Vauxhall Workshop Service and Repair Manuals

Update: This Bulletin Replaces Previous Ti-C-5 Dated 10/1998, Which Is To Be Discarded

 

A distribution was recently made of the MY ’99 Passenger Car Inspection System brochure KTA-2046-GB. This brochure, however, is only applicable to Opel vehicles. For Vauxhall vehicles, the MY ’98 brochure KTA-1939-GB continues to be applicable. As such, the Service Plans remain:

 

Service Plan A         (for vehicles with annual mileage of less than 20 000 miles/30 000 km)

                                 Main Service due every 10 000 miles/15 000 km or 12 months, whichever occurs first.

 

Service Plan B         (for vehicles with annual mileage of more than 20 000 miles/30 000 km)

                                 Interim Service due every 10 000 miles/15 000 km.

                                 Main Service due every 20 000 miles/30 000 km or 12 months, whichever occurs first.

 

Note:

For Omega-B 2.5 DT diesel engine, in addition to Service Plans A and B, an engine oil and filter change is necessary every 7 500 miles/10 000 km.

 

Service Plan C         (for all vehicles - performed in conjunction with either Service Plan A or B)

                                 Additional items due on an irregular basis or for vehicles operating under severe operating conditions.

 

A revised Service Booklet is being produced to reflect the new models available since MY ’98 (Astra-G and Zafira). For clarification of certain Service Operations and also to reflect these new models, please refer to the applicable Service Instructions and the following additional information:

 

Service Operations - Service Plans A and B

 

1     Coolant level, anti-freeze - check, correct

       Use only silicate anti-freeze when adjusting the anti-freeze concentration.

 

2     Drive belts and ribbed belts - check, correct

       A revised tensioning method for Omega-B X 25 DT engine is detailed in TI bulletin TI-C-37, J-311, Feb. 98.

 

3     Air cleaner element - replace

       For Astra-G and Zafira: Due every 40 000 miles/60 000 km or 4 years (except in severe operating conditions).

 

4     Pollen filter - replace

       For Astra-G, the filter is located in a housing behind the glove compartment. Additional information is detailed in the Service Instructions and TI bulletin TI-C-48, D-34, May 98.

 

8     Wheel attachment - loosen and retighten;

       tyre condition, inflation pressure (incl. spare wheel) - check correct

       When checking the tightening torque of wheel nuts/bolts, they must first be loosened. A future TI bulletin will detail new model tyre types and inflation details.

 

11   Headlight aiming (incl. additional headlights) - check, correct

       Vehicles with manual level control must be adjusted to the basic pressure. For vehicles with automatic level control, switch on ignition so that level control can position vehicle (kerb weight) to normal. The headlamps can be adjusted after approx. 1 minute.

 

       For vehicles with headlamp range control, the headlamp range control switch must be in the ’0’ position (basic headlamp setting). The intersection between the horizontal and the ascending parts of the light/dark border (break point) must lie perpendicular through the central marking. For easier determination of the intersection point, headlamp halves can be alternately covered and uncovered a few times.

 

14   Power steering - check for leaks; check, correct fluid level

       Only use Special fluid 19 40 766 90 544 116 for Astra-G with electro-hydraulic power steering (EHPS).

 

15   Automatic transmission fluid level - check, correct

       A transmission fluid check is only required in the event of leaks. These leaks must be remedied prior to refilling. Refer to the Service Instructions for the correct checking and refilling procedure.

 

17   Engine oil and oil filter - change

       Note: The Astra-G X 18 XE1 engine has an oil filter housing with a replaceable paper element.

 

18   Fuel Filter - change

       For petrol engines: Now due only every 40 000 miles/60 000 km or 4 years.

 

22   Front/rear wheel suspension, brake pipes, brake pressure hoses, fuel lines and exhaust system - check visually

       Ensure the stabiliser bar, tie rod and springs are checked for damage and also that the shock absorbers are examined for leaks.

 

28   Test drive incl. brake efficiency check, final inspection;

       Reset service interval display - Astra-G, Zafira

       Reset the Service Interval display following each Service.

 

       1.    Switch OFF ignition and press reset button (in the instrument) and keep depressed.

       2.    Switch ON ignition and keep reset button depressed for at least a further 2 seconds.

       3.    After switching the ignition ON the ”Insp” display flashes for 2 seconds.

       4.    If the resetting operation is successful, the text ”----” is shown on the display until the reset button is released.

              The odometer/time display will then reappear.

 

              Note: Periods in which the vehicle is parked with the battery disconnected are not accounted for by the service interval display.

 

Service Operations - Service Plan C

 

27   Brake fluid - change

       A new fluid change procedure, detailed in the Service Instructions, should be observed for the Astra-G combination rear calipers.

 

28   Coolant - change

       Under severe operating conditions, the coolant on the Omega-B X 25 DT engine must be changed every 3 years.

 

4     Pollen filter - replace

       Under severe operating conditions, the pollen filter must be replaced more frequently.

 

Technical Data

 

1    Drive belt tension

 

Engine	Drive	Dimension		Drive belt tension [N]
		Length in mm	Width in mm	new	run-in
X 15 DT (T 4 EC 1), X 17 D (4 EE 1)	Coolant pump/ alternator	916	13.3	440 to 540	320 to 390
C 14 NZ, C 14 SE, X 14 SZ	Alternator	925	9.5	450	250 to 300

 

 

2    Coding plug for Octane Number setting

 

Engine	Fuel grade		Plug designation
	Production (factory code)	Service
12 NZ, C 12 NZ, C 14 NZ, X 14 NZ, C 14 SE1), C 16 SE1)	Super unleaded EN228 - 95 RON	Normal unleaded EN228 - 91 RON	95/91
16 LZ 2	Normal - 91 RON	Normal - 87 RON	91/87

 

1)    If super unleaded fuel is not available, standard unleaded fuel (RON 91) can be used in conjunction with a special 95/91 coding plug.

 

 

3    Automatic transmission fluid

 

Model	Automatic transmission fluid
Corsa, Combo, Tigra, Astra-F	Dexron II 19 40 700 90 350 342
Astra-G, Vectra-B	AF 13-II/17/20 - Special fluid 19 40 767 09 117 946
Sintra, Omega-B	Dexron III 19 40 763 90 510 269

 

 

4    Lubricants - Astra-G

 

Fluid	Type
Power steering fluid	Special fluid 19 40 766 90 544 116
Brake and clutch fluid	DOT4 - FMVSS 571.116, SAE J1703

 

 

5    Engine oil filling quantity - Astra-G

 

Engine	Engine oil with filter change		MIN to MAX
	Sheet metal oil pan	Aluminium oil pan
X 12 XE X 14 XE C 16 SE C 16 SZR C 16 SEL X 16 XEL C 18 SEL X 18 XE1 X 20 XEV	- - 3.5 3.5 3.5 - 4.35 - -	3.5 3.25 3.25 3.25 3.25 3.25 - 4.25 4.25	1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0
X 17 DTL X 20 DTL	5.5 -	5.5 5.5	1.0 1.0

 

 

Distinguishing features of petrol engine oil pans

 

Aluminium oil pan:   metallic colour, with connection to transmission

Sheet metal oil pan: painted black, only connected to cylinder block

 

 

6    Clutch pedal travel adjustment

 

Model	Pedal travel [mm]
Corsa-B, Combo, Tigra	135 - 145
Astra-F (RHD)	133 - 140

 

 

Time Allowances - Astra-G

 

Operation No.	Vehicle/engine	Time allowances [hrs]
		Scheduled Service time according to Service Plan
		Service Plan A			Service Plan B
		1, 3, 5, 7, etc.	2, 6, 10, etc.	4, 8, 12, etc.	1, 3, 5, 7, etc.	2, 6, 10, etc.	4, 8, 12, etc.
P 0001 11 ... TC 00   P 0001 12 ... TC 00   P 0001 15 ... TC 00   P 0001 30 ... TC 00		X	X	X	X	X	X
	OHC, DOHC-0, DOHC-I (except X 18 XE1)	1.2	1.5	1.7	.7	1.5	1.7
	X 18 XE1, DOHC-II X 17 DTL X 20 DTL	1.2 1.3 1.2	1.6 1.7 1.7	1.8 1.7 1.7	.7 .7 .8	1.6 1.7 1.7	1.8 1.7 1.7
... 046	Add: for vehicles with navigation system	-	.1	.1	-	.1	.1

 

 

Additional operations - Astra-G

 

Operation No.	Description	Time allowances [hrs]	Interval
. .... .. 033	Automatic transmission oil change	.2	every 4 years, 40 000 miles/60 000 km 1)
. .... .. 011	Brake fluid change	.2	every 2 years
. .... .. 038	Replace batteries for remote control	.1	every 2 years

 

1)    Only for vehicles in severe operating conditions