vauxhall Workshop Repair Guides

Vauxhall Workshop Manuals


General Warnings and Safety Regulations

1.1 Contents

Air Conditioning


Running Gear, Wheels, Tyres

Brake System

Engine, Fuel and Exhaust Systems LUREF_1.gif

Natural Gas Vehicles

Clutch, Transmission

Electrics, Electronics



Paintshops in accordance with §14 Hazardous substances order

Restraint systems

List of technical terms - Technical ABC LUREF_1.gif

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...

Describes the implementation or omission of situations or measures, in order to prevent personal injury.

Describes the implementation or omission of situations or measures, in order to prevent damage to components or to vehicles.


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.


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:

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


  • 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


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

General Vehicle Information > Warnings, Disclaimers, Safety > General Warnings and Safety Regulations