2005-2008 Opel Vauxhall Vectra Workshop Repair Service Manual

Vauxhall/Opel Vectra Owners Workshop Manual John S. Mead Models covered Hatchback, Saloon & Estate Petrol: 1.8 litre (1796cc) & 2.2 litre {2198cc) Turbo-Diesel: 1.9 litre (1910cc) Does NOT cover 1.6 litre or 2.0 litre turfso 4-cyl petrol. 2.8 litre V6 petrol, or 3.0 litre V6 diesel engine Does NOT cover CVTronic transmission or dual fuel models O Haynes Publishing 2010 A book in the Haynes Owners Workshop Manual Series All rights reserved. No part of this book may be reproduced or Printed in the USA transmitted rn any form or by any means, electronic or mechanical, including photocopying, recording or by any information storage or Haynes Publishing retrieval system, without permission in writing from the copyright Sparkford, Yeo«il, Somerset BA22 7JJ, England holder. ISBN 978 1 84425 8871 Haynes North America, Inc 861 Uwrence Drive, Newbury Park, California 91320. USA

Contents LIVING WITH YOUR VAUXHALUOPEL VECTRA Introduction to the Vauxhall/Opel Vectra Page 0»4 Safety first! Page 0*5 Roadside Repairs If your car won't start Page 0*6 Jump starting Page 0*7 Wheel (hanging Page 0»8 Identifying leaks Page 0«9 Towing Page 0*9 Weekly Checl<s Introduction Page 0*10 Underbonnet check points Page 0»10 Engine oil level Page 0*12 Coolant level Page 0*12 Brake and clutch fluid level Page 0.13 Washer fluid level Page 0*13 Tyre condition and pressure Page 0'14 Wiper blades Page 0»15 Battery Page 0»15 Electrical systems Page 0»ie Lubricants and fluids Page 0-17 Tyre pressures Page 0»17 MAINTENANCE Routine Maintenance and Servicing Petrol models Page lA^I Servicing specifications Page 1A.2 Maintenance scheduie Page 1A«3 Maintenance procedures Page 1A»6 DJesel models Page 1B«1 Servicing specifications Page 1B«2 Maintenance schedule Page 1B«3 Maintenance pnscedures Page 1B-6 Illegal Copying /( is the policy of Haynes Publisliing to actively protect its Copyrights and Trade Marks. Legal action will be talten against anyone who unlawfully copies the cover or contents of this Manual. This includes all forms of unauthorised copying including digital, mechanical, and electronic in any form. Authorisation from Haynes Publishing will only be provided expressly and in writing. Illegal copying will also be reported to the appropriate statutory au&iohties.

Contents REPAIRS AND OVERHAUL Engine and Associated Systems 1.8 litre petrol engine in-car repair procedures Page 2A»1 2.2 litre petrol engine in-car repair procedures Page 2B»1 1.9 litre SOHC diesel engine in-car repair procedures Page 2C'1 1.9 litre DOHC diesel engine in-car repair procedures Page 2D»1 Engine removal and overhaul procedures Page 2E«1 Cooling, heating and air conditioning systems Page 3*1 Fuel and exinaust systems - petrol engines Page 4A»1 Fuel and exhaust systems - diesel engines Page 4B»1 Emission control systems Page 4C»1 Starting and charging systems Page 5A«1 Ignition system - petrol engines Page 5B»1 Transmission Cfufch Page 6*1 Manual transmission Page TA-I Automatic transmission Page 7B»1 Easytronic transmission Page 7C»1 Driveshafts Page 8«1 Braises and suspension Braking system Page 9»1 Suspension and steering Page 10«1 Body equipment Bodywork and fittings Page 11-1 Body electrical systems Page 12*1 Wiring diagrams Page 12*18 REFERENCE Dimensions and weights Page REF-1 Fuel economy Page REF«2 Conversion factors Page REF»6 Buying spare parts Page REF-7 Vehicle identification Page REF-7 General repair procedures Page REF'8 Jacking and vehicle support Page REF-S Disconnecting the battery Page REF»9 Tools and working facilities Page REF.10 MOT test checks Page REF.12 Fault finding Page REF-ie Glossary of technical terms Page REF*26 Index Page REF*31

0.4 Introduction The Vauxhall/Opel Vectra was Introduced in the UK in October 1995 as a teplacement for the Cavalier. It was originally available in Saloon and Hatchback versions with 1,6, 1,8, 2.0 and 2.5 litre petrol engines and 1,7 litre normally-aspirated diesel engines. The Estate range was launched in October 1996. Since its introduction, the Vectra has had various meclianical revisions and facelifts during tne course of the production run. This manual covers versions from October 2005, which were the subject of the third facelift, together with further mechanical revisions. Earlier models are covered in previous editions of the Haynes Vauxhall/Opel Vectra Owners Wori<shop Manual. A variety of engines are available in the Vectra range, compnsing 1,8 and 2.2 litre petrol engines and 1.9 litre diesel engines. All engines are of the four-cylinder, in-line type, featuring single, or double overhead camshafts. The engines all have fuel injection, and are fitted with a range of emission control systems. 1.6. 2.0 and 2,8 litre petrol, and 3.0 litre diesel engines are also available, but are not covered in this manual, Ttie Vectra is available in Saloon, Hatchback and Estate body styles, with a wide range of fittings and interior trim depending on the model specification. Fully-independent front and rear suspension is fitted; the front being of the MacPlierson- strut type and the rear being of multi-link design. According to engine type, the manual gearbox is of the five- or six-speed all synchromesfi type, with five- and six-speed electronically-controlled automatic trans- missions, and an 'Easytronic' manual/ automatic transmission, optionally available on certain models. A wide range of standard and optional equipment is available within the Vectra ranqe to suit most tastes, including power steering, air conditioning, remote central locking, electric windows, electric sunroof, anti-lock braking system, electronic alann system and supplemental restraint systems. For the home mechanic, the vectra is a relatively straightforward vehicle to rnairiiairi. and most of the items requiring frequent attention are easily accessible. Your Vauxhall/Opel Vectra manual The aim of this manual is to help you get the best value from your vehicle. It can do so in several ways. It can help you decide what work must t>e done (even should you choose to get it done by a garage), provide information on routine maintenance and servicing, and give a logical course of action and diagnosis when random faults occur. However. It is hoped that you will use the manual by tackling the work yourself. On simpler Jobs, it may even tje quicker than booking the car into a garage and going there twice, to leave and collect it. Perhaps most important, a lot of money can be saved by avoiding the costs a garage must charge to COVH its labour and overheads. The manual has drawings and descriptions to show the function of the various components, so that their layout can be understood. Then the tasks are described and photographed in a clear step-by-step sequence. References to the 'left' or 'right' are in the sense of a person in the driver's seat, facing fomvanJ. Project vehicles The mam vehicle used in the preparation of this manual, and which appears in many of the photographic sequences, was a Vauxhail Vectra Hatchback with a 1.9 litre EX)HC diesel engine. Other vehicles Included a Vectra Estate with a 1.9 litre SOHC diesel engine and a Vectra Hatchback with a 2,2 litre petrol engine. Acknowledgements Certain illustrations are the copyright of Vauxhail Motors Limited, and are used with their permission. Thanks are also due to Draper Tools Limited, who provided some of the workshop tools, and to alt those people at Sparkford who helped in the production of this manual. We take great pride In the accuracy of Information given in this manual, but vehicle manufacturers make alterations and design changes during the production run of a particular vehicle of which ttiey do not inform us. No liability can be accepted by the authors or publishers for loss, damage or injury caused by any errors in, or omissions from, the Information given.

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2005-2008 Opel Vauxhall Vectra Workshop Repair Service Manual

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