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Opel 1994 Astra Manuals
Manuals and User Guides for Opel 1994 Astra. We have
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Opel 1994 Astra manual available for free PDF download: Workshop Manual
Opel 1994 Astra Workshop Manual (1071 pages)
Brand:
Opel
| Category:
Automobile
| Size: 43.33 MB
Table of Contents
Definition of Procedures
3
Lifting Points for Lifting Equipment
3
Safety Notice
4
Maintenance, Body and Chassis Sheet Metal Parts
5
Table of Contents
6
Body and Chassis Sheet Metal Parts - General Instructions
8
Safety Measures
9
Body Repair Using Cementing
9
Legend for Welding Operations
11
Welding Seams
11
Plug Spot Welding
12
Stitch Seam Spot Welding
12
Full Seam
12
Body Dimension Chart
13
Body Dimension Table
19
Trim Panels, Trim Panel Parts, Spoiler
20
Front Panelling - Remove and Install
20
Front Panelling - Replace
21
Radiator Grille - Remove and Install
22
Wheel Well Inner Panelling - Remove and Install
22
Cowl Panel - Remove and Install
23
Outer B Pillar Panel - Remove and Install
24
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 - Bolted
30
Wing - Remove and Install
30
Bonnet, Bonnet Functioning Parts - Remove and Install
31
Bonnet Hinge - Replace
32
Tailgate - Remove and Install
33
Luggage Compartment Lid - Remove and Install (Astra)
34
Hinge Bow, Luggage Compartment Lid - Replace (Astra)
34
Sheet Metal Parts - Welded
36
Front Member (Radiator Crossmember) - Replace/Replace Partially
36
Front Member Centre - Replace
37
Air Deflector Panel Assembly - Replace Partially
38
Side Bracket for Front Panelling - Replace
39
Front Wheel Well - Replace Completely
39
Wheel Well and Front Frame Side Member - Replace Partially
40
Control Arm Brace - Front Frame Side Member - Replace
41
A Pillar - Replace
41
B Pillar - Replace
43
Door Still Panelling, Replace
44
Outer Panelling, Door - Replace
45
Outer Panelling, Tailgate - Replace
45
Rear Quarter Panel - Replace (Kadett)
47
Separation Points, Welding Information, Attaching Parts to be Removed
47
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 Tools
60
Paint
63
Paint - General Information
64
Negative Influences on Vehicle Paint
65
Paint Repairs
66
Procedure for Paint Repairs
67
Vehicle Identification Plate
68
Painting of Plastic Parts
68
Explanation of Time Allowance Painting Stages I, II and III
69
Body Equipment
71
Glass, Window Guides, Window Winders
73
Windscreen - Remove and Install or Replace
73
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 Cement
79
Front Door Sash Window (Manual/Electric Actuation) Remove and Install
80
Rear Door Sash Window Remove and Install
81
Front Door Window Actuation (Manual) - Remove and Install
81
Front Door Window Actuation (Electric) - Remove and Install
82
Rear Door Window Actuation - Remove and Install
83
Door Upper Window Guide Remove and Install
83
Rear Quarter Window - Remove and Install
84
Trim Mouldings, Letterings, Fittings, Hinges
85
Front Door Outer Handle - Remove and Install
85
Front Door Lock Cylinder - Remove and Install
85
Front Door Lock - Remove and Install
86
Rear Door Outside Handle - Remove and Install
86
Rear Door Lock - Remove and Install
87
Tailgate Outside Handle (Kadett) - Remove and Install
87
Luggage Compartment Lid Outside Handle (Atra) - Remove and Install
87
Tailgate Lock Cylinder (Kadett) - Remove and Install
88
Luggage Compartment Lid Lock Cylinder (Astra) - Remove and Install
88
Tailgate Lock - Remove and Install
88
Luggage Compartment Lock (Astra) - Remove and Install
89
Glove Compartment Lid Lock Cylinder - Remove and Install
89
Tailgate Hinge - Remove and Install
90
Side Protective Trim Strips - Replace
90
Roof Cover Strip - Remove and Install
91
Seats, Upholstery, Inner Panelling
92
Front Door Inner Panelling - Remove and Install
92
Rear Door Inner Panelling - Remove and Install
92
Rubber Door Seal - Remove and Install or Replace
93
Still Panelling Seal - Remove and Install
94
Front Seat - Remove and Install
95
Belt Lock Tensioner - Remove and Install or Replace
96
Front Seat Backrests - Remove and Install
98
Rear Seat - Remove and Install
99
Rear Seat Backrest - Remove and Install
99
Headrest Guide Sleeve - Remove and Install
100
Rear Seat Headrest - Service Install
101
Upholstery Cover for Front Seat - Remove and Install or Replace
101
Upholstery Cover for Front Seat Backrest - Remove and Install/Replace
102
Upholstery Cover for Rear Seat - Remove and Install or Replace
103
Upholstery Cover for Rear Seat Backrest - Remove and Install/Replace
103
Upholstery Cover for Armrest - Remove and Install or Replace
104
Moulded Headlining - Remove and Install or Replace
105
Instrument Panel Padding - Remove and Install
105
Centre Console - Remove and Install
107
A Pillar Upper Panelling - Disconnect and Connect
107
B Pillar Panelling (Kadett) - Remove and Install
107
C/D Pillar Panelling Remove and Install
108
Sill Panelling, Front Disconnect and Connect
109
Sill Panelling, Rear - Remove and Install
109
Rear End Panel Shelf (Astra) - Remove and Install
110
Rear Quarter Panelling, Rear (Kadett) - Remove and Install
110
Rear Quarter Panelling, Rear Section (Astra) - Remove and Install
110
Rear Wheel Well Panelling (Astra) - Remove and Install
111
Rear End Lower Panelling - Remove and Install
111
Tailgate Panelling - Remove and Install
112
Seat Belt, Front - Remove and Install or Replace
113
Seat Belt, Rear - Remove and Install or Replace
114
Body Equipment: Recommended Torque Values
119
Heating and Ventilation
121
Air Conditioning
122
Arrangement of Components for Mixed Air Heating
124
Ventilation Nozzle Inset - Remove and Install
125
Ventilation Nozzle Housing - Remove and Install (Driver's Side)
125
Ventilation Nozzle Housing, - Remove and Install (Passenger Side)
126
Cover, Centre, - Remove and Install
127
Heating Operating Unit - Remove and Install
130
Mixed Air Flap between Cable - Replace
131
Bowden Cable for Upper Air Distribution - Replace
131
Bowden Cable for Lower Air Distribution - Replace
132
Heater Core - Remove and Install
134
Heater Core (Air Conditioning) - Remove and Install
135
Air Distribution Housing - Remove and Install
137
Fan Motor - Remove and Install
139
Fan Housing - Remove and Install
139
Fan Motor Series Resistor - Replace
140
Mixed Air/Ac Switch - Remove and Install
140
Switch for Fan/Heated Rear Screen - Remove and Install
141
Mixed Air Actuation Vacuum Unit - Replace
141
Air Conditioning - General Instructions for the Repair and Storage
142
Safety Regulations for Handling Refrigerant
143
Air Conditioning Arrangement
144
Air Distribution in Vehicle
145
Air Conditioning Operating Controls
146
Adjusting the Cooling Functions
146
Maximum Cooling
146
Normal Cooling
146
Air Cooling with Temperature Levels
147
Demisting and De-Icing Window Panes
147
Glove Compartment Refrigeration
147
Refrigerant Circuit
148
Description of Refrigerant Circuit
149
Compressor
150
Circuit Diagram - Compressor
151
Compressor Lubricant
152
Design of Compressor
152
Displacement Variation
153
Performance Control and Functioning of Control Valve
154
High/Low Performance Requirement
155
Condenser
156
Accumulator
157
Operation of Harrison Accumulator/Dehydrator
157
Orifice Valve
158
Evaporator
158
Air Distribution in Air Distribution Case
159
Booster Fan
160
Service Connections
161
Moisture in Refrigerant Circuit
161
Lead Detection in Refrigerant Circuit
162
Air Conditioning, Drain Inspection
163
Air Conditioning, Drain Install, Connect, Remove, Disconnect
165
Air Conditioning, Evacuate and Charge
166
Accumulator - Remove and Install
167
Condenser - Remove and Install Accumulator - Replace
167
Booster Fan - Remove and Install
170
Evaporator - Remove and Install
170
Pipes and Hoses
172
Pipe and Hose Lines - Remove and Install
172
Location of Switches
173
Triple Switch
174
Terminal Assignment
174
Low/Low Pressure Safety Switch
174
Motronic Switch - Engine Speed Increase Switch
174
Switch System Block Diagram
175
Coolant Temperature Switch - Replace
176
Triple Switch - Replace
176
Motronic Switch - Replace
176
Compressor - Remove and Install
176
Compressor Clutch - Replace
180
Compressor Pulley Assembly - Replace
181
Compressor Safety Valve - Replace
182
Compressor Control Valve - Replace
182
Valve - Glove Compartment Cooling - Replace
183
Heating and Ventilation - Technical Data
187
Frame, Front Wheel Susp. Wheels and Tyres
189
Frame - General Information
190
General Notes for Underbody Repair
190
Quick Measure Method
191
Instructions for Use of Checking and Straightening Bench Systems
193
Underbody Dimensional Chart - View from below
194
Left Side Member - on Front Axle Body with Short Outrigger
195
Right Side Member - on Front Axle Body with Short Outrigger
196
Left Side Member - on Front Axle Body with Long Outrigger
197
Right Side Member - on Front Axle Body with Long Outrigger
198
Vehicle Front - Mounting Points View
199
Vehicle Rear - Mounting Points View
200
Front Axle - with Long Outrigger
201
Front Wheel Suspension General Information
202
Camber, Caster and Toe-Out - Check
202
Toe-Out - Adjust
203
Axle Driving Shaft, Wheel Bearing, Front Wheel Hub - Remove/Install
204
Axle Driving Shaft, Remove and Install Completely
207
Joint of Axle Driving Shaft - Remove and Install Individually
211
Folding Covers of One Axle Driving Shaft - Remove and Install
212
Spring Strut, Remove and Install
212
Spring Strut Disassembly
213
Support Bearing - Remove and Install
215
Front Spring And/Or Damper Rings - Remove and Install
215
Spring Strut Cartridge - Remove and Install
216
Control Arm - Remove and Install
218
Damping Bushings in Control Arm - Remove and Install
220
Ball Joint on Control Arm - Remove and Install
221
Front Axle Body - Remove and Install
222
Front Axle Body - Transfer
222
Stabilizer - Remove and Install
225
Pendulum - Remove and Install
226
Wheels and Tyres Information
226
Wheel Balancing
227
Front and Rear Wheels - Electronically Balance
228
Tyre Sizes and Pressures
230
Front Wheel Adjustment
235
Radial/Lateral Runout
235
Frame, Front Wheel Susp., Wheels and Tyres - Torque Values
236
Rear Axle and Rear Wheel Suspension
238
Rear Axle and Rear Wheel Suspension - General Information
239
Rear Axle with Drum Brake View
240
Rear Axle - with Disc Brake
241
Rear Axle Alignment, Camber and Toe-In, Check
242
Tilt Play at Wheel Bearing
243
Wheel Bearing Unit with Disc Brake
243
Wheel Bearing Unit with Drum Brake
244
Radial and Lateral Runout, Measure
244
Rear Axle, Remove and Install
246
Rear Axle, Modify
246
Rear Axle Damping Bushings, Replace
249
Rear Springs And/Or Damping Rings of Rear Springs - Remove and Install
251
Rear Wheel Hub (Disc Hub), Replace One
252
Wheel Spindle, Remove and Install or Replace
256
Wheel Berings of Rear Wheel Hub (Disc Hub), Replace both
256
Seal Ring or One Rear Wheel Hub (Disc Hub), Replace
258
Shock Absorber And/Or Rubber Buffer of Shock Absorber - Remove/Install
260
Stabilizer, Remove and Install
261
Additional Stabilizer, Remove and Install
261
Rear Axle and Rear Wheel Suspension Technical Data
264
Rear Axle and Rear Wheel Suspension - Torque Values
265
Engine - Index
266
Engine - Illustrations
272
Engine Timing View
272
Engine Longitudinal Section
273
Engine Checking and Adjusting Operations
278
Engine - Recommended Torque Values
278
V-Belt Tension - Check and Adjust
279
Ribbed V-Belt Tension - Check and Adjust
280
Compression - Check
280
Engine Pressure Loss - Check
282
Engine Oil Temperature - Measure
283
Engine Oil Pressure - Check
284
Engine Oil Consumption - Measure
284
Timing, Check and Adjust - 1,4/1,6 Ltr.
286
Timing - Check and Adjust - 1,8/2,0 Ltr.
288
Toothed Belt - Install and Tension
289
Engine Timing Side View
292
Rear Toothed Belt Cover - Remove and Install
293
Toothed Belt - Replace
295
Toothed Belt Tension Roller - Replace
296
Cylinder Head, Camshaft Housing
298
Hydraulic Valve Lash Adjustment
299
Hydraulic Valve Tappet
300
Rear Seal Ring in Camshaft Housing - Replace
301
Front Seal Ring in Camshaft Housing - Replace
302
Gasket - Exhaust Manifold/Cylinder Head - Replace
303
Gasket - Intake Manifold/Cylinder Head - Replace
304
Hydraulic Valve Lash Adjuster - Replace
307
Fuel Pump - Replace (14 NV)
308
Camshaft and Rocker Arm - Remove and Install
308
Camshaft Housing - Replace
310
Strainer (Filter) in Camshaft Housing Cover - Clear
311
Spark Plug Thread - Recondition
312
Cylinder Head - Remove and Install
312
Cylinder Head - Disassemble and Assemble
316
Cylinder Head - Overhaul
317
Valve - Grind
318
Valve Guide - Ream
318
Valve Seating - Mill
319
Cylinder Head - Check for Plane Surface
320
Crank Drive - Recommended Torque Values
321
Starter Ring Gear - Replace
321
Drive Disc - Remove and Install - 18SE Only
322
Seal Ring - Crankshaft - Front (in Oil Pump Housing) - Replace
323
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 - Replace
328
Engine Block - Check for Plane Surface
329
Con-Rod Bearing - Replace
330
Con-Rod - Replace
330
Crankshaft - Remove and Install
332
Crankshaft - Check
334
Flywheel - Remove and Install
336
Recommended Torque Values - Oil Circuit
337
Oil Filter Cartridge - Replace
337
Bypass Valve - Replace
338
Oil Pump - Remove and Install
338
Oil Pump - Check
339
Oil Pump Safety Valve - Replace
339
Cooling System - Recommended Torque Values
340
Radiator - Remove and Install
340
Cooling System - Top up and Bleed
341
Cooling System - Check for Leaks
342
Coolant Temperature - Measure with Closed Cooling System
342
Fan Motor - Replace
342
Thermostat - Replace - 1,4/1,6 Ltr.
343
Thermostat - Replace - 1,8/2,0 Ltr.
344
Water Pump - Remove and Install
344
Engine Damping Blocks, Engine, Short Block Engine
346
Engine Damping Blocks, Short-Block - Torque Values
347
Engine Without Transmission - Remove and Install (1,4/1,6 Ltr.)
347
Engine - Repair Using Short Block
352
New Short Block - Complete
353
2 E 3 Carburetor - 14NV
356
Idle Speed and CO Content in Exhaust - Adjust
356
Fast Idle - Check and Adjust
356
Pulldown Unit - Check
357
Thermo Time Valve - Remove and Install
358
Choke Valve Gap - Check and Adjust
358
Choke Valve Forced Opening - Adjust
359
Position of Stepped Plate - Check and Adjust
359
Choke Cover Position - Check
360
Cold Start Adjustment, Throttle Valve Gap - Check and Adjust
360
Basic Adjustment of Throttle Valve - Stage II, Check
361
Injection Quantity - Check and Adjust
361
Accelerator Pump - Remove and Install
362
Release and Forced Return - Stage II, Check and Adjust
362
Pull Rod for Stage II - Check
362
Vacuum Unit - Stage II - Check for Leaks
363
Vacuum Unit - Stage II - Remove and Install
363
Enrichment Valve, Remove and Install
363
Choke Body - Remove and Install
364
Pulldown Unit - Remove and Install
364
2 E 3 Carburettor - Remove and Install
364
Carburettor Cover - Remove and Install (Carburettor Removed)
365
Float - Remove and Install
365
Main Nozzles - Remove and Install
366
Idler Nozzle - Remove and Install
366
Pre-Atomizer - Remove and Install
366
Accelerator Pipe - Remove and Install
367
Float Level - Check
368
Carburetor Actuation - Adjust
368
Filter in Fuel Feed - Remove and Install
368
Enrichment Pipe - Check and Adjust
368
Troubleshooting Chart - 2 E 3 Carburettor
369
Multitec Central Fuel Injection - C 16 NZ
371
Arrangement of Throttle Valve Injection Housing
371
Control Unit - Remove and Install
372
Throttle Valve Injectoin Housing - Remove and Install
373
Throttle Valve Potentiometer - Remove and Install
374
Injection Valve, Remove and Install
374
Fuel Pressure Regulator Diaphragm - Remove and Install
375
Fuel Pressure - Check
375
Throttle Valve Injection Housing Upper Part - Remove and Install
376
Idle Air Control Stepper Motor - Remove and Install
376
Motronic M 1.5.4 Diagram
378
Throttle Valve Potentiometer Remove and Install
379
Idle Air Control Stepper Motor Remove and Install
379
Fuel Pressure Check
380
Fuel Pressure Regulator - Remove and Install
380
Motronic M 1..5.4 (18 SE/20 SEH)
381
Hot Film Mass Air Flow Meter - Remove and Install
382
Fuel Pressure Regulator Remove and Install
382
Idle Speed Adjuster - Remove and Install
383
Throttle Body - Remove and Install
383
Tank Vent Valve - Remove and Install
385
Injection Valves - Remove and Install
385
Bosch M1.5.4 - C 16 SE Diagram
387
Intake Air Temperature Sensor - Remove and Install - C 16 SE
388
Coolant Temperature Sensor - Remove and Install - C 16 SE
388
Intake Air Temperature Sensor - Remove and Install - 16NZ/18SE/20 SEH
388
Coolant Temperature Sensor - Remove and Install - C 16 NZ
389
Coolant Temperature Sensor - Remove and Install - 18 SE/20 SEH
390
Control Unit Remove and Install
390
Intake Manifold Pressure Sensor - Remove/Install - C 16 SE, C 16 NZ
391
Ignition Distributor - Remove and Install - 14 NV, C 16 NZ
392
Ignition Basic Adjustment - 14 NV
392
High Voltage Distributor - Remove and Install - 18 SE/20 SEH
393
Ignition Coil - Remove and Install - 14 NV, 18 SE/20 SEH
393
Ignition Coil - Remove and Install - C 16 NZ
394
Dual Spark Ignition Coil - Remove and Install - C 16 SE
394
Inductive Pulse Pick-Up - Remove and Install - C 16 SE
395
Gap between Inductive Pulse Pick-Up and Increment Disc - Check
395
Octane Number Plug, Code - All Except 14 NV
396
Bosch Starter View
397
Bosch Starter with Reduction Gear View
398
Starter - Remove and Install
399
Starter - Check (Installed)
400
Starter - Check (Removed and Disassembled) (Bosch)
400
Field Winding - Replace
402
Carbon Brushes - Replace (Bosch Starter)
402
Bearing Bushings - Replace (Bosch Starter)
403
Bosch Starter - Disassemble and Assemble
405
Bosch Reduction Gear Starter - Disassemble and Assemble
408
Bosch Alternator
413
Alternator - Remove and Install
414
Bosch Alternator - Check
414
Bosch Alternator - Disassemble and Assemble
416
Bosch Alternator - Overhaul
421
C 20 XE/E20 LET Engine Timing
441
C 20 XE Cross-Section View
442
C 20 XE/20 LET Longitudinal Section View
443
C 20 LET - Side View
444
C 20 LET - Cross-Section View
445
C 20 LET - Engine Intake Side
446
Engine Checking and Adjusting Operations - Torque Values
447
Compression Check
447
Engine Pressure Loss Check
448
Engine Oil Temperature Measure
451
Engine Oil Pressure Check
451
Engine Oil Consumption - Measururing Method
452
Timing - Check and Adjust
453
Engine Timing Side - Air Cleaner Housing
454
Toothed Belt Replacement
455
Toothed Belt Tension Roller Replacement
458
Toothed Belt Guide Roller Replacement
459
Air Cleaner Housing - Remove and Install (C 20 LET)
460
Cylinder Head - Recommended Torque Values
460
Camshat Seal Ring Replacement
461
Gasket - Intake Manifold/Cylinder Head Replacement (C 20 LET)
461
Exhaust Camshaft - Replace Inlet Camshaft
466
Camshaft Sprockets - Remove and Install
468
Cylinder Head Remove and Install
469
Cylinder Head Disassembly and Assembly
475
Exhaust Valve (Sodium-Filled) Disposal
479
Cylinder Head Overhaul
479
Valve Guide Ream
480
Valve Seat - Cut
480
Rear Crankshaft Seal Ring - Replace
482
Seal Ring - Rear Crankshaft - Replace (with Pot Flywheel)
484
Crankshaft Front Seal Ring (Oil Pump Housing) Replace
484
Piston with Con-Rod - Remove and Install
487
Con-Rod Bearing Replacement
488
Con-Rod Replacement
488
Flywheel Remove and Install
489
Pot Flywheel - Remove and Install
490
Cylinder Block - Check for Plane Surface
490
By-Pass Valve - Replace
492
Oil Pump Remove and Install
493
Gasket - Oil Pan - Replace
495
Thermostat Replacement
497
Oil Pump Safety Valve Replacement
498
Cooling System Torque Values
498
Seal Ring - Thermostat Housing/Cylinder Head - Replace
499
Cooling System Top up and Bleed
500
Coolant Temperature Measuring with Closed Cooling System
500
Water Pump Remove and Install
501
Engine Damping Blocks - Engine - Short Block - Torque Values
503
Engine with Transmission - Remove and Install (C 20 Let)
504
Engine Repair Using Short Block
513
New Short Block Complete
516
Motronic M 1.5.4 (C 20 XE)
521
Throttle Body Remove and Install
522
Throttle Valve Switch Remove and Install
523
Throttle Valve Switch - Adjust
523
Injection Valves Remove and Install
523
Hot Wire Mass Air Flow Meter - Remove and Install
526
High Voltage Distributor - Remove and Install
526
Inductive Pulse Pick-Up - Remove and Install
527
Knock Sensor - Remove and Install
527
Ignition Coding Plug
528
Fuel Pressure Check
529
Idle Speed Adjuster Remove and Install
529
Coolant Temperature Sensor Remove and Install
530
Pre-Volume Chamber - Remove and Install
531
Turbocharging System View (C 20 LET)
532
Air Feed View
532
Engine Exhaust Side - 2,0 LET
533
Overall Survey of Pressure and Vacuum Hoses Diagram
534
Survey of Pressure/Vacuum Hoses
535
Survey - Turbocharger Attaching Parts
537
Recommended Torque Values - Turbocharging System
540
Turbocharging System - Important Repair Instructions
540
Coolant Return Line (Turbocharger) - Remove and Install
541
Coolant Feed Line (Turbocharger) - Remove and Install
542
Charge Cooler - Remove and Install
542
Water Cooler - Remove and Install
543
Oil Return Line (Turbocharger) - Remove and Install
544
Oil Feed Line (Turbocharger) - Remove and Install
544
Gasket - Exhaust Manifold/Cylinder Head - Replacement
544
Motronic M 2.7 (C 20 LET) Injection System View
549
Throttle Body Removal and Installation
552
Branch Piece Connection
556
Throttle Valve Potentiometer Removal and Installation
557
Injection Valves Removal and Installation
557
Hot Start Valve - Remove and Install
560
Hot-Wire Mass Air Flow Meter - Remove and Install
560
Inductive Pulse Pick-Up Remove and Install
562
Fuel Pump Relay - Remove and Install
564
Idle Speed Adjuster Removal and Installation
564
Control Unit Remove and Install
565
Tank Vent Valve Remove and Install
565
Intake Air Temperature Sensor - Remove and Install
566
Coolant Temperature Sensor - Remove and Install
566
Bypass Valve - Charge Pressure Control - Remove and Install
567
Ignition Coil - Remove and Install
567
Starter Remove and Install
568
Alternator Remove and Install
568
Cooling System Technical Data
583
Radiator Data
583
Coolant Filling Quantity Anti-Freeze Mixture
583
Toothed Belt Tension
583
Engine Oil Viscosity
584
Engine Oil Quality
584
Engine Oil Filling Quantities
584
Oil Pump Data
584
Adjustment Values, Checknig Values
585
Idle Speeds, CO Content, Ignition Adjustment
585
Cylinder Head Data
586
Valve Dimensions
587
Valve Seat Machining
589
Intake and Exhaust Camshafts Data
589
Crank Drive
590
Cylinder Grinding and Piston Dimensions
590
Cylinder Bore Data
593
Piston Data
593
Connecting Rod Data
593
Crankshaft Grinding Dimensions 20 LET
596
Carburettor Data
598
Injection Systems Data
599
Starter Data
600
Test Data (Bosch)
600
Alternator Characteristics
601
Recommended Torque Values - 1,4/1,6 Ltr. Engine
603
Recommended Torque Values - 1,8/2,0 Ltr. Engine
605
Recommended Torque Values - DOHC 16V - 2,0 XE/2,0 LET
606
Clutch - Manual Transmission and Automatic Transmission
609
Manual Transmission View - F 10/5, F 13/5
613
Differential F 10, F 13 View
614
Manual Transmission F 16/5 View
615
Differential F 16 View
616
Manual Transmission F 20 View
617
Differential F 20 View
618
Clutch Assembly View
619
Transmission Shift Linkage View
620
F 28 Manual Transmission View
621
Manual Transmission and Differential
626
Transmission Identification
626
Transmission Fluid Level Check
627
Transmission Shift Linkage - Adjust
628
Operations on Transmission Shift Linkage
629
Manual Shift Lever - Remove and Install
629
Rubber Cap for Manual Shift Lever - Remove and Install
629
Shift Linkage - Remove and Install
630
Folding Cover on Shift Linkage - Replace
632
Shift Guide - Remove and Install
633
Selector Rod - Replace
633
Shift Linkage Lever - Remove and Install
633
Shift Cover - Remove and Disassemble
635
Shift Cover - Assemble and Install
636
Sealing Operations on Installed Transmission
638
Axle Shaft Seal Rings - Replace
638
Rubber O-Ring for Speedometer Helical Gear (Driven) - Replace
640
Gasket for Shift Cover - Replace
641
Gasket for End Shield - Replace
641
Gasket for Differential Cover - Replace
643
Operations on Manual Transmission and Differential
645
Switch for 1St Gear Recognition - Seal or Replace
645
Reversing Lamps Switch - Seal or Replace
645
Manual Transmission and Differential - Remove and Install
646
Transmission Housing - Replace
652
Differential, Overhaul
656
Differential - Remove and Disassemble
656
Differential Remove and Disassemble
658
Differential - Assemble and Install
662
Tapered Roller Bearing (Differential) - Prescribed Adjustment
666
F 10/5, F 13/5 Manual Transmission View
667
F 16/5 Manual Transmission View
668
F 20/5 Manual Transmission
669
Manual Transmission - Overhaul
670
End Shield with Main Shaft and Drive Shaft - Remove and Disassemble
670
Drive Shaft - Disassemble
677
Main Shaft - Disassemble
678
Main Shaft Disassemble
679
Bearing Rings in Transmission Housing - Replace
681
Bearing Rings in Transmission Housing Replacement
683
Main Shaft - Assemble
684
Drive Shaft - Assemble
689
End Shield - Assemble
690
Synchronizer Rings - Replace
694
Drive Gears (Driving and Driven) - Remove and Install
695
Drive Gear (Driving) - Remove and Install
696
Speedometer Helical Gear - Remove and Install
697
Clutch Disc and Pressure Plate - Remove and Install
698
Clutch Pressure Bearing and Release Lever - Remove and Install
703
Bearing Bushings for Clutch Release Lever - Remove and Install
703
Clutch Cable - Replace
704
Clutch Pedal - Remove and Install
706
Automatic Transmission AF 20 View
708
Converter and Bridge Clutch View
709
AF 20 - Attaching Parts Diagram
710
AF 20 - Housing Parts Diagram
711
Automatic Transmission AF 20
712
Transmission Fluid Level - Check
714
Selector Lever Position Switch Check
714
Selector Lever Position Switch - Adjust
715
Fluid Pressure Check - Mechanical
716
Operations on on Installed Transmission
718
Electronic Control Unit - Remove and Install
718
Selector Actuation Cable - Adjust
718
Kickdown Switch - Adjust
720
Solenoid Valves or Fluid Pressure Regulator - Remove and Install
720
Solenoid Valve Wiring Harness - Replace
721
Axle Shaft Seal Rings Replacement
721
Fluid Filler Pipe And/Or Gasket - Replace
723
Speedometer Helical Gear (Driven) And/Or Seal Ring - Replace
723
Sensor - Transmission Input/Output Speed - Remove and Install
724
Fluid Temperture Sensor And/Or Gasket - Replace
724
Fluid Cooler Lines, Connecting Hose And/Or Seal Rings - Replace
725
Seal Rings for Check Bore (Fluid Pressure) - Replace
725
Auxiliary Housing Cover And/Or Gasket - Replace
726
Gasket for Side Cover - Replace
726
Bulb/Socket for Lighting - Remove and Install
728
Driving Mode Switch - Remove and Install "Winter" Mode
728
"Sport" Mode
729
Kickdown Switch - Remove and Install
729
Selector Actuation Cable - Remove and Install
730
Selector Lever Assembly - Remove and Install
731
Selector Lever Console - Remove and Install
732
Operations on Removed Transmission
734
Converter And/Or Fluid Pump Seal Ring - Replace
734
Housing Parts And/Or Gasket - Replace
734
Transmission - Remove and Install
736
AF 20 - Assemblies Diagram
745
Transmission, Overhaul
746
Assemblies - Remove from Transmission
746
Attaching Parts from Transmission - Remove
746
Fluid Pump Assembly Diagram
758
Assemblies, Disassemble and Assemble
759
Fluid Pump, Multi-Disc Brakes B1 and B2 - Ovehaul
759
Freewheel F1 View
766
Freewheel F1 Overhaul
767
Multi-Plate Clutch C1 and C2 Assembly
769
Planetary Gear Set Assembly P1
770
Multi-Plate Clutch Assembly C1 and C2 - Overhaul
771
Planetary Gear Set P1 - Overhaul
775
Multi-Disc Brake B3 and Freewheel F2
777
Multi-Disc Brake B3 and Freewheel F2 Overhaul
778
Multi-Plate Clutch C3 and Freewheel F3 View
780
Multi-Plate Clutch C3 and Freewheel F3 Overhaul
781
Reduction Brake View
785
Reduction Brake - Overhaul
786
Intermediate Drive Gear View
788
Intermediate Drive Gear - Check
789
Planetary Gear Set P2 View
790
Planetary Gear Set P2 - Ovehaul
791
Rear Cover with Piston C1 - Overhaul
798
Differential - Overhaul
801
Valve Body Assembly View
805
Front Valve Body View
806
Valve Body - Overhaul
807
Centre Valve Body View
810
Rear Valve Body View
819
AF 20 Housing Parts View
829
AF 20 Attaching Parts View
830
AF 20 Thrust Bearing Installation View
831
Assemblies, Install in Transmission
832
Clutch, Manual Transmission and Differential - Special Tools
848
Clutch Technical Data
870
Manual Transmission and Differential Technical Data
870
Recommended Torque Values - Clutch and Transmission
872
Automatic Transmission AF 20 Technical Data
874
Fuel System
878
Fuel System - Warnings and Cautions
879
Instructions for Working on Fuel Tank
879
Fuel Tank View
880
Electric Fuel Pump - Replace
881
Function Check of "Anti-Leak Mechanism" Valve
882
Fuel Filler Pipe with Anti-Leak Seal - Remove and Install
883
Fuel Fine Filter, (Injection Engines) - Replace
884
Fuel Tank Sender Unit - Replace
885
Fuel Tank - Remove and Install
886
Technical Data Fuel System
891
Recommended Torque Values - Fuel System
892
Steering
894
Manual Steering Gear Assembly
896
Steering Column Assembly View
897
Steering Column Assembly View - Height Adjustable Steering Wheel
898
Steering Checking and Adjusting Operations
899
Straight Ahead Position, Check/Adjust
899
Hydraulic System, Bleed
900
Fluid Pressure - Check
901
Steering Gear - Remove and Install
903
Steering Gear, Seal - Power Steering
913
Steering Gear, Overhaul
913
Folding Cover on Steering Gear - Replace
919
Steering Linkage - Tie Rod - Replace
920
Tie Rod End - Replace
920
Steering Wheel/Slip Ring - Replace
922
Steering Column
923
Steering Shaft Upper Ball Bearing - Replace
923
Steering Column Assembly - Remove and Install
924
Steering Column Assembly - Disassemble and Assemble
926
Steering Column Assembly Disassembly and Assembly
928
Disc Joint - Replace
932
Steering Column - Replace
932
Power Steering - General Information
934
Hydraulic System, Top up
934
V-Belt for Hydraulic Pump - Replace
935
Ribbed V-Belt for Hydraulic Pump - Replace
937
Fluid Reservoir - Remove and Install
937
Hydraulic Lines - Replace
938
Coolant Loop - Replace
939
Hydraulic Pump - Remove and Install
941
Hydraulic Pump Remove and Install
943
Steering - Special Service Tools
945
Steering - Technical Data
949
Steering - Recommended Torque Values
950
Body Equipment - Index
952
General Information for Service Installation of Accessories
953
Trailer Hitch View
954
Automatic Antenna - Service Install
956
Electrical Connections
957
Rod Antenna - Service Install (Kadett)
957
Rod Antenna - Service Install (Astra)
958
Outside Rear View Mirror - Replace
959
Relay for Mirror Heating - Replace
959
Switch for Mirror Actuation - Replace
960
Mirror Glass - Replace
960
Mirror Motor - Replace
961
Mirror Cover - Remove and Install
961
Radio, Loudspeakers
963
Rear Loudspeakers - Replace
963
Treble Loudspeakers in Front Doors - Replace
964
Bass Loudspeakers in Front Doors - Replace
964
Radio - Service Install
964
Antenna Cable Install, Connect
966
Auxiliary Lighting
967
Front Fog Lamp Bulb - Replace
967
Front Fog Lamp - Replace
967
Fog Lamp - Service Install
967
Front Fog Lamps - Service Install
969
Front Fog Lamp Switch - Replace
972
Front Fog Lamp - Adjust
972
Relay - Front Fog Lamps - Replace
973
Lamps - Circuit Diagram
974
Electrical Equipment and Instruments
978
Wiring Harness, Fuse Box
980
Survey of Fuse Box - Fuse Box with 28 Fuses
983
Survey of Fuses and Relays in Engine Compartment
984
Wiring Harness Front and Rear Doors
985
Wiring Harness, Doors
986
Wiring Harness, Rear Body - Kadett
987
Wiring Harness, Tailgate - Kadett
988
Wiring Harness, Body, Rear - Astra
989
Wiring Harness, Luggage Compartment Lid - Astra
990
Wiring Harness, Instrument Panel
991
Wiring Harness, Engine
992
Wiring Harness, Front Body
993
Headlamp Adjustment, Check and Adjust
994
Turn Signal Lamp, Front - Remove and Install
997
Bulb - Turn Signal Lamp, Front - Replace
997
Side Turn Signal Lamp - Remove and Install
997
Bulb - Side Turn Signal Lamp - Replace
998
Rear Lamp (Astra) - Remove and Install
998
Bulb - Rear Lamp (Astra) - Replace
998
Rear Lamp (Kadett) - Remove and Install
999
Bulb - Rear Lamp (Kadett) - Replace
999
License Plate Lamp - Remove and Install
999
Bulb - License Plate Lamp - Replace
1000
Interior Lamp - Remove and Install
1000
Bulb - Interior Lamp - Replace
1000
Rear Reading Lamp - Remove and Install
1001
Bulb - Rear Reading Lamp - Replace
1001
Headlamp - Remove and Install
1002
Headlamps with Headlamp Range Control - Replace
1002
Turn Signal/Wiper Switch - Remove and Install
1003
Light and Interior Lamp Switch - Remove and Install
1003
Hazard Warning Lamp Switch - Remove and Install
1004
Signal Switch - Remove and Install
1004
Brake Lamp Switch - Remove and Install
1005
Parking Brake Telltale Switch - Remove and Install
1005
Horn - Remove and Install
1006
Signal Switch Cover - Remove and Install
1006
Fog Lamp Switch - Remove and Install
1006
Steering and Ignition Lock
1007
Contact Piece for Steering and Ignition Lock - Replace
1007
Lock Cylinder for Steering and Ignition Lock - Replace
1008
Instrument Housing Cover - Remove and Install
1009
Instrument Assembly - Remove and Install
1009
Temperature Gauge, Fuel Gauge - Remove and Install
1010
Speedometer - Remove and Install
1011
Voltage Stabilizer - Remove and Install
1011
Printed Circuit Board - Remove and Install
1012
Instrument/Telltales - Replace
1012
Tachometer - Remove and Install
1013
Central Door Locking
1014
Servo Motor - Driver's Door, Adjust
1014
Servo Motor - Passenger Door, Adjust
1015
Servo Motor - Rear Door Adjust
1016
Servo Motor (Front Door) - Remove and Install
1017
Servo Motor (Rear Door) - Remove and Install
1017
Servo Motor (Fuel Filler Flap) - Kadett, Remove and Install
1017
Servo Motor (Fuel Filler Flap) (Astra) - Remove and Install
1018
Servo Motor (Luggage Copmartment Lid) (Astra) - Remove and Install
1018
Servo Motor (Tailgate) (Kadett) - Remove and Install
1018
Display Systems
1020
Function Display - Remove and Install
1020
Coolant Residue Sensor - Replace
1020
Cleaning Fluid Residue Sensor - Replace
1021
Engine Oil Residue Sensor - Replace
1021
Outside Temperature Sensor - Replace
1021
Heated Rear Screen Relay - Replace
1022
Heated Rear Screen Switch - Remove and Install
1022
Screen Wipers, Screen Wash/Wipe System, Headlamp Washer System
1023
Windscreen Wiper Motor with Linkage - Remove and Install
1023
Rear Screen Wiper Motor (Kadett) - Remove and Install
1023
Interval Relay - Screen Wash/Wipe System - Replace
1024
Pump - Screen Wash/Wipe System - Remove and Install
1024
Wash/Wipe System Reservoir - Remove and Install
1024
Electronically Operated Window Winders
1025
Operating Switch (Driver's Door) - Remove and Install
1025
Operating Switch (Passenger Door) - Remove and Install
1025
Gas Analysis
1026
Air: Fuel Ratio and Gas Emission Theory
1027
HC and CO Analysis
1027
Carbon Monoxide
1027
CO2 and O2 Analysis
1028
Diagnostics
1029
Possible Cause
1029
EFI Engine Fault Finding Chart
1030
Injection Systems
1031
Testing Information and Test Procedures
1032
Typical Simultaneous Injection Duration
1032
The Use of a 4 Gas Analyser
1032
Injector Waveform Components
1032
Defita200 Microcontroller Based Fuel Injection and Spark Timing System
1034
Table of Contents
1034
Defita200 Features
1036
Product Description
1036
Product Identification and Application
1038
Defita200 Specification
1039
Electrical
1039
Environmental
1041
Fuel Delivery
1041
Connections
1042
Spark Timing
1044
Distributor Bypass Operation
1045
Engine Speed and Crankshaft Position Measurement
1045
Engine Load Measurement
1046
Advance Angle Look-Up
1046
Ignition Firing Delay Calculation
1047
Dwell Time Calculation
1048
Engine Water Temperature Measurement
1048
Fuel Injection
1049
Air Mass to Fuel Mass Ratio
1050
Air Mass Measurement
1051
Speed Density Concept
1052
Fuel Metering
1053
Continuous Fuel Flow Rate
1054
Injector Opening and Closing Time
1054
Injection Timing
1055
Injection Duration
1056
Correction Factors
1056
Injection Hardware Deficiencies
1056
Engine Operating Conditions
1057
Intake Air Temperature
1057
Engine Temperature
1057
Cold Starting Conditions
1058
Post-Start and Warm-Up Conditions
1058
Acceleration Conditions
1059
Deceleration Lean-Out Conditions
1059
Coasting Conditions
1059
Flooded Engine Conditions
1060
Full Load Operation
1060
Idle Speed Control
1061
Immobiliser Operation
1062
Default Mode Selection
1063
Diagnostic Codes
1064
Volt- and Ohmmeter
1066
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