This manual covers the Astra G, also known as the Mk4 or T98 generation, produced from 1998 to 2000. As a compact family car, the Astra G offered a range of body styles including 3-door and 5-door hatchbacks, a 4-door saloon, and a 5-door estate. It was engineered to be a practical and reliable vehicle, continuing a legacy of accessible transportation. Key features included a variety of petrol and diesel engines, front-wheel drive, and available safety systems like ABS and airbags, making it a competitive option in its segment against rivals like the Ford Focus and Volkswagen Golf.
This comprehensive workshop service repair manual, written in English, provides detailed information for the maintenance, diagnosis, and repair of the Astra G. It covers all major systems, including the powertrain (engine, transmission, drivetrain), chassis (suspension, steering, brakes), electrical systems (12V, ignition, lighting, instrumentation, SRS, immobilizer), and body/interior components (body panels, HVAC). Within its extensive scope, the manual details routine maintenance procedures, troubleshooting guides, diagnostic steps, and repair or rebuild procedures for all components. It is designed to assist owners, mechanics, and technicians in performing accurate and efficient servicing and repairs, ensuring the longevity and optimal performance of the vehicle.
Generation Code:
Mk4 / T98
Production Years:
1998-2000
Vehicle Segment:
Compact/Small Family Car (C-segment)
Key Competitors Era:
Ford Focus, Volkswagen Golf, Renault Mégane, Peugeot 306/307
Manual Advantage:
Provides DIY mechanics and professional technicians with the detailed procedures and specifications necessary for accurate and efficient servicing and repair, reducing guesswork and costly errors.
Regions Covered:
Global (Vauxhall and Opel variants)
Type:
Workshop Service Repair Manual
Format:
PDF (Digital Download)
Powertrain:
Engine (petrol & diesel), Transmission (manual & automatic), Drivetrain (FWD)
Chassis:
Suspension (front & rear), Steering, Brakes (front & rear disc/drum, ABS)
Electrical:
12V system, Battery, Alternator, Starter motor, Lighting, Ignition, Instrumentation, Body control modules, SRS (Airbag), Immobilizer
Body And Interior:
Body panels, Doors, Hood, Trunk, Bumpers, Interior trim, Seats, HVAC (Heating, Ventilation, Air Conditioning)
Maintenance:
Oil changes, Filter replacements, Fluid checks and top-ups, Spark plug replacement, Belt inspections and replacement
Diagnostics:
Troubleshooting guides, Fault code interpretation (OBD-II where applicable), Component testing
Repair And Rebuild:
Engine overhauls, Transmission repairs, Brake system servicing, Suspension component replacement, Electrical component repair/replacement
Adjustments And Settings:
Wheel alignment, Clutch adjustment, Headlight aiming, Idle speed adjustment
Depth:
Comprehensive (from routine maintenance to complete engine/transmission rebuilds)
Compatibility:
PC & Mac compatible (Windows 95-11, macOS, Linux)
Readability:
High-resolution PDF, optimized for screen viewing and printing
Digital Format:
N/A (Digital Download)
Digital Format:
N/A (Digital Download)
Engine Codes Common:
X16XEL, X18XE1, X20XEV, Z16XE, Z18XE (representative codes)
Engine Codes Common:
X17DTL, X17DTH, Y17DT (representative codes)
Power Range:
60 HP (1.4L) to 150 HP (2.0L Turbo OPC/GSi variants)
Fuel Delivery:
Multi-point fuel injection (MPI), Direct Injection (DI for some diesel variants)
ECU Types:
Bosch Motronic, Siemens Simtec (typical)
Manual Transmissions:
5-speed manual (e.g., F17, M32)
Automatic Transmissions:
4-speed automatic (e.g., AF13, AF17)
Clutch Type:
Hydraulically operated single dry plate clutch
Body Styles:
3-door hatchback, 5-door hatchback, 4-door saloon, 5-door estate (Caravan/Sports Tourer)
Curb Weight Range:
Approx. 1100 kg - 1350 kg
Euro Ncap Era:
Participated in Euro NCAP testing during its lifespan. Later models achieved reasonable scores for the era.
ABS:
Anti-lock Braking System (ABS) available on many models
Airbags:
Driver and front passenger airbags standard on many variants, side airbags optional.
Seatbelts:
Pre-tensioning front seatbelts
Audio Systems:
Factory fitted radio/cassette or CD players, often with steering wheel controls on higher trims.
Cruise Control:
Optional on many engine variants, particularly higher-powered ones.
Phone Integration:
Limited to aftermarket Bluetooth kits or basic cradles for mobile phones during this era.
Oil Change Interval:
Typically 15,000 km or 12 months, whichever comes first (variable by engine and oil type).
Timing Belt Interval:
Varies by engine, e.g., 60,000-100,000 km or 4-6 years for petrol engines, diesel timing chains may not have a fixed interval.
Engine Oil:
API SL/SJ or ACEA A3/B3, A3/B4. Viscosity grade typically 5W-30 or 5W-40 (check specific engine requirement).
Coolant:
Ethylene glycol-based coolant with corrosion inhibitors (e.g., GM DEX-COOL equivalent or OAT type).
Common Problems Petrol:
EGR valve clogging, ignition coil failure, lambda sensor issues, thermostat housing leaks, piston ring wear (on some older engines).
Common Problems Diesel:
Turbocharger issues (especially on early 1.7Dti), glow plug failure, injector seals.
Common Problems General:
Rear axle bush wear, ABS sensor failures, central locking issues, minor electrical gremlins, exhaust system corrosion.
Vauxhall Opel Legacy:
Continuation of Vauxhall/Opel's long history in producing reliable and accessible family cars.
Astra G Positioning:
Replaced the Astra F, introducing a more modern design, improved chassis dynamics, and a wider range of engines. Later updated into the Astra H.
Manufacturing Locations:
Primarily Ellesmere Port (UK - Vauxhall), Rüsselsheim (Germany - Opel), and other Opel/GM plants globally.
Industry Awards:
The Astra G was a strong performer in its class and a consistent seller, often praised for its ride comfort and practicality. Specific awards varied by market.
