Astra F
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Fuel System, Exhaust Gas Recirculation System, Secondary Air System Safety Measures It is expressly requested that the warnings and cautionary measures listed in these Service Instructions be carefully read and observed in order to minimise the risk of injury to workshop personnel - as a consequence of unprofessional conduct - and to avoid damaging the vehicle and jeopardising the operational safety.
- Remove the underside protector if required for operations which are performed from below the vehicle. When installing, ensure the tightening torque of 20 Nm/15 lbf. ft. is correct. - For operations where there is the risk of a short circuit, disconnect the battery. Disconnecting the ground cable automatically erases the contents of electronic system memories. After reconnecting the battery, reprogram clock, onboard computer and, if necessary, electric window winders. If the radio is coded, the customer must be informed that the system is decoded. - Disconnect battery from the vehicle electrical system before charging or quick-charging. - Never use the quick-charger for starting. - Never disconnect or re-connect wiring harness plugs from/to control units or trigger boxes with the ignition switched on. - For temperatures over 80 ° C (dry bulb) remove the modulator unit. - Wiring harnesses and wiring troughs detached or removed for repair work must always be refastened at the original point using genuine parts (cable ties, clips, wiring trough brackets, etc.) from Parts and Accessories. - Before removing parts of the fuel system, thoroughly clean connection points and their immediate vicinity.
Safety Advice (Continued)
- During operations on the fuel system, keep sources of ignition away and avoid generating sparks. - For operations on the fuel system, ensure utmost cleanliness. - Observe the relevant environmental, health and work safety regulations regarding explosive and flammable materials. - Check that fuel lines are correctly routed, do not have chafed points and are firmly connected. Fuel hoses must be installed without twisting and without cross section restrictions. - Fuel lines must not be allowed to contact moving parts or sharp edges. Cables must not be fastened to them. - Check fuel system for leaks. - Set up appropriate warning signs during operations on the fuel tank. - Only work on lifting ramps in sufficiently ventilated area. - Never drain fuel tank above to installation pit; fuel vapour sinks to the bottom of the pit and remains there. - Drain fuel tanks with a fuel refilling unit, see catalogue "Opel/Vauxhall Workshop Equipment". Store drained fuel in a suitable sealed container. - Leaking fuel must be mopped up immediately. - If repairs cannot be carried out immediately, close off opened components or mask them carefully. - Leads (false air) in the intake and exhaust system - in front of the catalytic converter - lead to malfunctions.
Safety Advice (Continued)
- The exhaust system must be routed without tension according to the contours of the vehicle underbody. - Check exhaust system for leaks. - When replacing the exhaust system or individual components, use only parts that are suitable for the vehicle. - If re-using the Lambda-sensor, coat the thread with specialty grease (black). The thread of new Lambda-sensors is already coated with specialty grease (black). - Exercise utmost care during all operations on the secondary air system. - Any leak in the secondary air system can cause damage to the catalytic converter and/or the engine. - Check all parts for signs of wear and replace if necessary.
These warnings and precautions are not exhaustive. Adam Opel AG/Vauxhall Motors Ltd. cannot possibly foresee and evaluate all the conceivable ways in which maintenance and repair might be carried out or the possible hazardous consequences of each method. It is therefore particularly important that anyone who carries out repair work on a vehicle first satisfies himself thoroughly that neither his own safety nor vehicle safety will be jeopardised by the service method he selects. Attention is drawn to the fact that all work in connection with the following service operations should only be carried out in accordance with the pertinent rules and instructions of the local trade authorities regarding health protection, accident prevention and environmental protection. Contact with some materials may be damaging to health. |
