Auto Repair Manual Free Download and ReviewsFree download ebook pdf files automotive manual

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Keys, doors, windows, sunroof To raise Turn the rotary switch to any position between d and e. The sunroof w ill automatic ally move to the desired position. When the rotary switch is in position e, the sunroof is fully raised. 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. Automatic closing 3 See page 33. If when the vehicle is being driven the sunroof encounters resistance during automatic closing, because of the higher closing forces involved the protective function cannot be guaranteed, and there is a risk of injury. If the sunroof movement is stiff, e.g. due to frost, turn rotary switch to d and keep it pressed until the sunroof is closed. Keys, doors, windows, sunroof Sunshade To reduce the sunlight in the interior with the sliding roof closed or raised. O pen or close sunshade as required. When the sunroof is opened, the sunshade is also opened. Overload If the sy stem is overloaded, the power sup ply is automatically cut off for a short time. Fault If the sunroof no longer assumes the desired position automatically , programm e sunroof electronics as follow s: 1. Switch on ignition. 2. Press the rotary switch until the sunroof is shut, then keep it pressed for a t least a further 3 seconds. 3. Turn rotary switch to ü and keep it depressed until the sunroof is open. 4. Turn rotary switch to d and keep it depressed until the sunroof is closed . 5. Turn rotary switch to e and leave there until the sunroof is fully raised. 6. Turn rotary switch to d and keep it depressed until the sunroof is closed . Electrically operated rear window blind 3 Reduces intensity of sunlight shining on to rear seats. Operation w ith ignition switched on. To raise To lower = = Do not operate blind if there are objects lying in front of the rear window. Sun blinds for rear door windows 3 To reduce sunlight a t the rear seats. Pull the blind upwards using the grip and engage it at the top in the door frame. Press N Press N again

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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.

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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.

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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.

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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