Vauxhall/Opel Astra & Zafira Petrol (Feb 98 – Apr 04) R-04 reg. Astra Hatchback, Saloon & Estate, & Zafira MPV, inc. special/limited editions.
Does NOT cover Coupe or Convertible, new range introduced May 2004, Diesel or bi-fuel models
1.4 litre (1389cc), 1.6 litre (1598cc), 1.8 litre (1796cc), 2.0 litre (1998cc) & 2.2 litre (2198cc).
Does NOT cover 1.6 litre ‘Twinport’ or 2.0 litre turbo engines

Fault
Caller reported to the helpline that the vehicle had developed a misfire under load, especially when the engine was hot. It was also mentioned that as the misfire occurred, the engine would suddenly appear to run on only 3 cylinders. The engine running on 3 cylinders would continue until the ignition was switched OFF. If the engine was re-started the engine would run on all 4 cylinders again until the misfire reoccurred under load, and then the engine once again appeared to be running on only 3 cylinders.
Cause
The initial misfire fault under load was finally traced to cylinder no 1 on the engine. The fault was caused by a poor output from the DIS ignition coil pack fitted to the vehicle. Upon testing the vehicle, it was discovered that when the misfire occurred on cylinder no 1, the Multec engine management ECM would switch OFF the fuel injector for the affected cylinder. The caller reported that when the engine was switched OFF and then restarted the misfire would disappear, and the fuel injector for cylinder no 1 would operate normally again download

Coolant loss through the water pump bearing seal is commonly caused by a faulty cooling system pressure cap. With certain designs of the plastic pressure cap, if the cooling system overheats distortion of the pressure relief valve in the cap can cause the valve to stick and result in excessive pressure in the cooling system. It is recommended that the coolant pressure cap is always checked for correct operation, prior to the fitment of a new water pump. Thermostat Testing In order to confirm if the thermostat is operating as required, the correct testing procedure should be adopted.

Equipment required : 1) A container of undiluted anti-freeze mixture, to allow the temperature of the liquid to be raised above boiling point. (DO NOT use plain water). 2) A suitable heating element to raise the temperature of the liquid. 3) An accurately calibrated thermometer, with a range suitable for the thermostat to be tested. Testing Lower the thermostat into the container of anti-freeze, along with the thermometer, and heat the liquid slowly to the temperature marked on the thermostat, e.g 88 degrees, whilst agitating the thermostat. Let the temperature remain stable for one minute, then check for initial opening of the thermostat valve, Note: The valve will only just crack open at this temperature. Increase the temperature of the liquid to at least 14 degrees above the initial opening temperature, e.g.102 degrees, again allow one minute, then check the valve is fully opened. Allow the liquid to cool to below the initial opening temperature, then check that the valve is fully closed. Opening and fully open temperatures should be within plus or minus 2 degrees of those stated A build up of sediment coating on the thermostat can adversely effect the performance of the thermostat. download

Special Precautions Special Precautions Disconnect battery earth lead. DO NOT turn crankshaft or camshaft when timing belt removed. Remove glow plugs to ease turning engine. Turn engine in normal direction of rotation (unless otherwise stated).

DO NOT turn engine via camshaft or other sprockets. Observe all tightening torques. Check diesel injection pump timing after belt replacement. Removal Removal 1. Support engine. 2. Remove: Air filter and air intake hoses. Auxiliary drive belts. RH engine mounting. Vacuum pipe bracket. Timing belt upper cover [1]. 3. Turn crankshaft clockwise to TDC on No.1 cylinder. Ensure crankshaft sprocket timing marks aligned [2]. 4. Insert M6 x 1,00 bolt in camshaft sprocket and M8 x 1,25 bolt in injection pump sprocket to lock sprockets in position [3]. NOTE: If locating holes not aligned: Turn crankshaft one turn. 5. Remove: Crankshaft pulley (4 bolts). Timing belt lower cover [4]. 6. Slacken tensioner bolts [6]. Remove tensioner spring [5]. 7. Move tensioner pulley away from belt. Lightly tighten bolts. 8. Remove timing belt. Installation Installation 1. 2. 3. 4. 5. Use crankshaft pulley to check TDC marks aligned [2]. Ensure locking bolts located correctly [3]. Fit timing belt in clockwise direction, starting at crankshaft sprocket. Ensure belt is taut between sprockets. Temporarily fit crankshaft pulley.

Ensure timing marks aligned [2]. Fit tensioner spring [5]. Corsa-B/Corsavan/Combo: Slacken tensioner bolts [6]. Allow tensioner to operate. Remove locking bolts [3]. Tighten tensioner bolts to 19 Nm [6]. Turn crankshaft slowly two turns clockwise. Ensure timing marks aligned [2]. 6. Astra-F/Vectra/Cavalier: Slacken tensioner bolts [6]. Temporarily fit crankshaft pulley. Remove locking bolts [3]. Turn crankshaft 60° anti-clockwise (against normal direction of rotation) [7]. Tighten tensioner bolts to 19 Nm [6]. Turn crankshaft slowly two turns + 60° clockwise until timing marks aligned [2]. 7. 8. 9. 10. 11. Ensure timing marks aligned [2]. Ensure locking bolts can be inserted in sprockets [3]. If not: Repeat tensioning procedure. Remove crankshaft pulley. Fit timing belt lower cover [4]. Fit crankshaft pulley. Tighten bolts to 20 Nm. Install components in reverse order of removal. 

Disconnect battery. Disconnect harness multi-plug from engine coolant temperature (ECT) sensor Fig.1 [2] . Disconnect harness multi-plug from mass air flow (MAF) sensor Fig.1 [4] . Remove protective cover Fig.1 [1] . Remove plastic tube from wiring harness Fig.1 [3] . Remove insulation tape from wiring harness. Cut engine coolant temperature (ECT) sensor wiring and remove from cable ducting.

Cut new engine coolant temperature (ECT) sensor wiring a minimum of 120 mm long. Fit new wiring harness multi-plug to wires Fig.2. Repair wiring with repair kit listed. Seal with insulation tape Fig.3. Remove engine coolant temperature (ECT) sensor. Fit modified engine coolant temperature (ECT) sensor. Tightening torque: 18 Nm. Refit wiring harness multi-plug. Reconnect battery. Erase fault memory. 1995 – 2001 VAUXHALL Vectra 2.5 i Poor starting from colddownload

To lower Turn rotary switch to d. Posit ion memory After the ignition has been switched on, the sunroof c an be automatically returned to its last position b y briefly pressing the rotary switch. Safety function If the sunroof encounters resistance during automatic closing, it is immediately stopped and opened again, as long as the vehicle is stationary. Operated using rotary switch in the overhead control panel.

To open Turn the rotary switch to any position between d and ü. The sunroof will automatically move to the desired position. When the switch is in position ü , the sunroof is fully opened . Com fort position Set rotary switch to position f.

With the roof in this position, w ind noise is reduced. To close: Turn rotary switch to d. 9 Warning Closing sunroof from outside To close the sunroof from outside with the remote control: Press button p until the sunroof is closed. If the electric windows 3 are to be closed from outside the vehicle, but the sunroof is to be left op en, briefly press the rotary switch before switching off the ignition.  download

TROUBLE SHOOTING OPEL / VAUXHALL 1 A0909032-1 Trouble shooting – OPEL / VAUXHALL Preface The program cassette in the Multi-Tester pro is the component which gives the diagnostic equipment its unique test performance. The program cassette can easily be changed to set the Multi-Tester pro up quickly for the diagnostic task at hand. The Multi-Tester pro software is available in two levels of functionality, Plus line and Pro line. This manual covers the operation of the Pro line cartridge. Although operation and display screens are identical for each line, please be aware that some of the functions described are not available on Plus line cartridges. The Plus line cartridge has the following functions: engine DTC:s and monitor list, airbag DTC:s, ABS DTC:s and service light resetting as well as snapshots. This fault-finding instruction describes the serial application for trouble shooting via the diagnostic connector on Opel and Vauxhall.