Astra H
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
2 Coding plug for Octane Number setting
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
4 Lubricants - Astra-G
5 Engine oil filling quantity - Astra-G
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
Time Allowances - Astra-G
Additional operations - Astra-G
1) Only for vehicles in severe operating conditions
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