Vauxhall Astra Mk 5 (2004-2008): service and repair manuals

Vauxhall / Opel Astra - Petrol (May 2004 - 2008) - Haynes Service and Repair Manual

Haynes workshop manual on the Vauxhall / Opel Astra petrol models.

Versions: Hatchback, Sport Hatch and Estate.

Petrol engines:
- 1.4 (1364 cc, engine codes Z14XEP and Z14XEL)
- 1.6 (1598 cc, type Z16XEP)
- 1.8 (1796 cc, types Z18XE and Z18XER).

Production years: 5/2004-2008.

Exclusions: Please note that this manual does not cover the 1.6 or 2.0 litre turbo engines, the 1.6 litre VVT engine (Z16XER) or the Astra TwinTop.

Using photos and step-by-step instructions this Haynes manual on the Vauxhall / Opel Astra petrol models describes maintenance, repair and overhaul of the petrol engines (distribution, belts, valves, camshaft, cylinder head, oil pump, seals and radiator).
It also addresses issues related to the heater, fuel system, exhaust, starting and charging system. Furthermore, it covers work on the clutch, gearbox, driveshafts, braking system, suspension, steering gear, body, interior and electrical system.

• Based on a complete strip-down and rebuild.
• Includes a maintenance schedule, technical specifications, torque wrench settings and troubleshooting tables.
• Clear and detailed wiring diagrams for easy reference.

Click here to know more about the Haynes Car Service and Repair Manuals

Vauxhall / Opel Astra - Diesel (May 2004 - 2008) - Haynes Service and Repair Manual

Haynes workshop manual on the Vauxhall / Opel Astra diesel models.

Versions: Hatchback, Sport Hatch and Caravan estate.
Turbo diesel engines:
- 1.3 (1248 cc, type Z13DTH)
- 1.7 (1686 cc, 80 and 100 hp, types Z17DTL and Z17DTH)
- 1.9 (1910 cc, SOHC, 101 and 120 hp, types Z19DTL and Z19DT)
- 1.9 (1910 cc, DOHC, 150 hp, type Z19DTH).

Production years: 5/2004-2008.

Exclusions: Please note that this manual does not cover the Astra TwinTop or the Easytronic transmission.

Using photos and step-by-step instructions this Haynes manual on the Vauxhall / Opel Astra Diesel describes maintenance, repair and overhaul of the diesel engines (distribution, belts, valves, camshaft, cylinder head, oil pump, seals and radiator).
It also addresses issues related to the heater, the injection pump and injector nozzles, the exhaust, the starting and charging system. Furthermore, it covers work on the clutch, gearbox, driveshafts, braking system, suspension, steering gear, body, interior and electrical system.

• Based on a complete strip-down and rebuild.
• Includes a maintenance schedule, technical specifications, torque wrench settings and troubleshooting tables.
• Clear and detailed wiring diagrams for easy reference.

Click here to know more about the Haynes Car Service and Repair Manuals

Opel Astra H - Benziner (ab Modelljahr 2004) - Bucheli Reparaturanleitung

Bucheli Reparaturanleitung for service and repair of the Opel Astra H petrol models, Limousine and Kombi.

Petrol engines:
- 1.4 Twinport Ecotec (66 kW/90 hp)
- 1.6 Twinport Ecotec (77 kW/105 hp)
- 1.8 Ecotec (103 kW/140 hp)
- 2.0 Turbo Ecotec (125 kW/170 hp)
- 2.0 Turbo Ecotec (147 kW/200 hp)
- 2.0 Turbo Ecotec (177 kW/241 hp).

Production years: since model year 2004.

This Bucheli repair manual on the Opel Astra H petrol models provides detailed instructions for work on the engine (removal - refitting, crankshaft, connecting rods, pistons, distribution, valves, oil pump, cooling, fuel system).
Covers also the clutch, gearbox (only removal and installation), driveshafts, steering system, front and rear suspension, brakes, electrical system and the exhaust.

• Includes comprehensive technical data and torque wrench settings.
• Clear wiring diagrams.

Click here to know more about the Bucheli repair manuals

Opel Astra - Benzin- und Dieselmotoren (ab Modelljahr 2004) - Jetzt helfe ich mir selbst

Repair manual from the series "Jetzt helfe ich mir selbst" (nr. 243, reprint) for maintenance of the Opel Astra H, including Caravan.

Petrol engines:
- 1.4 16V Twinsport Ecotec (66 kW/90 hp)
- 1.6 16V Twinsport Ecotec (77 kW/105 hp)
- 1.8 16V Ecotec (92 kW/125 hp)
- 2.0 Turbo Ecotec (125 kW/170 hp and 147 kW/200 hp).

Diesel engines:
- 1.3 CDTI Ecotec (66 kW/90 hp)
- 1.7 CDTI 16V Ecotec (59 kW/80 hp and 74 kW/100 hp)
- 1.9 CDTI 16V Ecotec (88 kW/120 hp and 110 kW/150 hp).

Production years: since 2004.

• This owner's guide describes the technology of the Opel Astra.
• Comprehensive instructions for the replacement of current parts such as: shock absorbers, brake pads, brake discs, master cylinder and brake fluid / door mirrors, fuel cap, grille, bumpers, bonnet, tailgate, interior trim and seats / alternator and starter motor, voltage regulator, headlamps, tail lights / air filter, drivebelt, thermostat, coolant, oil filter and spark plugs.
• Complete with adjustment data and a maintenance schedule.

Click here to know more about the series "Jetzt helfe ich mir selbst"

Opel Astra - Diesel 1.7 CDTi 100 et 1.9 CDTi 120 (depuis 04/2004) - Revue Technique Automobile (RTA 699.1)

Revue Technique Automobile (RTA 699) covering the Opel Astra diesel models, 3-door, 5-door and station wagon.

Versions: Enjoy, Cosmo, Elegance, Sport, etc.

Diesel engines:
- 1.7 CDTi (1686 cc, 100 hp, Z17DTH)
- 1.9 CDTi (1910 cc, 120 hp, Z19DTH [16V] and Z19DT [8V]).

Production years: since 4/2004.

This Revue Technique for the Opel Astra Diesel describes extensively service and repair of the diesel engines (including timing gear, cylinder head, lubrication, coolant pump, injection pump and injectors).
Covers also work on the clutch, transmission, driveshafts, steering system, suspension, wheel hubs, brakes, electric equipment and body.

• Includes adjustment data and wiring diagrams.
• An integral owner's handbook provides information on operation and daily maintenance.
• Additional chapter with tips and a checklist to prepare for the MOT test.

Opel Astra H (3/2004-11/2009), Zafira B (7/2005-11/2010) - Benziner und Diesel - So wird's gemacht

Workshop manual from the German series So wird's gemacht (nr. 135) on the Opel models:
- Astra H (03/2004-11/2009)
- Zafira B (07/2005-11/2010)

Petrol engines:
- 1.4 L (66 kW/90 hp, 03/04-11/09)
- 1.6 L (77 kW/105 hp, 03/04-11/07)
- 1.6 L (85 kW/115 hp, 02/07-11/10)
- 1.6 L (132 kW/180 hp, 02/07-11/09)
- 1.8 L (92 kW/125 hp, 03/04-01/07)
- 1.8 L (103 kW/140 hp, 07/05-11/10)
- 2.0 L (125 kW/170 hp, 03/04-01/07)
- 2.0 L (147 kW/200 hp, 09/04-08/10)
- 2.2 L (110 kW/150 hp, 07/05-08/10)

Diesel engines:
- 1.3 L (66 kW/90 hp, 04/05-11/09)
- 1.7 L (59 kW/80 hp, 03/04-03/05)
- 1.7 L (74 kW/100 hp, 03/04-01/07)
- 1.7 L (81 kW/110 hp, 02/07-11/10)
- 1.7 L (92 kW/125 hp, 02/07-11/10)
- 1.9 L (74 kW/100 hp, 07/05-01/07)
- 1.9 L (88 kW/120 hp, 08/04-08/10)
- 1.9 L (110 kW/150 hp, 08/04-08/10).

The initial section of this manual on the Opel Astra H and Zafira B covers inspection and daily maintenance of the petrol and diesel engines, transmission, brakes, steering and body (including the electrical system, windscreen wipers, lighting and heating or air conditioning).

Furthermore, this book provides detailed guidance on the following components:
- Suspension (replacement of driveshafts, springs and shock absorbers), steering (ball joints) and brakes (discs, brake linings and handbrake).
- Electrical system (battery, voltage regulator and starter motor).
- Dismantling and assembly of the engine cylinder head and cam drive, including replacement of the v-belt and the timing belt or chain.
- The lubricating system with the oil pump.
- The cooling system (replacement of radiator, thermostat and cooling fan).
- The fuel system (air filter, fuel pump and fuel filter) and exhaust (replacement of mufflers).
- Interior: removal and refitting of the dashboard, instrument panel, consoles, interior trim and seats.
- Body: dismantling and assembly of bumpers, fenders, bonnet, tailgate, doors, window mechanisms, locks and mirrors.

• Extensive technical specifications, adjustment data and torque wrench settings.
• 16 clear wiring diagrams of the main circuits.

Click here to know more about the series "So wird's gemacht"