Right Side Member - On Front Axle Body With Short Outrigger196
Left Side Member - On Front Axle Body With Long Outrigger197
Right Side Member - On Front Axle Body With Long Outrigger198
Vehicle Front - Mounting Points View199
Vehicle Rear - Mounting Points View200
Front Axle - With Long Outrigger201
Front Wheel Suspension General Information202
Camber, Caster And Toe-Out - Check202
Toe-Out - Adjust203
Axle Driving Shaft, Wheel Bearing, Front Wheel Hub - Remove/Install204
Axle Driving Shaft, Remove And Install Completely207
Joint Of Axle Driving Shaft - Remove And Install Individually211
Folding Covers Of One Axle Driving Shaft - Remove And Install212
Spring Strut, Remove And Install212
Spring Strut Disassembly213
Support Bearing - Remove And Install215
Front Spring And/Or Damper Rings - Remove And Install215
Spring Strut Cartridge - Remove And Install216
Control Arm - Remove And Install218
Damping Bushings In Control Arm - Remove And Install220
Ball Joint On Control Arm - Remove And Install221
Front Axle Body - Remove And Install222
Front Axle Body - Transfer222
Stabilizer - Remove And Install225
Pendulum - Remove And Install226
Wheels And Tyres Information226
Wheel Balancing227
Front And Rear Wheels - Electronically Balance228
Tyre Sizes And Pressures230
Front Wheel Adjustment235
Radial/Lateral Runout235
Frame, Front Wheel Susp., Wheels And Tyres - Torque Values236
Rear Axle And Rear Wheel Suspension238
Rear Axle And Rear Wheel Suspension - General Information239
Rear Axle With Drum Brake View240
Rear Axle - With Disc Brake241
Rear Axle Alignment, Camber And Toe-In, Check242
Tilt Play At Wheel Bearing243
Wheel Bearing Unit With Disc Brake243
Wheel Bearing Unit With Drum Brake244
Radial And Lateral Runout, Measure244
Rear Axle, Remove And Install246
Rear Axle, Modify246
Rear Axle Damping Bushings, Replace249
Rear Springs And/Or Damping Rings Of Rear Springs - Remove And Install251
Rear Wheel Hub (Disc Hub), Replace One252
Wheel Spindle, Remove And Install Or Replace256
Wheel Berings Of Rear Wheel Hub (Disc Hub), Replace Both256
Seal Ring Or One Rear Wheel Hub (Disc Hub), Replace258
Shock Absorber And/Or Rubber Buffer Of Shock Absorber - Remove/Install260
Stabilizer, Remove And Install261
Additional Stabilizer, Remove And Install261
Rear Axle And Rear Wheel Suspension Technical Data264
Rear Axle And Rear Wheel Suspension - Torque Values265
Engine - Index266
Engine - Illustrations272
Engine Timing View272
Engine Longitudinal Section273
Engine Checking And Adjusting Operations278
Engine - Recommended Torque Values278
V-Belt Tension - Check And Adjust279
Ribbed V-Belt Tension - Check And Adjust280
Compression - Check280
Engine Pressure Loss - Check282
Engine Oil Temperature - Measure283
Engine Oil Pressure - Check284
Engine Oil Consumption - Measure284
Timing, Check And Adjust - 1,4/1,6 Ltr.286
Timing - Check And Adjust - 1,8/2,0 Ltr.288
Toothed Belt - Install And Tension289
Engine Timing Side View292
Rear Toothed Belt Cover - Remove And Install293
Toothed Belt - Replace295
Toothed Belt Tension Roller - Replace296
Cylinder Head, Camshaft Housing298
Hydraulic Valve Lash Adjustment299
Hydraulic Valve Tappet300
Rear Seal Ring In Camshaft Housing - Replace301
Front Seal Ring In Camshaft Housing - Replace302
Gasket - Exhaust Manifold/Cylinder Head - Replace303
Gasket - Intake Manifold/Cylinder Head - Replace304
Hydraulic Valve Lash Adjuster - Replace307
Fuel Pump - Replace (14 Nv)308
Camshaft And Rocker Arm - Remove And Install308
Camshaft Housing - Replace310
Strainer (Filter) In Camshaft Housing Cover - Clear311
Spark Plug Thread - Recondition312
Cylinder Head - Remove And Install312
Cylinder Head - Disassemble And Assemble316
Cylinder Head - Overhaul317
Valve - Grind318
Valve Guide - Ream318
Valve Seating - Mill319
Cylinder Head - Check For Plane Surface320
Crank Drive - Recommended Torque Values321
Starter Ring Gear - Replace321
Drive Disc - Remove And Install - 18Se Only322
Seal Ring - Crankshaft - Front (In Oil Pump Housing) - Replace323
Seal Ring - Crankshaft - Rear - Replace (1,6 Ltr. Engine)324
Seal Ring - Crankshaft - Rear - Replace (Mt Exc. 1,6 Ltr. Engine)325
Piston With Con-Rod - Remove And Install (Engine Installed)327
Piston Rings - Replace328
Engine Block - Check For Plane Surface329
Con-Rod Bearing - Replace330
Con-Rod - Replace330
Crankshaft - Remove And Install332
Crankshaft - Check334
Flywheel - Remove And Install336
Recommended Torque Values - Oil Circuit337
Oil Filter Cartridge - Replace337
Bypass Valve - Replace338
Oil Pump - Remove And Install338
Oil Pump - Check339
Oil Pump Safety Valve - Replace339
Cooling System - Recommended Torque Values340
Radiator - Remove And Install340
Cooling System - Top Up And Bleed341
Cooling System - Check For Leaks342
Coolant Temperature - Measure With Closed Cooling System342
Fan Motor - Replace342
Thermostat - Replace - 1,4/1,6 Ltr.343
Thermostat - Replace - 1,8/2,0 Ltr.344
Water Pump - Remove And Install344
Engine Damping Blocks, Engine, Short Block Engine346
Engine Damping Blocks, Short-Block - Torque Values347
Engine Without Transmission - Remove And Install (1,4/1,6 Ltr.)347
Engine - Repair Using Short Block352
New Short Block - Complete353
2 E 3 Carburetor - 14Nv356
Idle Speed And Co Content In Exhaust - Adjust356
Fast Idle - Check And Adjust356
Pulldown Unit - Check357
Thermo Time Valve - Remove And Install358
Choke Valve Gap - Check And Adjust358
Choke Valve Forced Opening - Adjust359
Position Of Stepped Plate - Check And Adjust359
Choke Cover Position - Check360
Cold Start Adjustment, Throttle Valve Gap - Check And Adjust360
Basic Adjustment Of Throttle Valve - Stage Ii, Check361
Injection Quantity - Check And Adjust361
Accelerator Pump - Remove And Install362
Release And Forced Return - Stage Ii, Check And Adjust362
Pull Rod For Stage Ii - Check362
Vacuum Unit - Stage Ii - Check For Leaks363
Vacuum Unit - Stage Ii - Remove And Install363
Enrichment Valve, Remove And Install363
Choke Body - Remove And Install364
Pulldown Unit - Remove And Install364
2 E 3 Carburettor - Remove And Install364
Carburettor Cover - Remove And Install (Carburettor Removed)365
Float - Remove And Install365
Main Nozzles - Remove And Install366
Idler Nozzle - Remove And Install366
Pre-Atomizer - Remove And Install366
Accelerator Pipe - Remove And Install367
Float Level - Check368
Carburetor Actuation - Adjust368
Filter In Fuel Feed - Remove And Install368
Enrichment Pipe - Check And Adjust368
Troubleshooting Chart - 2 E 3 Carburettor369
Multitec Central Fuel Injection - C 16 Nz371
Arrangement Of Throttle Valve Injection Housing371
Control Unit - Remove And Install372
Throttle Valve Injectoin Housing - Remove And Install373
Throttle Valve Potentiometer - Remove And Install374
Injection Valve, Remove And Install374
Fuel Pressure Regulator Diaphragm - Remove And Install375
Fuel Pressure - Check375
Throttle Valve Injection Housing Upper Part - Remove And Install376
Idle Air Control Stepper Motor - Remove And Install376
Motronic M 1.5.4 Diagram378
Throttle Valve Potentiometer Remove And Install379
Idle Air Control Stepper Motor Remove And Install379
Fuel Pressure Check380
Fuel Pressure Regulator - Remove And Install380
Motronic M 1..5.4 (18 Se/20 Seh)381
Hot Film Mass Air Flow Meter - Remove And Install382
Fuel Pressure Regulator Remove And Install382
Idle Speed Adjuster - Remove And Install383
Throttle Body - Remove And Install383
Tank Vent Valve - Remove And Install385
Injection Valves - Remove And Install385
Bosch M1.5.4 - C 16 Se Diagram387
Intake Air Temperature Sensor - Remove And Install - C 16 Se388
Coolant Temperature Sensor - Remove And Install - C 16 Se388
Intake Air Temperature Sensor - Remove And Install - 16Nz/18Se/20 Seh388
Coolant Temperature Sensor - Remove And Install - C 16 Nz389
Coolant Temperature Sensor - Remove And Install - 18 Se/20 Seh390
Control Unit Remove And Install390
Intake Manifold Pressure Sensor - Remove/Install - C 16 Se, C 16 Nz391
Ignition Distributor - Remove And Install - 14 Nv, C 16 Nz392
Ignition Basic Adjustment - 14 Nv392
High Voltage Distributor - Remove And Install - 18 Se/20 Seh393
Ignition Coil - Remove And Install - 14 Nv, 18 Se/20 Seh393
Ignition Coil - Remove And Install - C 16 Nz394
Dual Spark Ignition Coil - Remove And Install - C 16 Se394
Inductive Pulse Pick-Up - Remove And Install - C 16 Se395
Gap Between Inductive Pulse Pick-Up And Increment Disc - Check395
Octane Number Plug, Code - All Except 14 Nv396
Bosch Starter View397
Bosch Starter With Reduction Gear View398
Starter - Remove And Install399
Starter - Check (Installed)400
Starter - Check (Removed And Disassembled) (Bosch)400
Field Winding - Replace402
Carbon Brushes - Replace (Bosch Starter)402
Bearing Bushings - Replace (Bosch Starter)403
Bosch Starter - Disassemble And Assemble405
Bosch Reduction Gear Starter - Disassemble And Assemble408
Bosch Alternator413
Alternator - Remove And Install414
Bosch Alternator - Check414
Bosch Alternator - Disassemble And Assemble416
Bosch Alternator - Overhaul421
C 20 Xe/E20 Let Engine Timing441
C 20 Xe Cross-Section View442
C 20 Xe/20 Let Longitudinal Section View443
C 20 Let - Side View444
C 20 Let - Cross-Section View445
C 20 Let - Engine Intake Side446
Engine Checking And Adjusting Operations - Torque Values447
Compression Check447
Engine Pressure Loss Check448
Engine Oil Temperature Measure451
Engine Oil Pressure Check451
Engine Oil Consumption - Measururing Method452
Timing - Check And Adjust453
Engine Timing Side - Air Cleaner Housing454
Toothed Belt Replacement455
Toothed Belt Tension Roller Replacement458
Toothed Belt Guide Roller Replacement459
Air Cleaner Housing - Remove And Install (C 20 Let)460
Cylinder Head - Recommended Torque Values460
Camshat Seal Ring Replacement461
Gasket - Intake Manifold/Cylinder Head Replacement (C 20 Let)461
Exhaust Camshaft - Replace Inlet Camshaft466
Camshaft Sprockets - Remove And Install468
Cylinder Head Remove And Install469
Cylinder Head Disassembly And Assembly475
Exhaust Valve (Sodium-Filled) Disposal479
Cylinder Head Overhaul479
Valve Guide Ream480
Valve Seat - Cut480
Rear Crankshaft Seal Ring - Replace482
Seal Ring - Rear Crankshaft - Replace (With Pot Flywheel)484
Crankshaft Front Seal Ring (Oil Pump Housing) Replace484
Piston With Con-Rod - Remove And Install487
Con-Rod Bearing Replacement488
Con-Rod Replacement488
Flywheel Remove And Install489
Pot Flywheel - Remove And Install490
Cylinder Block - Check For Plane Surface490
By-Pass Valve - Replace492
Oil Pump Remove And Install493
Gasket - Oil Pan - Replace495
Thermostat Replacement497
Oil Pump Safety Valve Replacement498
Cooling System Torque Values498
Seal Ring - Thermostat Housing/Cylinder Head - Replace499
Cooling System Top Up And Bleed500
Coolant Temperature Measuring With Closed Cooling System500
Water Pump Remove And Install501
Engine Damping Blocks - Engine - Short Block - Torque Values503
Engine With Transmission - Remove And Install (C 20 Let)504
Engine Repair Using Short Block513
New Short Block Complete516
Motronic M 1.5.4 (C 20 Xe)521
Throttle Body Remove And Install522
Throttle Valve Switch Remove And Install523
Throttle Valve Switch - Adjust523
Injection Valves Remove And Install523
Hot Wire Mass Air Flow Meter - Remove And Install526
High Voltage Distributor - Remove And Install526
Inductive Pulse Pick-Up - Remove And Install527
Knock Sensor - Remove And Install527
Ignition Coding Plug528
Idle Speed Adjuster Remove And Install529
Coolant Temperature Sensor Remove And Install530
Pre-Volume Chamber - Remove And Install531
Turbocharging System View (C 20 Let)532
Air Feed View532
Engine Exhaust Side - 2,0 Let533
Overall Survey Of Pressure And Vacuum Hoses Diagram534
Survey Of Pressure/Vacuum Hoses535
Survey - Turbocharger Attaching Parts537
Recommended Torque Values - Turbocharging System540
Turbocharging System - Important Repair Instructions540
Coolant Return Line (Turbocharger) - Remove And Install541
Coolant Feed Line (Turbocharger) - Remove And Install542
Charge Cooler - Remove And Install542
Water Cooler - Remove And Install543
Oil Return Line (Turbocharger) - Remove And Install544
Oil Feed Line (Turbocharger) - Remove And Install544
Gasket - Exhaust Manifold/Cylinder Head - Replacement544
Motronic M 2.7 (C 20 Let) Injection System View549
Throttle Body Removal And Installation552
Branch Piece Connection556
Throttle Valve Potentiometer Removal And Installation557
Injection Valves Removal And Installation557
Hot Start Valve - Remove And Install560
Hot-Wire Mass Air Flow Meter - Remove And Install560
Inductive Pulse Pick-Up Remove And Install562
Fuel Pump Relay - Remove And Install564
Idle Speed Adjuster Removal And Installation564
Tank Vent Valve Remove And Install565
Intake Air Temperature Sensor - Remove And Install566
Coolant Temperature Sensor - Remove And Install566
Bypass Valve - Charge Pressure Control - Remove And Install567
Ignition Coil - Remove And Install567
Starter Remove And Install568
Alternator Remove And Install568
Cooling System Technical Data583
Radiator Data583
Coolant Filling Quantity Anti-Freeze Mixture583
Toothed Belt Tension583
Engine Oil Viscosity584
Engine Oil Quality584
Engine Oil Filling Quantities584
Oil Pump Data584
Adjustment Values, Checknig Values585
Idle Speeds, Co Content, Ignition Adjustment585
Cylinder Head Data586
Valve Dimensions587
Valve Seat Machining589
Intake And Exhaust Camshafts Data589
Crank Drive590
Cylinder Grinding And Piston Dimensions590
Cylinder Bore Data593
Piston Data593
Connecting Rod Data593
Crankshaft Grinding Dimensions 20 Let596
Carburettor Data598
Injection Systems Data599
Starter Data600
Test Data (Bosch)600
Alternator Characteristics601
Recommended Torque Values - 1,4/1,6 Ltr. Engine603
Recommended Torque Values - 1,8/2,0 Ltr. Engine605
Recommended Torque Values - Dohc 16V - 2,0 Xe/2,0 Let606
Clutch - Manual Transmission And Automatic Transmission609
Manual Transmission View - F 10/5, F 13/5613
Differential F 10, F 13 View614
Manual Transmission F 16/5 View615
Differential F 16 View616
Manual Transmission F 20 View617
Differential F 20 View618
Clutch Assembly View619
Transmission Shift Linkage View620
F 28 Manual Transmission View621
Manual Transmission And Differential626
Transmission Identification626
Transmission Fluid Level Check627
Transmission Shift Linkage - Adjust628
Operations On Transmission Shift Linkage629
Manual Shift Lever - Remove And Install629
Rubber Cap For Manual Shift Lever - Remove And Install629
Shift Linkage - Remove And Install630
Folding Cover On Shift Linkage - Replace632
Shift Guide - Remove And Install633
Selector Rod - Replace633
Shift Linkage Lever - Remove And Install633
Shift Cover - Remove And Disassemble635
Shift Cover - Assemble And Install636
Sealing Operations On Installed Transmission638
Axle Shaft Seal Rings - Replace638
Rubber O-Ring For Speedometer Helical Gear (Driven) - Replace640
Gasket For Shift Cover - Replace641
Gasket For End Shield - Replace641
Gasket For Differential Cover - Replace643
Operations On Manual Transmission And Differential645
Switch For 1St Gear Recognition - Seal Or Replace645
Reversing Lamps Switch - Seal Or Replace645
Manual Transmission And Differential - Remove And Install646
Transmission Housing - Replace652
Differential, Overhaul656
Differential - Remove And Disassemble656
Differential Remove And Disassemble658
Differential - Assemble And Install662
Tapered Roller Bearing (Differential) - Prescribed Adjustment666
F 10/5, F 13/5 Manual Transmission View667
F 16/5 Manual Transmission View668
F 20/5 Manual Transmission669
Manual Transmission - Overhaul670
End Shield With Main Shaft And Drive Shaft - Remove And Disassemble670
Drive Shaft - Disassemble677
Main Shaft - Disassemble678
Main Shaft Disassemble679
Bearing Rings In Transmission Housing - Replace681
Bearing Rings In Transmission Housing Replacement683
Main Shaft - Assemble684
Drive Shaft - Assemble689
End Shield - Assemble690
Synchronizer Rings - Replace694
Drive Gears (Driving And Driven) - Remove And Install695
Drive Gear (Driving) - Remove And Install696
Speedometer Helical Gear - Remove And Install697
Clutch Disc And Pressure Plate - Remove And Install698
Clutch Pressure Bearing And Release Lever - Remove And Install703
Bearing Bushings For Clutch Release Lever - Remove And Install703
Clutch Cable - Replace704
Clutch Pedal - Remove And Install706
Automatic Transmission Af 20 View708
Converter And Bridge Clutch View709
Af 20 - Attaching Parts Diagram710
Af 20 - Housing Parts Diagram711
Automatic Transmission Af 20712
Transmission Fluid Level - Check714
Selector Lever Position Switch Check714
Selector Lever Position Switch - Adjust715
Fluid Pressure Check - Mechanical716
Operations On On Installed Transmission718
Electronic Control Unit - Remove And Install718
Selector Actuation Cable - Adjust718
Kickdown Switch - Adjust720
Solenoid Valves Or Fluid Pressure Regulator - Remove And Install720
Solenoid Valve Wiring Harness - Replace721
Axle Shaft Seal Rings Replacement721
Fluid Filler Pipe And/Or Gasket - Replace723
Speedometer Helical Gear (Driven) And/Or Seal Ring - Replace723
Sensor - Transmission Input/Output Speed - Remove And Install724
Fluid Temperture Sensor And/Or Gasket - Replace724
Fluid Cooler Lines, Connecting Hose And/Or Seal Rings - Replace725
Seal Rings For Check Bore (Fluid Pressure) - Replace725
Auxiliary Housing Cover And/Or Gasket - Replace726
Gasket For Side Cover - Replace726
Bulb/Socket For Lighting - Remove And Install728
Driving Mode Switch - Remove And Install "Winter" Mode728
"Sport" Mode729
Kickdown Switch - Remove And Install729
Selector Actuation Cable - Remove And Install730
Selector Lever Assembly - Remove And Install731
Selector Lever Console - Remove And Install732
Operations On Removed Transmission734
Converter And/Or Fluid Pump Seal Ring - Replace734
Housing Parts And/Or Gasket - Replace734
Transmission - Remove And Install736
Af 20 - Assemblies Diagram745
Transmission, Overhaul746
Assemblies - Remove From Transmission746
Attaching Parts From Transmission - Remove746
Fluid Pump Assembly Diagram758
Assemblies, Disassemble And Assemble759
Fluid Pump, Multi-Disc Brakes B1 And B2 - Ovehaul759
Freewheel F1 View766
Freewheel F1 Overhaul767
Multi-Plate Clutch C1 And C2 Assembly769
Planetary Gear Set Assembly P1770
Multi-Plate Clutch Assembly C1 And C2 - Overhaul771
Planetary Gear Set P1 - Overhaul775
Multi-Disc Brake B3 And Freewheel F2777
Multi-Disc Brake B3 And Freewheel F2 Overhaul778
Multi-Plate Clutch C3 And Freewheel F3 View780
Multi-Plate Clutch C3 And Freewheel F3 Overhaul781
Reduction Brake View785
Reduction Brake - Overhaul786
Intermediate Drive Gear View788
Intermediate Drive Gear - Check789
Planetary Gear Set P2 View790
Planetary Gear Set P2 - Ovehaul791
Rear Cover With Piston C1 - Overhaul798
Differential - Overhaul801
Valve Body Assembly View805
Front Valve Body View806
Valve Body - Overhaul807
Centre Valve Body View810
Rear Valve Body View819
Af 20 Housing Parts View829
Af 20 Attaching Parts View830
Af 20 Thrust Bearing Installation View831
Assemblies, Install In Transmission832
Clutch, Manual Transmission And Differential - Special Tools848
Clutch Technical Data870
Manual Transmission And Differential Technical Data870
Recommended Torque Values - Clutch And Transmission872
Automatic Transmission Af 20 Technical Data874
Fuel System878
Fuel System - Warnings And Cautions879
Instructions For Working On Fuel Tank879
Fuel Tank View880
Electric Fuel Pump - Replace881
Function Check Of "Anti-Leak Mechanism" Valve882
Fuel Filler Pipe With Anti-Leak Seal - Remove And Install883
Fuel Fine Filter, (Injection Engines) - Replace884
Fuel Tank Sender Unit - Replace885
Fuel Tank - Remove And Install886
Technical Data Fuel System891
Recommended Torque Values - Fuel System892
Steering894
Manual Steering Gear Assembly896
Steering Column Assembly View897
Steering Column Assembly View - Height Adjustable Steering Wheel898
Steering Checking And Adjusting Operations899
Straight Ahead Position, Check/Adjust899
Hydraulic System, Bleed900
Fluid Pressure - Check901
Steering Gear - Remove And Install903
Steering Gear, Seal - Power Steering913
Steering Gear, Overhaul913
Folding Cover On Steering Gear - Replace919
Steering Linkage - Tie Rod - Replace920
Tie Rod End - Replace920
Steering Wheel/Slip Ring - Replace922
Steering Column923
Steering Shaft Upper Ball Bearing - Replace923
Steering Column Assembly - Remove And Install924
Steering Column Assembly - Disassemble And Assemble926
Steering Column Assembly Disassembly And Assembly928
Disc Joint - Replace932
Steering Column - Replace932
Power Steering - General Information934
Hydraulic System, Top Up934
V-Belt For Hydraulic Pump - Replace935
Ribbed V-Belt For Hydraulic Pump - Replace937
Fluid Reservoir - Remove And Install937
Hydraulic Lines - Replace938
Coolant Loop - Replace939
Hydraulic Pump - Remove And Install941
Hydraulic Pump Remove And Install943
Steering - Special Service Tools945
Steering - Technical Data949
Steering - Recommended Torque Values950
Body Equipment - Index952
General Information For Service Installation Of Accessories953
Trailer Hitch View954
Automatic Antenna - Service Install956
Electrical Connections957
Rod Antenna - Service Install (Kadett)957
Rod Antenna - Service Install (Astra)958
Outside Rear View Mirror - Replace959
Relay For Mirror Heating - Replace959
Switch For Mirror Actuation - Replace960
Mirror Glass - Replace960
Mirror Motor - Replace961
Mirror Cover - Remove And Install961
Radio, Loudspeakers963
Rear Loudspeakers - Replace963
Treble Loudspeakers In Front Doors - Replace964
Bass Loudspeakers In Front Doors - Replace964
Radio - Service Install964
Antenna Cable Install, Connect966
Auxiliary Lighting967
Front Fog Lamp Bulb - Replace967
Front Fog Lamp - Replace967
Fog Lamp - Service Install967
Front Fog Lamps - Service Install969
Front Fog Lamp Switch - Replace972
Front Fog Lamp - Adjust972
Relay - Front Fog Lamps - Replace973
Lamps - Circuit Diagram974
Electrical Equipment And Instruments978
Wiring Harness, Fuse Box980
Survey Of Fuse Box - Fuse Box With 28 Fuses983
Survey Of Fuses And Relays In Engine Compartment984
Wiring Harness Front And Rear Doors985
Wiring Harness, Doors986
Wiring Harness, Rear Body - Kadett987
Wiring Harness, Tailgate - Kadett988
Wiring Harness, Body, Rear - Astra989
Wiring Harness, Luggage Compartment Lid - Astra990
Wiring Harness, Instrument Panel991
Wiring Harness, Engine992
Wiring Harness, Front Body993
Headlamp Adjustment, Check And Adjust994
Turn Signal Lamp, Front - Remove And Install997
Bulb - Turn Signal Lamp, Front - Replace997
Side Turn Signal Lamp - Remove And Install997
Bulb - Side Turn Signal Lamp - Replace998
Rear Lamp (Astra) - Remove And Install998
Bulb - Rear Lamp (Astra) - Replace998
Rear Lamp (Kadett) - Remove And Install999
Bulb - Rear Lamp (Kadett) - Replace999
License Plate Lamp - Remove And Install999
Bulb - License Plate Lamp - Replace1000
Interior Lamp - Remove And Install1000
Bulb - Interior Lamp - Replace1000
Rear Reading Lamp - Remove And Install1001
Bulb - Rear Reading Lamp - Replace1001
Headlamp - Remove And Install1002
Headlamps With Headlamp Range Control - Replace1002
Turn Signal/Wiper Switch - Remove And Install1003
Light And Interior Lamp Switch - Remove And Install1003
Hazard Warning Lamp Switch - Remove And Install1004
Signal Switch - Remove And Install1004
Brake Lamp Switch - Remove And Install1005
Parking Brake Telltale Switch - Remove And Install1005
Horn - Remove And Install1006
Signal Switch Cover - Remove And Install1006
Fog Lamp Switch - Remove And Install1006
Steering And Ignition Lock1007
Contact Piece For Steering And Ignition Lock - Replace1007
Lock Cylinder For Steering And Ignition Lock - Replace1008
Instrument Housing Cover - Remove And Install1009
Instrument Assembly - Remove And Install1009
Temperature Gauge, Fuel Gauge - Remove And Install1010
Speedometer - Remove And Install1011
Voltage Stabilizer - Remove And Install1011
Printed Circuit Board - Remove And Install1012
Instrument/Telltales - Replace1012
Tachometer - Remove And Install1013
Central Door Locking1014
Servo Motor - Driver's Door, Adjust1014
Servo Motor - Passenger Door, Adjust1015
Servo Motor - Rear Door Adjust1016
Servo Motor (Front Door) - Remove And Install1017
Servo Motor (Rear Door) - Remove And Install1017
Servo Motor (Fuel Filler Flap) - Kadett, Remove And Install1017
Servo Motor (Fuel Filler Flap) (Astra) - Remove And Install1018
Servo Motor (Luggage Copmartment Lid) (Astra) - Remove And Install1018
Servo Motor (Tailgate) (Kadett) - Remove And Install1018
Display Systems1020
Function Display - Remove And Install1020
Coolant Residue Sensor - Replace1020
Cleaning Fluid Residue Sensor - Replace1021
Engine Oil Residue Sensor - Replace1021
Outside Temperature Sensor - Replace1021
Heated Rear Screen Relay - Replace1022
Heated Rear Screen Switch - Remove And Install1022
Screen Wipers, Screen Wash/Wipe System, Headlamp Washer System1023
Windscreen Wiper Motor With Linkage - Remove And Install1023
Rear Screen Wiper Motor (Kadett) - Remove And Install1023
Interval Relay - Screen Wash/Wipe System - Replace1024
Pump - Screen Wash/Wipe System - Remove And Install1024
Wash/Wipe System Reservoir - Remove And Install1024
Electronically Operated Window Winders1025
Operating Switch (Driver's Door) - Remove And Install1025
Operating Switch (Passenger Door) - Remove And Install1025
Gas Analysis1026
Air: Fuel Ratio And Gas Emission Theory1027
Hc And Co Analysis1027
Carbon Monoxide1027
Co2 And O2 Analysis1028
Diagnostics1029
Possible Cause1029
Efi Engine Fault Finding Chart1030
Injection Systems1031
Testing Information And Test Procedures1032
Typical Simultaneous Injection Duration1032
The Use Of A 4 Gas Analyser1032
Injector Waveform Components1032
Defita200 Microcontroller Based Fuel Injection And Spark Timing System1034
Defita200 Features1036
Product Description1036
Product Identification And Application1038
Defita200 Specification1039
Electrical1039
Environmental1041
Fuel Delivery1041
Connections1042
Spark Timing1044
Distributor Bypass Operation1045
Engine Speed And Crankshaft Position Measurement1045
Engine Load Measurement1046
Advance Angle Look-Up1046
Ignition Firing Delay Calculation1047
Dwell Time Calculation1048
Engine Water Temperature Measurement1048
Fuel Injection1049
Air Mass To Fuel Mass Ratio1050
Air Mass Measurement1051
Speed Density Concept1052
Fuel Metering1053
Continuous Fuel Flow Rate1054
Injector Opening And Closing Time1054
Injection Timing1055
Injection Duration1056
Correction Factors1056
Injection Hardware Deficiencies1056
Engine Operating Conditions1057
Intake Air Temperature1057
Engine Temperature1057
Cold Starting Conditions1058
Post-Start And Warm-Up Conditions1058
Acceleration Conditions1059
Deceleration Lean-Out Conditions1059
Coasting Conditions1059
Flooded Engine Conditions1060
Full Load Operation1060
Idle Speed Control1061
Immobiliser Operation1062
Default Mode Selection1063
Diagnostic Codes1064
Volt- And Ohmmeter1066