Opel ASTRA H 2004 Service Manual
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Opel ASTRA H 2004 Service Manual

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O P E L A S T R A H
S E R V I C E M A N U A L

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Summary of Contents for Opel ASTRA H 2004

  • Page 1 O P E L A S T R A H S E R V I C E M A N U A L...

  • Page 2: Table Of Contents

    Table of Contents OPEL ASTRA H (2004 and 2006 editions) ................8 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.
  • Page 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) ..................
  • Page 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) ..........
  • Page 5 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 ................
  • Page 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 ....................
  • Page 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 ...............

  • Page 8: Opel Astra H (2004 And 2006 Editions)

    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.
  • Page 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...
  • Page 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)
  • Page 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).

  • Page 12: Keys, Door Locks, Sunroof, Anti-Theft System

    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.
  • Page 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.
  • Page 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);...
  • Page 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.
  • Page 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.
  • Page 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).
  • Page 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).

  • Page 19: Power Windows

    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.
  • Page 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.
  • Page 21 To open the panoramic glass roof sheeting move forward from any position behind. In its most forward position lining locks (Figure 1.33). NOTE You move the ceiling sheathing fold sun visors up. Sunroof Fig. 1.34. Keys hatch on the roof Luc control keys on the console on the roof (Figure 1.34).

  • Page 22: Controls And Combination Devices

    In case of sensors fail, you will not receive a timely message about the fall of oil pressure and engine may be damaged. If the indicator does not light up when you turn the ignition, do not run the engine. Refer to the service station official Opel dealer for inspection and repair signaling.
  • Page 23 The need for topping up the brake fluid can sometimes be a consequence of its leakage. Therefore, immediately refer to the service station official Opel dealer to check the functioning of the braking system, even if the indicator is not lit.
  • Page 24 Indicator is lit after ignition for a few seconds. After that the system is ready to work. Blinking during movement indicates actuation system. Engine power is somewhat reduced (changing the engine noise), and the car automatically slows down. If the indicator is lit during motion - means the system is off or malfunctioning. You can continue to travel, but the sustainability of progress may deteriorate depending on the condition of the road.
  • Page 25 Failure tell-tale levels of coolant If the indicator light up when the engine is running, stop and turn off the engine. Too high temperature of the coolant is hazardous and can cause damage to the powertrain. Check the coolant and top up if necessary. Detector electronics of the vehicle (engine and gearbox) Indicator lights for a few seconds after ignition.
  • Page 26 If the cause of eating disorders is not in a discharged battery, you should ask for help at service stations. In case if you want to move the car from the flow of a moving vehicle, the clutch can be turned off in the manner described below.
  • Page 27 Mode «SPORT» Fig. 1.43. Key activate «SPORT» To activate this mode, press the corresponding button, located on the center console (Figure 1.43). In sports mode while moving the parameters of the suspension, steering, engine intake, as well as the switching point automatic gearbox and Easytronic. Suspension and steering are becoming more stringent and provide improved contact with the road.
  • Page 28 Fig. 1.44. Control panel exterior lighting Dip headlamp Install light switch in position «AUTO». When the engine is running short-range light will be activated automatically depending on the outdoor light. Outdoor lighting is turned off when you turn off the ignition. Fig.
  • Page 29 Reversing Lamps They burn when the ignition key and switch on the reverse. Alarm "parking pilot" If the indicator is lit - this indicates a system failure. Eliminate the problem or refer to the service station. Flashing sensors indicate contamination sensors, or the presence of these ice or snow. Sensors must be undamaged and free from dirt, snow and ice.
  • Page 30 Fig. 1.49. Key to enable or disable the system Index fuel level Fig. 1.50. Index fuel level Index fuel level shows the approximate amount of available fuel in the tank (Fig. 1.50). Timely directly charge the fuel tank. Make sure that the amount of fuel in the tank is at least a quarter of total capacity.

  • Page 31: Steering Wheel

    When the high beam indicator light is blue Fig. 1.52. Filing light signal To file a brief movement of the light signal, move the lever to the steering wheel (Figure 1.52). Railroad switch LED indicators The corresponding indicator (arrow) blinks when the direction indicator. Blinking indicates the failure of the lamp one of the flashing lights or the appropriate fuse.
  • Page 32 Recognition System employment system disables the front seat side airbags and front seat passenger, if the front passenger seat is occupied or not at the front passenger seat mounted system for ensuring the safety of children «Opel» with transponders. Head airbag system is activated at the same time.
  • Page 33 Install a system for ensuring the safety of children in the back seat. If the system is to ensure the safety of children Opel with transponders not installed, the alarm should not be lit or blinking, otherwise the system airbags for the front passenger will not work.
  • Page 34 Availability of child safety «Opel» with transponders automatically registered with the proper mounting system for the front passenger seat. When using these systems the safety of children on the front passenger front and side airbags with his side are disabled. Head airbag system, however, remains activated.
  • Page 35 In the case of malfunction of the ABS when excessive braking wheel may lock up. A car loses control and can get into the skid. In this situation, you can continue to travel, driving a car with caution. For troubleshooting, visit the service station. Alarm monitoring system pressure drop and the current tire pressure Red light sensors shows a pressure drop in the bus, a yellow light - a malfunction in the system.
  • Page 36 Alarm indicators trailer Indicator light flashes while driving with a trailer with a frequency indicators. Do not blink at a failure of one of the indicator lamps on the trailer or towing truck. Alarm system, adaptive headlamps (AFL - Adaptive Forward Lighting) If the indicator lights continuously - this indicates a system failure.
  • Page 37 Speed controller Speed regulator can remember and always maintain the value of the speed of about 30 to 200 km / h. For safety reasons, speed controller is switched on only after tapping the brake pedal. Speed regulator is controlled by keys on the lever indicators (see Figure 1.65).
  • Page 38 FOG-F9 Fog lights FL-NXNL Headlamps (except xenon) GLOV-L Highlighting the main glove compartment HOR horn with the alarm Light, license plate KZL LAMP-D Door Lamp (backlight door) LIG-R rear light SHL Lights vanity mirrors (in sunshield) SL-M Stop-signal top-level TRUMPETDM switch the alarm TRUNK-L Lights trunk 9.2.
  • Page 39 9.5. Switch stop-signalov/Vyklyuchatel reversing lamps / switches Control outdoor lighting / lighting of the dashboard 9.6. The rear combination lamps / Podssvetka license plate / brake light upper level 9.7. Headlamps (except Xenon) / Fog lights...

  • Page 40: Information Display

    9.8. Domestic interior lighting / PTO socket / cigarette lighter / Lighting bogazhnogo Branch...

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