2004-2006 Opel Astra H Service Manual – PDF DOWNLOAD
DESCRIPTION:
2004-2006 Opel Astra H Service Manual – PDF DOWNLOAD
OPEL ASTRA H (2004 and 2006 editions):
Issue serial Opel Astra began in February 2004. The car remains front-wheel drive. Campaign was launched in a model with five-door hatchback. Later appears three-door and station wagon version. For the new Opel Astra to develop two new engines, and are taken from the previous most recent engines, thereby obtaining a line of six engines, continues a series Ecotec and meet Euro 4 standards. To start the proposed petrol engines 1.4 TWINPORT (90 hp), 1.6 TWINPORT (105 hp), 1.8 (125 hp) and 2.0 Turbo (170 hp), as well as two diesel engines volume of 1.7 (80 and 100 hp) equipped with a turbo and fuel system type “Common Rail”.
- From June 2004 to these engines added two turbo unit with a system of “Common Rail” volume of 1.9 liter capacity of 120 and 150 hp These modern diesels on the dynamics are not inferior to their petrol counterparts. For example, aster with a motor of 150 hp zero to 100 km / h in 8.9 seconds. Not all petrol engine has the momentum. Moreover, the Astra engine has a maximum speed of 210 km / hour, and spends 100 km. less than 6 liters of fuel.
- Among other things, new engines tailored to the mistakes of the past models, they do not require fuel additives and as an option can be supplied with a special filter fuel that does not require any maintenance throughout the lifetime. Naturally, both engines are equipped with the latest models of catalysts, which give almost no way out all the toxic components: CO, HC and even reduce emissions of soot.
- New diesel engines are manufactured at the plant of the group in Pratola Serra (Italy), and since the spring of 2005 will be released yet, and at the factory in Kaiserslautern (Kaiserslautern). “The third generation Opel Astra car reflects mainly the emotional side and the direction of the new design style of the company Opel. The exterior design of the car is harmoniously complemented by its inner nature. The lounge is dominated by smooth and free surface.
- High quality materials used are organically combined with the high level design of the internal finishing the car “- said the head of design department, Martin Smith (Martin Smith). Decorative bend on the hood smoothly inside the passenger compartment of elegantly designed central console. Cabin were increased compared with the previous model Astra. Length increased by approximately 14, the height and width of 2 to 4 centimeters.
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
2004-2006 Opel Astra H Service Manual – PDF DOWNLOAD
OPEL ASTRA H (2004 and 2006 editions) 8
1 Operation and maintenance of vehicles 8
1 1 General 8
Identification of the vehicle 8
Keys, door locks, sunroof, anti-theft system 12
Power windows 19
1 2 Controls and combination devices 22
Combination of devices and light detectors 22
Information display 40
Wipers and washers 53
1 3 Air conditioner and heater 57
Heating and ventilation with air conditioning 57
Electronic climate control system 57
Automatic mode electronic climate control 60
1 4 Salon Equipment 67
Lamps indoor lighting 67
Interior rearview mirror 68
Outside mirrors 69
Steering wheel 70
Cigarette lighter plug and power outlet 71
Ashtrays 72
Folding tables 73
Front box kit 73
Glove compartment in front armrest 74
Compartment for glasses 74
Sun visors 74
Seats 74
1 5 Passive safety 90
Seatbelts 90
Three-way security system 91
System of airbags «Opel Full Size» 93
1 6 Driving and car maintenance 95
Start Engine 95
Easytronic transmission 95
Driving a car with automatic transmission 98
Trailer coupling, riding with trailer 101
Installation of new tires 106
Condition of tires, rims state 108
Start the engine by using an auxiliary start cable 110
Spare wheel 112
Replacement wheel 114
Towing 116
Tire repair kit 118
Motor Oil 121
Coolant 121
Brake fluid 122
Replacement lamps 123
Electrical equipment 135
1 7 Tables 137
Table 1 1 Specifications of engines 137
Table 1 2 Gas volumes and operational materials used 137
2 Engine 137
2 1 New petrol engine Z 18 XER DOHC-I 137
General 137
Adjustable stars camshaft 139
The principle of controlled camshaft sprockets 140
Rack and belting 143
Poly-V belt 143
Cylinder head 144
Crankshaft and Pistons 145
Rear crankshaft oil seal with the sensor 145
Intake manifold 148
Contour grease gasoline engine Z 18 XER DOHC-I 148
3
Oil cooler module 149
Sump 149
Module thermostat petrol engine Z 18 XER DOHC-I 149
Simtec 75 1 electronic control module petrol Z 18 XER DOHC-I 150
2 2 Petrol engines – general inspection procedures 151
Checking the pressure loss in the engine (1,4-1,6 l) 151
Checking the pressure loss in the engine (1,8 l) 156
Checking the pressure loss in the engine (2,0 l) 160
Checking compression (1,4-1,8 liter engines) 164
Check compression (engine 2 0 l) 166
Checking the engine oil pressure (engine 2 0 liters) 168
Check tightness of the engine (CO content in the cooling system) 168
Measurement of oil 169
Check tension Poly-V belt (engine 2 0 l) 170
Checking the synchronization of the timing mechanism (motor 2,0 l) 170
Adjusting the tension of the toothed belt (engine 2 0 l) 172
Checking the tension of the toothed belt (engine 2 0 l) 174
Replacing the front lower lid toothed belt (engine 2 0 l) 178
Replacing the toothed belt (engine 2 0 liters) 179
2 3 Removing and installing the power unit 183
General and safety by disconnecting power unit 183
Removing sealant 184
Removing and installing the power unit (engine 1 4 l) 185
Removing and installing the power unit (engine 2 0 l) 202
2 4 The mechanical part of the engine 219
Removing and installing the flywheel (engine 1 4 liters) 219
Removing and installing the flywheel (engine 2 0 liters) 220
Replacing the rear flange of the crankshaft 221
Replacing the valve stems seals (installed cylinder head) 223
Removing and installing the crankshaft (engine 1 4 liters) 228
Checking the axial free motion of the crankshaft 244
Removing and installing cylinder head (engine 2 0 l) 245
Removing and installing cylinder head (engine 1,4-1,6 l) 248
2 5 Inspection, and repair operations components of the mechanical part of the engine 257
Checking the gap in the connecting rod bearings 257
Checking the gap in the connecting rod bearings 258
Replace connecting rod bearings 259
Replacing piston rings 260
Replacing the piston rod with 262
2 6 Cooling 265
Filling and removing air from the cooling system 265
Checking the tightness of the cooling system 266
Replacing the auxiliary electric fan (2 0 liter engines) 266
Replacing the radiator (2 0 liter engines) 269
Removal and installation of coolant pump 272
Replacing the intercooler 273
2 7 The system of fuel injection gasoline engines 273
Removing and installing fuel injectors 273
Replacing the fuel line pressure (High pressure pump – pressure chamber) 276
Fuel Pump Module 278
Replacement module dosage 280
Replacing the fuel pressure regulator 282
Replacing the damping body fuel return 283
Replacing the fuel level sensor 284
Fuel Tank 287
Replacing the tube fuel filler (petrol engines) 288
Vapor Fuel System 294
Replacing the front vent tube 295
Removing and installing tanks with activated charcoal 296
Removing and installing the sensor mass air flow 297
Replacing boost pressure sensor (Z 20 LEH) 297
Removing and installing the thermostat housing (engine 2 0 l) 298
Exhaust system (Z 14 XEP, Z 14 XEL, Z 16 XEP) 300
Exhaust system (Z18 XE) 300
Exhaust system (Z 20 LEL) 300
4
Replacing a refrigerator exhaust gas recirculation (2 0 liter engine) 301
2 8 Lubrication 305
Replacing the oil pump (1 4 l) 305
2 9 Tables 317
Table 2 1 Specifications petrol engine Z 18 XER DOHC-I 317
Table 2 2 Validation and tuning values – DOHC-I (engine volume 1 4 liters) 317
Table 2 3 Validation and tuning values – DOHC-I (engine volume 1 6 liters) 317
Table 2 4 Validation and tuning values – DOHC-I (engine volume 1 8 liters) 317
Table 2 5 Validation and tuning values – DOHC-I (engine capacity of 2,0 l) 318
Table 2 6 Poly-V belt – valve gear (engine volume 1 4 liters) 318
Table 2 7 Poly-V belt – valve gear (engine volume 1 6 liters) 318
Table 2 8 Poly-V belt – valve gear (engine volume 1 8 liters) 318
Table 2 9 Poly-V belt – valve gear (engine capacity of 2,0 l) 318
Table 2 10 Specifications (engine volume 1 4 liters) 319
Table 2 11 Specifications (engine volume 1 6 liters) 319
Table 2 12 Specifications (engine volume 1 8 liters) 319
Table 2 13 Specifications (engine capacity of 2,0 l) 320
Table 2 14 toothed belt (engine volume 1 6 liters) 320
Table 2 15 toothed belt (engine volume 1 8 liters) 320
Table 2 16 Recommended tightening torques threaded 320
Table 2 17 Cooling system (engine 1 4 l) 322
Table 2 18 Cooling system (engine 1 6 l) 322
Table 2 19 Cooling system (engine 1 8 l) 322
Table 2 20 Cooling system (engine 2 0 l) 323
Table 2 21 Lubrication system (1 4 liter engines) 323
Table 2 22 Lubrication (Engine 1,6 l) 323
Table 2 23 Lubrication system (1 8 liter engines) 324
Table 2 24 Lubrication system (2 0 liter engines) 324
3 Transmission 325
3 1 Strength 325
General 325
The flow of hydraulic clutch (gearbox – F13 / F17 + / F23 / M20 / M32) 325
Removal, inspection and installation of hard plates and the driven clutch plate (without SAC) 326
Removing and installing the piping and discharge hose coupling (gear – F13 / F17 / F17 + / F23 / M20 / M32) 332
Replacing the clutch pedal 335
3 2 Manual transmission 337
General 337
Gears and gear lever 337
Check transmission oil level (gearbox M20 / M32) 338
Check transmission oil level (gearbox F13) 340
Removing and installing transmission (F13) 340
Transmission, removing and installing on the engine (dismantled) 344
Replacing the transmission housing (gearbox F13) 349
Removing and installing the rear cover gearbox (F 13) 350
Removal and assembly of the differential (gearbox F13) 359
Removal and installation of the main shaft (gearbox F 13) 364
3 3 Automatic transmission 365
General 365
Torque 365
Main gear 365
Adjust the cable selector switch automatic transmission 366
3 4 Propulsion mechanism 366
General 366
Measurement of radial and lateral runout of the bearing wheels 367
Measurement oblique gap block bearing 368
Removing and installing shaft wheel 369
Replacing the internal velocity joints 372
Replacing the external velocity joints 374
Disassembly outer constant velocity joints 375
3 5 Tables 376
Table 3 1 Potential problems of adhesion, their causes and solutions 376
Table 3 2 Possible malfunctions of the INC, their causes and solutions 377
Table 3 3 Volume of transmission oil 377
Table 3 4 Troubleshooting the drive wheels, their causes and solutions 378
4 Chassis 378
4 1 General 378
Building front axle 378
Rear axle 379
Damping sleeve 379
Shock Absorber – rear axle 380
Spring rack with springs of the all-clear 381
Spring rack 382
Stabilizer / swivel arm 383
Continuous Damping Control (CDC) 383
4 2 Wheels and tires 385
General 385
4 3 Front suspension 389
Adjusting the front suspension 389
Difference Base chassis 391
Offset wheels 392
Removal and installation of arm suspension 393
Removing and installing racks CDC spring with shock absorbers 394
Replacing the front damping arm bushings 396
Replacing the spring supporting tube rack 398
Replacement Stabilizer 400
Replacing the rotary lever 401
4 4 Rear suspension 402
Elastic beam rear suspension, Astra-G, Astra-H, Zafira – rear axle 402
Removing and installing wheel bearing 403
4 5 Tables 404
Table 4 1 Potential problems, their causes and solutions 404
Table 4 2 Recommended tightening torques – front suspension, wheels and tires 407
Table 4 3 Options for design of the rear axle 408
Table 4 4 Recommended values tightening torques – rear axle, rear suspension 408
Table 4 5 Angles adjustment wheels, Opel Astra-H 2006 409
Table 4 6 Values of the wheels for the Zafira – B 2006 410
Table 4 7 Potential problems, their causes and solutions 410
5 Steering Gear 411
5 1 General 411
Principle of operation EHPS 411
The visual differences between the systems, TRW and ZF 411
Principle of operation – EHPS ZF 411
Wiring harness connector electrohydraulic module 412
Casing steering column 413
Steering Gear / tie rods 413
5 2 Preliminary checks 413
Check wheel play 413
Checking the efforts of the steering wheel 414
The flow of power steering 414
Check tie-rod ends and seals 415
Check constant velocity joints 415
Check power steering leak 416
Check level of hydraulic fluid hydraulic 416
Filling and removal of air from the hydraulic system 417
5 3 Steering Gear 418
Replacing the steering column module (CIM) 418
Replacing the steering column 419
Replacing the steering mechanism (ZF) 424
Replacement Tie rod 426
Replacing the tie rod 427
Replacing the steering mechanism (TRW) 428
Replacing the covers on the steering mechanism 430
Replacement of pipelines hydraulic steering system with amplifier (ZF) 431
5 4 Tables 433
Table 5 1 Recommended values of the moments 433
Table 5 2 Technical data of hydraulic steering 433
Table 5 3 Potential problems, their causes and solutions (Power steering) 434
Table 5 4 Elements of a EHPS 435
Table 5 5 Pin – wiring harness connector with a 5-pin (X1) (TRW) 435
6
Table 5 6 Pin – wiring harness connector 2-pin (X2) (ZF) 435
Table 5 7 Pin – wiring harness connector 3-pin (ZF) 435
Table 5 8 Change of the slats is achieved through the use of different axial joints 435
Table 5 9 Structures of axial joints tie rod 435
6 Brakes 436
6 1 General 436
Front brakes 436
Rear brakes 436
Power Brakes 436
Brake line 436
The main brake cylinder 437
-Lock braking system ESP MK60 439
6 2 General test procedures 442
Checking and adjustment of the brake system 442
Check brake fluid level in the cistern hydraulic braking system 443
Removal of air from the hydraulic braking system 443
Brake hoses 444
6 3 Operation adjustment and replacement of the brake system 444
Adjusting the parking brake system 444
Replacing the brake pedal 445
Removing and installing front brake hoses 448
Replacing brake pipes 450
Replacing the tank hydraulic brake 451
Removing and installing brake booster vacuum line 453
Replacing the control unit ABS (ESP MK60) 454
Removing and installing brake caliper front wheel 456
Removing and installing brake shoes lining the front wheel 457
Removing and installing protective casing brake front wheel 459
Replacing the brake disc front wheel 461
Removing and installing rear wheel brake shield 462
Removing and installing rear wheel brake caliper 462
Removing and installing brake pads rear wheel 465
Adjust drum brake mechanism 468
Replacing brake pads disc brake rear wheel 468
6 4 Tables 472
Table 6 1 Specifications front brake mechanism 472
Table 6 2 Specifications rear drum brake mechanism 473
Table 6 3 Specifications rear brake mechanism 473
Table 6 4 Recommended tightening torques values of threaded connections 474
Table 6 5 Potential problems, their causes and solutions 474
Table 6 6 versions of systems installed in vehicles Astra-H 476
Table 6 7 Pin connector ABS control unit 476
Table 6 8 Pin assignment connector yaw angular velocity sensor 476
7 On-board electrical 477
7 1 General 477
Principle of CAN 477
Safety 477
Check for voltage 477
Search of the short circuit 477
Check serviceability of earth 477
Checks in the absence of breakage 477
Wires, fuses and relays 478
Battery 479
7 2 System power 483
Generator 483
Starter 484
7 3 On-board electrical 485
Removing and installing windshield washer nozzles 485
Removing and installing rear window washer nozzles 485
Removing and installing faroomyvateley 485
Removing and installing the tank / pump for washer fluid 486
Removing and installing front wiper levers 487
Removing and installing the electric motor cleaners windscreen 488
Removing and installing rear window wiper motor 488
Removing and installing a rain sensor 489
Removing and installing the instrument cluster 489
Removing and installing the information display 490
Removing and installing outdoor lighting panel switches / lighting devices 490
Removing and installing the module gearshift paddles 491
Removing and installing the block switches console section of dashboard 491
Removing and installing the switch of the winter driving mode 492
Removing and installing switches, electric windows front door 492
Removing and installing switches, electric windows rear door 493
Removing and installing panels remote control switches on the steering wheel 493
Removing and installing sensor-switch hood (model with anti-theft system) 494
Removing and installing the sensor-back of the door lock switch 495
Removing and installing speakers 496
Removing and installing the outdoor antenna 497
7 4 Tables 498
Table 7 1 Generator (Bosch) 498
Table 7 2 Starter (Valeo) 498
8 Body 499
8 1 Design Features 499
Central and door locks 499
8 2 Suspended elements 499
Removal and installation of body linings (moldings) 499
Laths in the back of the door 499
Removing and installing fairing lattice 499
Removing and installing wheel arch protection 500
Removing and installing the front bumper / bumper moldings 500
Removing and installing decorative radiator grille 502
Removing and installing front wings 502
Removal, installation and adjustment of the hood 504
Removing and installing transmission cable release hood latch lock 504
Removal, installation and adjustment of the back of the door 505
Removing and installing door lining the back of 506
Removing and installing lock the door back of 507
Removal, installation and adjustment of the side doors 507
Removing and installing lock side doors 508
Removing and installing exterior side door handles 508
Removing and installing the base outside door handles 509
Removing and installing upholstery, side door 510
Care for car body 510
9 Electrical Circuits 512
9 1 The designations used on electrical circuits 512
9 2 The cooling system of engine (engines Z14XEP, Z16XEP, Z18XE and Z17DTL) 516
9 3 Front and rear steloochistiteli / rain sensor / headlamp washers 516
9 4 Windowlifter 516
9 5 Switch stop-signalov/Vyklyuchatel reversing lamps / switches Control outdoor lighting / lighting of the dashboard 517
9 6 The rear combination lamps / Podssvetka license plate / brake light upper level 517
9 7 Headlamps (except Xenon) / Fog lights 517
9 8 Domestic interior lighting / PTO socket / cigarette lighter / Lighting bogazhnogo Branch 518
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- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
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