2012 OPEL ASTRA H Service and Repair Manual

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

2 Table of Contents OPEL ASTRA H (2004 and 2014 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

5 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

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 ............................................................... 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

8 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. 1. Operation and maintenance of vehicles 1.1. General Identification of the vehicle Typical plate Fig. 1.1. Location type plate Typical plaque installed on the frame right front door (see Figure 1.1).

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 specific to the country ID Fig. 1.3. ID number, located on the floor of the car ID number of the car knocked on the floor on the right side under the cover between the front door and the seat (Figure 1.3). Fig. 1.4. ID number, located on the dashboard ID number of the car and knocked on the dashboard (see Figure 1.4).

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)

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2012 OPEL ASTRA H Service and Repair Manual

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