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Other Vauxhall Workshop Service and Repair Manuals
Other Makes
Astra G Workshop Manual
General Vehicle Information
A Maintenance, Body and Chassis Sheet Metal Parts, Frame
B Paint
C Body Equipment
D Heating, Ventilation, Air Conditioning (HVAC)
E Front Wheel Suspension, Wheels and Tyres
F Rear Axle and Rear Wheel Suspension
H Brakes
J Engine and Engine Aggregates
Repair Instructions
Description and Operation
Specifications
Special Tools and Equipment
Other Information
Technical Service Bulletins
Technical Information
OHC Petrol Engine
DOHC Petrol Engine
Diesel Engine
Repair Instructions
Description and Operation
Specifications
Special Tools and Equipment
Technical Service Bulletins
Schematic and Routing Diagrams
General
Repair Instructions
Measuring oil consumption
OHC Diesel engine (X 20 DTL, Y 20 DTL, Y 20 DTH, Y 22 DTR) - engine identification / engine number
Vacuum routing in engine compartment (X 20 DTL, Y 20 DTL, Y 20 DTH up to MY 2003)
Ribbed V-belt Tensioner, Check
Test compression pressure (X 20 DTL, Y 20 DTL, Y 20 DTH up to MY 2003)
Pressure Loss, Check
Oil Temperature, Measure
Oil Pressure, Check
Oil Consumption, Measure
Engine, Lock at 1st Cylinder TDC (Timing, Check)
Timing, Adjust
Low Pressure System, Check for Leaks
Illustration: Air Ducts, X 20 DTL, Y 20 DTL
Timing Case, Remove and Install
Cylinder Head Cover, Remove and Install
Vacuum Pump, Remove and Install
Removing and installing inlet manifold upper section (X 20 DTL, Y 20 DTL, Y 20 DTH up to MY 2003)
Intake Manifold - Lower Part, Remove and Install
Exhaust Manifold with Turbocharger, Remove and Install
Cylinder Head, Remove and Install
Engine Oil with Oil Filter Change
Oil Intake Pipe, Remove and Install
Dynamic Oil Level Control, Remove and Install
Oil Temperature Sensor, Remove and Install
Oil Pressure Regulating Valve, Remove and Install
Safety Valve, Remove and Install
Oil Pump, Remove and Install
Cooling System, Charge and Bleed
Cooling System, Check for Leaks
Engine, Check for Leaks, (CO Content in Cooling System)
Thermostat/Thermostat Housing (Radiator), Remove and Install
Coolant Pump, Remove and Install
Coolant Pipe, Remove and Install
Removing and installing engine (X 20 DTL, Y 20 DTL, Y 20 DTH up to MY 2003)
Injection Nozzle Traverse, Remove and Install
Crankshaft Pulse Pick-up, Remove and Install
Coolant Temperature Sensor, Remove and Install
Engine Control Unit, Remove and Install
Charge Pressure Control Solenoid Valve, Remove and Install
Switchover Valves Solenoid Valve, Remove and Install
Switchover Valves Vacuum Unit, Remove and Install
Return Manifold, Remove and Install
Accelerator Pedal Module with Pedal Position Sensor, Remove and Install
Immobiliser Control Unit, Remove and Install
Special Service Tools
Specifications
Checking and Adjustment Values
Engine Timing
Cooling system
Oil circuit
Cylinder head
Crank drive, cylinder block
Engine Management
Sealants, Lubricants and Locking Agents
Recommended Torque Values
OHC II Turbo-Diesel-Engine (X 17 DTL) Number
Compression, Check
Pressure Loss, Check
Oil Temperature, Measure
Oil Pressure, Check
Oil Consumption, Measure - General
Air Cleaner Housing, Air Duct Ducts
Cylinder Head, Remove and Install
Seal Ring - Rear Crankshaft, Replace
Front Seal Ring - Crankshaft, Replace, Seal Ring - Oil Pump, Replace
Cooling System, Charge and Bleed system
Cooling System, Check for Leaks
Engine, Check for Leaks, (CO Content in Cooling System)
Fan Motor, Remove and Install
Auxiliary Fan Motor, Remove and Install motor
Radiator, Remove and Install (Without Air Conditioning)
Radiator (With Air Conditioning), Remove and Install
Control Unit - Cooling module, Remove and Install
Engine Damping Block, Front, Remove and Install Remove and Install
Rear Engine Damping Block, Remove and Install
Engine Damping Block, Left, Remove and Install
Engine Damping Block, Right, Remove and Install
Engine, Remove and Install
Engine, Repair Using Short-block
Fuel Injection Pump, Remove and Install
Turbocharger, Remove and Install Remove and Install
Intercooler, Remove and Install
Immobiliser Control Unit, Remove and Install Install
Accelerator Pedal, Remove and Install accelerator
Starter, Remove and Install
Sealants, Lubricants and Locking Agents Compounds
Control Unit - Cooling module, Remove and Install
Description and Operation
Component Locator
Specifications
Special Tools and Equipment
Other Information
Seals and Seal Rings
Ribbed V-Belt
Engine Damping Block
Oil Circulating
Timing Gear Case
Cylinder Block
Cylinder Head
Vacuum Pump
Auxiliary aggregate drive
Fuel Injection Systems
Engine Electrics
Cooling System
Turbo-Charging
K Clutch and Transmission
L Fuel and Exhaust System
M Steering
N Electrical Equipment and Instruments
R Accessories