Vauxhall Workshop Service and Repair Manuals

Type:     ASTRA-F

Time Allowances

2-C-Acryl Uni./Metallic

2-Coat Metallic

Combined Operations

Combined Operations

TC:        16,17,18,19,20,21,22,23,98

Major Operat.

Adjacent Part

Non - adjacent Part

Major Operat.

Adjacent Part

Non - adjacent Part

Pos. No.

Part Description

Paint Stage

Op. No.

Model

00

01

02

17

18

19

24

Front panelling

I/III

B 0765 15

52, 57, 59

1.0

-

.7

1.1

-

.8

ditto

II

B 0765 25

52, 57, 59

.9

-

.6

1.0

-

.7

ditto

I/III

B 0765 15

53-B, Sport

1.4

-

1.0

1.5

-

1.2

ditto

II

B 0765 25

53-B, Sport

1.1

-

.7

1.3

-

.9

Front panelling (removed)

I

B 0765 10

52, 57, 59

1.0

-

.7

1.1

-

.8

ditto

II

B 0765 20

52, 57, 59

.9

-

.6

1.0

-

.7

ditto

I

B 0765 10

53-B, Sport

1.4

-

1.0

1.5

-

1.2

ditto

II

B 0765 20

53-B, Sport

1.1

-

.7

1.3

-

.9

25

Rear panelling

I/III

B 0775 15

51, 52

1.4

-

1.1

1.5

-

1.2

ditto

II

B 0775 25

51, 52

1.1

-

.7

1.3

-

.9

ditto

I/III

B 0775 15

53-B, Sport

1.6

-

1.3

1.9

-

1.6

ditto

II

B 0775 25

53-B, Sport

1.3

-

.9

1.5

-

1.2

ditto

I/III

B 0775 15

57, 59

1.2

-

.9

1.4

-

1.1

ditto

II

B 0775 25

57, 59

1.0

-

.7

1.1

-

.8

25

Rear panelling (removed)

I

B 0775 10

51, 52

1.4

-

1.1

1.5

-

1.2

ditto

II

B 0775 20

51, 52

1.1

-

.7

1.3

-

.9

ditto

I

B 0775 10

53-B, Sport

1.6

-

1.3

1.9

-

1.6

ditto

II

B 0775 20

53-B, Sport

1.3

-

.9

1.5

-

1.2

ditto

I

B 0775 10

57, 59

1.2

-

.9

1.4

-

1.1

ditto

II

B 0775 20

57, 59

1.0

-

.7

1.1

-

.8

38

Rear spoiler

I/III

B 0833 10

53, 58 sport

.8

-

.5

.9

-

.6

ditto

II

B 0833 20

53, 58 sport

.7

-

.4

.8

-

.5

Rear spoiler (removed)

I/III

B 0830 01

53, 58 sport

.6

-

.2

.7

-

.3

ditto

II

B 0830 02

53, 58 sport

.5

-

.2

.5

-

.2

59

Outside handle

I/III

B 0787 07

51, 52, 55

-

-

.1

-

-

.2

ditto

II

B 0787 08

51, 52, 55

-

-

.1

-

-

.2

60

Tailgate panel

I/III

B 0784 10

51 sport

.8

-

.5

.9

-

.6

ditto

II

B 0784 20

51 sport

.7

-

.4

.8

-

.5

60

Tailgate panel (removed)

I/III

B 0784 01

51 sport

.6

-

.3

.7

-

.4

ditto

II

B 0784 02

51 sport

.5

-

.2

.6

-

.3

Op. No.

Operation

hrs.

Code

C 8639 00

Tailgate Panel - Replace

TC: 04, 07, 11, 24, 27, 29

.4

53, 58, 59

C 8655 00

Trim Strip - Luggage Compartment Lid - Replace

TC: 04, 07, 11, 24, 27, 29

.3

56, 57

P 5012 00

Toothed Belt Tension - Check and Correct

TC: 26

+:    For diesel engines, adjust timing and start of supply

.7

1.7

X 16 XEL

X 17 DTL

Engine - Remove and Reinstall (with Transmission Downwards)

TC: 06, 12, 13, 15, 30, 34 36, 40, 42, 47, 62, 69)

J 3401 00

Petrol engine

4.2

X 16 XEL

J 4501 00

Diesel engine

3.4

X 17 DTL

07

Add:

Det. + reatt. manual transmission from engine

.5

06

For vehicles with AC

1.4

X 16 XEL

12

Disassemble and assemble engine

+:  Check cylinder head for plane surface, measure crankshaft, cylinder bores and pistons, spray-paint engine, retighten cylinder head bolts with engine at operating temperature

-:   Dis. + reass. or overhaul cylinder head, camshaft housing or engine attaching parts

7.0

X 17 DTL

Engine - Repair Using Short-block

TC: 01, 03, 04, 06, 12, 13, 15, 30, 31, 34, 36, 40, 42, 62

+:    R + R engine, disassemble engine as far as short-block and mount dismantled parts on short-block, check cylinder head for plane surface, retighten cylinder head bolts with engine at operating temperature (does not apply for X 17 DTL)

-:     Dis. + reass. or overhaul cylinder head, camshaft housing or engine attaching parts,

dis. + reass. cylinder block with engine parts, R + R manual transmission from engine

J 3400 00

Petrol engine

8.5

X 16 XEL

J 4500 80

Diesel engine

8.3

X 17 DTL

07

Add:

Det. + reatt. manual transmission from engine

.5

06

For vehicles with AC

1.4

X 16 XEL

Cylinder Head - Remove and Reinstall

TC: 03, 04, 06, 11, 12,13, 15, 30, 31, 60, 62, 78

+:    Check cylinder head for plane surface Diesel engine: adjust fuel injection pump,

retighten cylinder head bolts with engine at operating temperature (only applies to X 17 DTL)

J 3120 00

Petrol engine

3.5

X 16 XEL

J 4573 00

Diesel engine

4.9

X 17 DTL

Cylinder Head Gasket - Replace

+:  Check cylinder head for plane surface, corr. idle speed

Diesel engine: adjust fuel injection pump,

retighten cylinder head bolts with engine at operating temperature (only applies to X 17 DTL)

J 3100 00

Petrol engine

3.5

X 16 XEL

J 4575 00

Diesel engine

4.9

X 17 DTL

J 4619 00

Camshaft Housing - Replace

+:  R + R cylinder head, check cylinder head for plane surface,

corr. idle speed. Diesel engine: adjust fuel injection pump,

retighten cylinder head bolts with engine at operating temperature (only applies to X 17 DTL)

5.0

X 17 DTL

J 4619 30

Camshaft Housing to Cylinder Head - Seal

+:  R + R camshaft housing and cylinder head, check cylinder head for plane surface. Diesel engine: adjust fuel injection pump,

retighten cylinder head bolts with engine at operating temperature (only applies to X 17 DTL)

4.9

X 17 DTL

J 3070 00

Cylinder Head Cover - Remove and Reinstall

TC: 01, 04, 11, 27, 42

.6

X 16 XEL

Closure Cap for Water Chamber on Side of Cylinder Block - Replace

TC: 27, 42, 55

Right side

J 4854 10

Diesel engine

.5

X 17 DTL

03

Add:

When replacing 1st closure cap from front

+:  R + R front exhaust pipe

.4

04

When replacing 2nd closure cap from front

+:  R + R front exhaust pipe and starter

.7

05

When replacing 3rd closure cap from front

+:  R + R front exhaust pipe and starter

.7

Left side

J 4854 20

Diesel engine

.5

X 17 DTL

06

Add:

When replacing 1st closure cap from front

+:  R + R fuel injection pump and mount, R + R radiator

3.9

07

When replacing 2nd closure cap from front

+:  R + R fuel injection pump and mount.

R + R radiator

3.9

08

When replacing 3rd closure cap from front

+:  R + R radiator

.4

09

When replacing 4th closure cap from front

+:  R + R cylinder block vent flange, R + R radiator

.6

Toothed Belt Cover - Remove and Reinstall

TC: 01, 04, 27

J 3137 00

Petrol engine (front)

.6

X 16 XEL

J 4630 51

Diesel engine (upper)

.3

X 17 DTL

J 4630 52

Diesel engine (lower)

.5

X 17 DTL

04

When replacing rear cover

1.1

1.8

X 16 XEL

X 17 DTL

J 4715 00

Intake Manifold - Replace

TC: 01, 03, 04, 11, 27, 30, 31, 42, 49

1.9

X 17 DTL

J 3006 00

Upper Part of Intake Manifold - Replace

TC: 01, 03, 04, 11, 27, 30, 31, 42, 49

.5

X 16 XEL

J 3008 00

Lower Part of Intake Manifold - Replace

TC: 01, 03, 04, 11, 27, 30, 31, 42, 49

+:    R + R upper part of intake manifold

2.7

X 16 XEL

J 4713 00

Intake Manifold Gasket - Replace

TC: 42

+:    Drain and refill coolant

1.8

X 17 DTL

J 3015 10

Gasket - Upper Part of Intake Manifold - Replace

TC: 42

.5

X 16 XEL

J 3015 20

Gasket - Lower Part of Intake Manifold - Replace

TC: 42

+:    R + R upper part of intake manifold

2.6

X 16 XEL

J 4705 00

Exhaust Manifold - Replace

TC: 01, 03, 04, 11, 27, 30, 31, 42

1.7

X 17 DTL

J 4703 00

Exhaust Manifold Gasket - Replace

TC: 14, 42

1.6

X 17 DTL

J 4620 00

Camshaft - Replace

TC: 01, 03, 06, 15, 31, 40

+:    Camshaft running-in procedure.

Diesel engine: check and adj. fuel injection pump adjustment

3.0

X 17 DTL

J 3145 50

Camshaft (Intake) - Replace

TC: 01, 03, 06, 15, 31, 40

+:    Camshaft running-in procedure

1.8

X 16 XEL

J 3145 60

Camshaft (Exhaust) - Replace

TC: 01, 03, 06, 15, 31, 40

+:    Camshaft running-in procedure

1.8

X 16 XEL

J 3145 70

Both Camshafts - Replace

TC: 01, 03, 06, 15, 31, 40

+:    Camshaft running-in procedure

2.2

X 16 XEL

Seal Ring - Camshaft (Front) - Replace

TC: 40, 42

+:    For vehicles with diesel engine, check valve timing and check and corr. start of injection of fuel injection pump

J 3146 00

Petrol engine

1.5

X 16 XEL

J 4620 60

Diesel engine

2.0

X 17 DTL

05

Add:

Replace one further seal ring

.2

X 16 XEL

All Valve Stem Seals - Replace

+:  R + R cylinder head.

Diesel engine: adj. fuel injection pump

J 3123 15

Petrol engine

5.8

X 16 XEL

J 4590 15

Diesel engine

5.5

X 17 DTL

One Valve Spring - Remove and Reinstall

+:  R + R cylinder head.

Diesel engine: adj. fuel injection pump

J 3123 00

Petrol engine

4.2

X 16 XEL

J 4590 00

Diesel engine

5.1

X 17 DTL

Crankshaft - Remove and Reinstall

+:  R + R engine with transmission downwards

-:   Det. + reatt. manual transmission from engine

J 3200 00

Petrol engine

8.7

X 16 XEL

J 4550 00

Diesel engine

7.6

X 17 DTL

07

Add:

Det. + reatt. manual transmission from engine

.5

06

For vehicles with AC

1.4

X 16 XEL

Crankshaft Seal Ring in Oil Pump Housing - Replace

TC: 38, 40, 42

J 3215 00

Petrol engine

1.0

X 16 XEL

J 4561 10

Diesel engine

2.2

X 17 DTL

Pistons with Con-rods - Remove and Reinstall (All)

+:  R + R cylinder head and oil pan, measure cylinder bores and pistons

J 3301 00

Petrol engine

5.6

X 16 XEL

J 4527 00

Diesel engine

6.6

X 17 DTL

J 3355 00

Flywheel - Remove and Reinstall

TC: 01, 04, 06, 27, 31, 34

2.9

X 16 XEL

12

Add:

Replace seal ring for rear crankshaft bearing

(pot flywheel removed)

+:  Check and corr. engine oil level

.2

J 3155 00

Oil Pan - Remove and Reinstall

TC: 01, 03, 04, 06, 11, 12, 15, 27, 40, 42, 61

1.0

X 16 XEL

20

Add:

Replace oil pan

.4

X 16 XEL

Oil Pump - Remove and Reinstall

TC: 01, 04, 06, 12, 15, 27, 40, 42, 61

+:    R + R oil pan. For vehicles with diesel engine, check and corr. valve timing and start of injection of fuel injection pump

J 3163 00

Petrol engine

3.0

X 16 XEL

J 4566 00

Diesel engine

3.8

X 17 DTL

Oil Pump - Overhaul

+:  R + R oil pump. For vehicles with diesel engine, check and corr. valve timing and start of injection of fuel injection pump

J 3165 00

Petrol engine

3.2

X 16 XEL

J 4566 05

Diesel engine

4.1

X 17 DTL

J 3174 30

Thermostat - Engine Oil Cooling - Replace

TC: 01, 27, 29, 30, 42

.2

X 17 DTL

J 3174 00

Engine Oil Thermostat Housing - Replace

TC: 01, 11, 15, 27, 42

.4

X 17 DTL

J 3156 00

Engine Oil Cooler - Replace

+: R + R front panelling

.6

X 17 DTL

J 3172 10

Feed Line for Engine Oil Cooling - Replace

TC: 01, 06, 11, 27, 40, 42, 75

+:    R + R front panelling

.8

X 17 DTL

J 3172 20

Return Line for Engine Oil Cooling - Replace

TC: 01, 06, 11, 27, 40, 42, 75

+:    R + R front panelling

.8

X 17 DTL

J 8546 00

Fuel Distributor Pipe - Replace

TC: 04, 42

.7

X 16 XEL

J 8525 10

Throttle Body - Replace

TC: 01, 03

1.5

X 16 XEL

J 7940 00

Idle Stepper Motor - Replace

TC: 15, 27, 86, 87

.8

X 16 XEL

J 7425 00

Throttle Valve Potentiometer - Replace

TC: 06, 26, 82, 83, 84, 86, 87

1.1

X 16 XEL

J 7406 00

Intake Air Temperature Sensor - Replace

TC:  01, 42, 86, 87

.3

X 16 XEL

J 8555 10

Injectors - Replace (1 Injector or All)

TC: 12, 42, 75, 82, 86, 87

.7

X 16 XEL

J 8575 00

Fuel Pressure Regulator - Replace

TC: 12, 40, 42, 56

.3

X 16 XEL

J 4917 00

Diesel Fuel Injection Pump - Replace (Bosch)

TC: 01, 06, 40, 42, 61, 83, 84

+:    All adjustment work

3.4

X 17 DTL

J 4919 00

Mount for Diesel Fuel Injection Pump - Replace

TC: 01

3.5

X 17 DTL

J 4920 00

Pressure Switch - Cold Start Enrichment - Replace

TC: 01, 86, 87

.2

X 17 DTL

J 4920 10

Pressure Unit - Cold Start Enrichment - Replace

TC: 01, 42, 86, 87

.3

X 17 DTL

J 4918 00

Solenoid - Diesel Fuel Injection Pump - Replace

TC: 01, 15, 86, 87

.4

X 17 DTL

J 4617 10

Oil Pipe to Turbocharger - Replace

TC: 01, 12, 27, 40, 42

.2

X 17 DTL

J 4617 30

Oil Return Pipe from Turbocharger to Oil Pan - Replace

TC: 01, 12, 27, 40, 42

+:    R + R exhaust manifold

2.0

X 17 DTL

J 4704 00

Turbocharger - Replace

TC: 01, 06, 13, 14, 15, 30, 40, 42

1.9

X 17 DTL

J 6004 00

Intercooler - Replace

TC: 01, 12, 27, 42

.3

X 17 DTL

J 4709 10

One Charge Air Hose Bend - Replace

TC: 04, 06, 27, 42, 54

.1

X 17 DTL

J 6005 00

Radiator - Replace

TC: 12, 42, 54

.6

X 17 DTL

J 6013 00

Centre Coolant Hose Bend - Replace

(between coolant pipe and water pump)

TC: 04, 27, 30, 42

.5

X 17 DTL

J 6015 10

Coolant Pipe - Replace

TC: 01, 04, 42

1.3

X 17 DTL

J 8093 00

Feed Hose for Air/Fuel Mixture Preheating - Replace

TC: 04, 27, 42

1.3

X 16 XEL

J 8093 10

Return Hose for Air/Fuel Mixture Preheating - Replace

TC: 04, 27, 42

1.2

X 16 XEL

J 6091 00

Water Pump - Remove and Reinstall

TC: 06, 15, 40, 42

2.3

X 17 DTL

J 6085 00

Thermostat Housing - Remove and Reinstall

TC: 01, 04, 30, 31, 42

+:    For vehicles with diesel engine, check and corr.

valve timing and start of injection for fuel injection pump

2.7

X 17 DTL

J 6070 00

Ribbed V-belt - Replace

TC: 04, 06, 40

+:    R + R right engine damping block

.7

X 16 XEL

Toothed Belt - Replace

TC: 04, 06, 27, 40, 58

+:    For vehicles with diesel engine, check and corr.

valve timing and start of injection for fuel injection pump

-:     Adj. firing angle

J 3139 00

Petrol engine

.9

X 16 XEL

J 4624 00

Diesel engine

2.0

X 17 DTL

Crankshaft Toothed Belt Pulley - Replace

TC: 01, 03, 04, 31, 40

+:    For vehicles with diesel engine, check and corr.

valve timing and start of injection for fuel injection pump

-:     Adj. firing angle

J 3141 00

Petrol engine

.8

X 16 XEL

J 4696 00

Diesel engine

2.0

X 17 DTL

Camshaft Toothed Belt Pulley - Replace

+:    For vehicles with diesel engine, check and corr.

valve timing and start of injection for fuel injection pump

-:     Adj. firing angle

J 3143 00

Petrol engine

1.3

X 16 XEL

J 4629 00

Diesel engine

1.9

X 17 DTL

06

Add:

Replace one further toothed belt pulley

.1

X 16 XEL

Toothed Belt Tension Roller - Replace

TC: 01, 06, 11, 15, 40

J 3139 10

Petrol engine

.9

X 16 XEL

J 4352 10

Diesel engine

1.9

X 17 DTL

J 4914 00

Diesel Injection Pump Toothed Belt Pulley - Replace

TC: 01, 03, 04, 31, 40

+:    Check and corr. valve timing and start of injection of fuel injection pump

2.1

X 17 DTL

J 4352 00

Toothed Belt Guide Roller - Replace

TC: 01, 15, 40

+:    Check and corr. valve timing and start of injection of fuel injection pump

.9

1.9

X 16 XEL

X 17 DTL

01

Add:

Replace one further guide roller

.1

X 16 XEL

J 7001 00

Starter - Remove and Reinstall

TC: 01, 06, 15, 37, 40, 86, 87

.6

X 17 DTL

J 7952 00

Camshaft Sensor - Replace

TC: 01, 86, 87

.4

X 16 XEL

J 9825 00

Control Valve - Replace (Exhaust Gas Recirculation)

TC: 01, 27, 42

.6

X 16 XEL

N 4515 95

Wiring Harness - Front - Replace (Air Deflector Panel)

TC: 88

+:    R + R front panelling

-:     Separating wiring harness and connecting using plug connectors not required (use designated separation points only)

2.2

N 4535 98

Wiring Harness - Rear - Replace (Body)

TC: 88

+:    R + R seats, moulded headlining, centre console

 -:    Separating wiring harness and connecting using plug connections not required (use designated separation points only)

5.0

5.1

56,57,53-B

N 4001 00

Wiring Harness - Complete - Replace (Front + Rear)

TC: 88

+:    R + R front panelling, seats, moulded headlining, centre console

-:     Separating wiring harness and connecting using plug connections not required (use designated separation points only)

6.7

6.8

56,57,53-B

N 4054 99

Wiring Harness - Petrol Fuel Injection System - Replace

TC: 88

+:    R + R upper part of intake manifold

1.5

X 16 XEL

03

Add:

Replace injector wiring harness

.2

N 4067 00

Wiring Harness - Secondary Air Injection System - Replace

TC: 88

+:    R + R front panelling, battery

1.4

W 1000 00

Vehicle from Parking Place to Workplace and Back

TC: 99

.1