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General Warnings and Safety Regulations
1.1 Contents
Air Conditioning
Steering
Running Gear, Wheels, Tyres
Brake System
Engine, Fuel and Exhaust Systems 
Natural Gas Vehicles
Clutch, Transmission
Electrics, Electronics
Body
Paintwork
Paintshops in accordance with §14 Hazardous substances
order
Restraint systems
List of technical terms - Technical ABC
1.2 Definitions
Carefully read and observe safety regulations and important
instructions before beginning diagnostic and repair work.
Safety regulations and important information in Checking
Procedures, Service Instructions, Service Plan, Pre-delivery
Inspection and Technical Information Bulletins are subdivided into
"Caution:" and "Note:" As of Model Year 2002, the previous
expression "Caution:" will be replaced by "Warning:" and
"Important:" in order to better differentiate between the danger of
personal injury and the danger of damage to components or to
vehicles.
Meaning of individual expressions...
Warning:
Describes the implementation or omission of situations or measures,
in order to prevent personal injury.
Important:
Describes the implementation or omission of situations or measures,
in order to prevent damage to components or to vehicles.
Caution:
Describes the implementation or omission of situations or
measures requiring extreme care so as to prevent personal injury as
well as damage to components or to vehicles.
Note:
Contains additional tips and tricks and a detailed explanation of
how to perform the associated operation.
1.3 Legislation
These "Safety Regulations and Important Instructions" are not
exhaustive, as Opel/Vauxhall cannot reasonably anticipate every
conceivable service and repair method and the consequences
thereof.
It is therefore vital for anyone carrying out repair work on a
vehicle to ensure that the repair method that has been selected
will not affect their own safety or the vehicle.
Since different laws apply in the different countries, it is not
possible to go into details in the service literature. Anyone
involved in maintenance and repair work must be aware of the
guidelines and laws that apply to their job and follow them
accordingly.
It is expressly pointed out that all work on the systems
described in the following must be carried out in accordance with
the applicable guidelines and regulations issued by the local
authorities and the health and safety, accident prevention and
environmental protection authorities.
Contact with certain operating materials may be damaging to
health. Specific national legislation pertaining to hazardous
substances governs the proper handling of materials. The
identification code is printed on the material container label.
Restrictions are subject to national legislation.
Danger classes applicable in individual countries govern the
proper storage of combustible liquids; relevant danger classes are
printed on the container label. Restrictions are subject to
national legislation.
Observe the relevant national regulations when handling and
disposing of hazardous substances (e.g. non-deployed airbag
modules) and recyclable materials (e.g. plastic, metal, used oil).
Opel safety data sheets must be observed.
Safety data sheets
The safety data sheets can be read on the Internet:
www.ifz-berlin.de
The product groups are subdivided there as follows:
- Airbags/belt tensioners
- Batteries
- Brake fluids
- Paints/raw materials
- Greases
- Radiator anti-freeze
- Spray paint/touch-up pens
- Engine oils
- Engineering oils
- Other products
1.4 Chemical Products
Fuels
- Fuel/air mixtures are explosive. Keep away from flames and
naked lights when working on the fuel system and avoid ignition
sources and sparks. The relevant environmental and health
regulations applicable to explosive, extremely flammable substances
must be observed.
- The fuel system must be checked for leaks before and after
repair work. Build-up of explosive petrol concentrations is
possible at leaking fuel-bearing components. Appropriate warning
signs must be set up during operations on the fuel tank.
- Petrol and diesel fuels are toxic. Swallowing of fuel or
inhalation of the fumes can be fatal. Contact with the skin must be
avoided.
- Do not drain fuel tanks above a workshop pit. Fuel vapours
settle at the bottom of the pit and remain there. Engine adjustment
operations can also lead to the release of fuel vapours and exhaust
gases that pose health risks. Work on lifting ramps in sufficiently
ventilated areas only.
- The fuel tank must only be emptied using a fuel refilling unit
using the gas displacement method, see also catalogue
"Opel/Vauxhall Workshop Equipment". Keep drained fuel in suitable
containers.
- Escaping fuel must be removed immediately, e.g. using a binding
agent.
- The utmost cleanliness is important when working on the open
fuel system.
- Among other things, engine exhaust contains carbon monoxide,
hydrocarbons and nitrous oxide. Ensure that there is an effective
extraction system. Exhaust from diesel engines can lead to skin and
respiratory organ diseases. Carbon monoxide is a powerful blood
poison.
Oils and Lubricants
- Explosive mixtures can result from heating or spraying oils and
lubricants – danger of explosion.
- Breathing or generating oil mist or vapours must be avoided.
Oils and lubricants are toxic when ingested.
- Oils and lubricants are flammable.
Handling Chemical Products
- Do not process any materials whose expiry dates have elapsed.
It is essential that the relevant instructions on container
packaging are observed.
- Avoid using adhesives that are no longer suitable for use
– they pose a threat to vehicle passengers and to the
environment – danger of injury.
Solvent-containing Substances
- The following materials and compounds contain solvents:
- Paints
- Primers, varnishes
- Glass primers
- Fillers
- Putties
- Hardeners
- Thinners
- Activators
- Additives
- Contents of spray cans
- Body seals
- Cavity sealants
- Underseals
- Follow storage instructions on container packages when storing
solvent-containing substances – fire hazard.
- Process solvent-containing substances either in painting booths
or in areas with suitable extraction.
- If not observed, risk of injury, above all to respiratory
system or explosion!
1.5 Protective Clothing
Employers and superiors are responsible for ensuring that
working environments are safe. The user must be protected from
hazards and possible pollution constituting a risk to health.
The following parts of the body require special
protection:
- Eyes
- Wear protective goggles when performing machining operations,
welding and when handling chemical products. If chemicals come into
contact with eyes, wash immediately with clean water (eye bath) and
seek medical attention. Failure to comply results in: Damage to the
eyes.
- Respiratory organs
- Perform adhesive and welding operations in well-ventilated
areas. Always process paints, primer and filler in painting booths.
Wear a filter mask (AB type) for short-term welding operations. For
long-term welding operations, also ensure that vapours are
effectively extracted. Failure to comply results in: Damage to
respiratory organs.
- Skin
- Wear protective clothing and protective gloves (e.g.
refrigerant-resistant). Wear silicone-free barrier creams or
salves. If adhesive comes into contact with skin, wash skin with
soap and water without using solvents of any kind. Failure to
comply results in: Damage to the skin.
Personal protective equipment includes:
- Work clothes
- Safety boots
- Protective goggles
- Ear protection
- Protective gloves as required
In addition, dependent upon work area:
- Respiratory equipment, as required
- Filter masks
- Special protective clothing (e.g. leather apron, painting
overall, protective gloves with sleeves, or appropriate leak-proof
clothing for air conditioner operations)
- Silicone-free barrier creams or salves
1.6 Workplace
General
Code of conduct at the workplace:
- These safety instructions and all other service information
must be accessible to all persons in the workshop area who are
directly or indirectly involved in maintenance, repair, diagnosis
and vehicle handovers. This includes supervisors, who have a
special duty of care (e.g. to employees, the environment, equipment
and vehicles being repaired). The operating instructions issued by
the manufacturers of devices, machines, diagnosis tools and special
tools must also be followed.
- Hazardous substances may only be stored and transported in
clearly marked, unbreakable, unmistakeable and sealed containers.
Vessels intended for food and drink may not be used for storing and
decanting hazardous substances.
- The quantity of hazardous substances kept at the workplace may
not exceed the amount required for the direct or expedient dispatch
of work.
- Personal protective clothing must be worn which corresponds to
the characteristics of the hazardous substance.
- Hazardous concentrations of gases, vapours and dust must be
removed immediately using suitable extraction equipment. Generally,
adequate ventilation of working areas must be ensured.
- Operations that can lead to the generation or release of gases
must never be performed in workshop pits, since gases such as
refrigerants that are heavier than air can collect in high
concentrations.
- Contact between wet cleaning materials and residues of
combustible hazardous materials and skin, eyes and clothing must be
avoided. Areas of the body which have come into contact with
hazardous materials must be washed off immediately with copious
quantities of water. If personnel are injured or feel unwell after
contact with a hazardous substance, call a doctor immediately. If
possible, inform the doctor giving treatment of the name of the
hazardous substance.
Work Safety
- Strict observance of the use of materials and additives is
required for certain operations in the Service Instructions. Only
parts from the "Service" area or parts and additives corresponding
to identical specifications may be used for these operations.
- All components that have been released or removed during repair
work must be re-fastened at their original installation
locations.
- During operations on the underbody or in the engine
compartment, it must be ensured that a safe distance is maintained
from components which become hot during driving operation (e.g.
engine, engine attaching parts, exhaust system, brakes and
transmission). Suitable protective measures must be taken (e.g.
wearing of protective gloves).
- Work that has not been properly executed poses a threat, not
only to your own safety, but also to the safety of the vehicle
driver and third parties involved in road traffic. All work on
vehicles must be performed with the utmost care and diligence.
- Several operations require special tools that may only be
utilised for the purpose specified in the Service Instructions.
Only the use of these tools ensures safe and technically reliable
repair work, as approved by Opel/Vauxhall.
- The continuous, diligent observance and implementation of the
relevant repair method is a prerequisite for maintaining road
traffic safety and operational safety of the vehicle.
- Specific national legislation, guidelines and information of
trade associations for the respective country, as well as those of
the chemical industry, must be observed to ensure work safety.
All employees are obligated to uphold and observe the work
safety measures. These duties include:
- Adhering to regulations and operating instructions.
- Making use of technical equipment.
- Using personal protective equipment.
- Participating in seminars.
- Reporting and eliminating faults.
- Reporting malfunctions and avoiding accidents.
- Eating or drinking are prohibited when handling toxic,
carcinogenic, or mutagenic hazardous substances.
- Do not smoke when handling flammable or explosive
substances.
Fire Hazards
- In order to prevent fire hazards in conjunction with cutting,
grinding or welding operations and material processing, the
appropriate guidelines and regulations with regard to accident
prevention issued by the specific national authorities must be
observed.
- During cutting operations, grinding operations or welding
operations, ensure that a suitable device for extraction of vapours
and dust particles is present. This is especially applicable to
galvanised body components.
- Additional protection is required for flying sparks.
- Follow storage instructions on container packages when storing
solvent-containing substances – fire hazard.
- Avoid naked flames.
- Fire extinguishers must be available in adequate numbers and
routinely serviced.
Lifting Platforms / Jacks
- Only lift and support the vehicle at the prescribed lifting
points. The lifting points on the body are specific to the vehicle
and are listed in the Service Instruction, Assembly A; they must be
observed. Lifting on other vehicle components, e.g. engine,
gearbox, axle components, tank, oil sump etc., is not
permitted.
- Always follow the relevant and manufacturer's instructions and
specifications for lifting platforms.
- The vehicle must be additionally secured on the lifting
platform when a change in weight distribution is caused by the
removal of parts.
- When using a trolley jack, use jack stands to secure the
vehicle against tilting, rolling or slipping.
1.7 Water Damage
Control units in passenger compartment and luggage compartment
have only limited resistance to water. Although no damage is caused
by drops of water, correct function of the affected control units
is no longer guaranteed if considerable amounts of water penetrate
the vehicle. In particular, if safety-relevant control units and
electric components in the passenger compartment (e.g. ABS, Airbag,
EPS, engine control unit, servotronic, seat memory) are damaged, it
is essential that they are replaced with new components.
1.8 Diagnosis
If the "Airbag system" indicator light is active, the fault in
the airbag system must first be remedied before starting diagnosis
and repair on other systems.
A pyrotechnic unit that has been diagnosed as defective must not
be deployed locally but must be returned. Follow the retention
systems safety instructions in the Transport and Storage chapter
and use the return address!
Do not suspend the diagnosis tester from the steering wheel by
the bracket.
Follow the special instructions in the "Safety Regulations -
Retention Systems" chapter. Vehicles with a fault code set in the
airbag system ("Airbag System" indicator light on) must not be
handed over to customers - danger to occupants!
Diagnosis with the diagnosis tester for all
systems except airbag:
- Ignition OFF
- Connect the diagnosis tester to the ALDL connector
- Ignition ON
- Switch on diagnosis tester
- Select system, follow menu
- De-select system
- Switch off diagnosis tester
- Ignition OFF
- Detach diagnosis tester from ALDL connector
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