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Holden ASTRA AH 2004-2009 Service Repair Manual

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🏷️ Basic Information Identification Make: Holden Model: Astra Generation Code: AH Model Years Covered: 2004-2009 👋 Introduction Market Position Vehicle Segment: Compact / Small Family Car Target Market: Affordable, practical,...
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Holden ASTRA AH 2004-2009 Service Repair ManualHolden ASTRA AH 2004-2009 Service Repair ManualHolden ASTRA AH 2004-2009 Service Repair ManualHolden ASTRA AH 2004-2009 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Holden
Model:
Astra
Generation Code:
AH
Model Years Covered:
2004-2009
👋 Introduction
Market Position
Vehicle Segment:
Compact / Small Family Car
Target Market:
Affordable, practical, and reliable transportation for individuals and families.
Competitive Analysis
Key Competitors:
Ford Focus, Toyota Corolla, Mazda3, Mitsubishi Lancer, Hyundai Elantra, Honda Civic
Key Features
Vehicle Strengths:
Generally considered to offer good value for money, comfortable ride, decent handling, and a practical interior for its class.
Manual Value Proposition:
Empowers owners and technicians with the knowledge to maintain and repair the vehicle effectively, potentially saving on labor costs and ensuring longevity.
📋 Manual Details
Coverage Areas
Primary Coverage:
Service and Repair Procedures
Target Audience:
DIY enthusiasts and professional mechanics
Page Count
Estimated Pages:
Varies by specific edition, but comprehensive service manuals typically range from 1000+ pages.
Manual Type
Type:
Service and Repair Manual
Language
Language:
English
Format
File Format:
PDF
Delivery Method:
Instant Download
📖 Manual Coverage
Systems Covered
Powertrain:
Engine mechanical, fuel system, cooling system, lubrication system, ignition system, exhaust system
Transmission:
Manual and Automatic Transmission (service, repair, diagnostics)
Chassis:
Suspension (front and rear), steering system, braking system (including ABS)
Electrical:
Body electrical systems, lighting, instruments, HVAC, infotainment, engine control unit (ECU) and related sensors, wiring diagrams
Body:
Body panels, doors, glass, interior trim, exterior components
Procedures Included
Maintenance:
Routine checks, fluid changes, filter replacements, scheduled service intervals
Repair:
Step-by-step repair instructions for all major components and systems
Diagnostics:
Troubleshooting guides, fault code interpretation, diagnostic procedures
Disassembly Assembly:
Detailed instructions for component removal and installation
Technical Depth
Depth:
Comprehensive, covering everything from basic maintenance to complex mechanical and electrical repairs.
📊 Manual Specifications
File Format
File Type:
PDF
Searchable Text:
Likely yes, common for professional PDF service manuals.
Print Quality
Printability:
Full Printable
Zoom Functionality
Zoom Capability:
YES
Requirements
Software Requirements:
Adobe PDF Reader & WinZip
Operating System Compatibility:
All Versions of Windows & Mac
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Quality:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Family:
GM Ecotec
Engine Code Examples:
Z18XER, Z22SE (check specific vehicle VIN for exact engine)
Displacement Liter:
1.8L (1796 cc) and 2.2L (2198 cc) typically
Configuration:
Inline 4-cylinder
Performance
Horsepower Range:
Approximately 125-150 PS (92-110 kW) depending on engine variant and tuning.
Torque Range:
Approximately 170-200 Nm (125-148 lb-ft) depending on engine variant.
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded Petrol (Octane rating as per manufacturer recommendation, typically 91 or higher).
Engine Management
ECU Type:
GM's ECU (e.g., Delphi, Siemens VDO) with OBD-II diagnostics.
🔧 Transmission
Standard
Type:
5-speed Manual Transmission
Optional
Type:
4-speed Automatic Transmission (e.g., GM 4T40-E / 4T45-E)
Features
Clutch Type:
Hydraulically operated diaphragm spring clutch (for manual)
Fluid Specifications
Manual Transmission Fluid:
API GL-4, SAE 75W-80 or 75W-90 (refer to manual for exact specification and capacity)
Automatic Transmission Fluid:
Dexron III or Dexron VI compatible fluid (refer to manual for exact specification and capacity)
📐 Dimensions
Exterior
Body Styles:
Hatchback (3-door and 5-door), Sedan (4-door), Wagon (5-door)
Wheelbase Mm:
Approximately 2600-2610 mm (102.4-102.8 inches), varies slightly by body style.
Weights
Curb Weight Kg:
Approximately 1200-1350 kg (2645-2976 lbs), depending on body style and equipment.
🛡️ Safety Features
Ratings
Ancap Rating:
Typically achieved 4 out of 5 stars in ANCAP testing for the Astra AH (check specific year and variant for official ratings).
Active Features
Standard Safety Equipment:
Anti-lock Braking System (ABS), Electronic Stability Program (ESP - often optional or on higher trims), Traction Control System (TCS)
Passive Features
Airbags:
Driver and front passenger airbags, side airbags (optional on some trims), curtain airbags (optional on some trims)
Seatbelts:
Three-point seatbelts with pretensioners and load limiters
💡 Technology Features
Infotainment
Audio System:
Factory fitted CD player with AM/FM radio, optional CD changer, various speaker configurations.
Display:
Digital display for radio and clock, multi-function display in instrument cluster.
Driver Assistance
Cruise Control:
Available on most models, often as standard on higher trims.
Parking Sensors:
Optional on some later models.
Connectivity
Auxiliary Input:
Rarely standard, may be an aftermarket addition or available on higher trim levels.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 15,000 km (9,300 miles) or 12 months, whichever comes first (refer to owner's manual for exact recommendation based on driving conditions).
Air Filter Replacement:
Every 30,000 km (18,600 miles) or as needed based on driving environment.
Spark Plug Replacement:
Around 60,000 km (37,000 miles) for standard plugs, up to 100,000 km (62,000 miles) for iridium/platinum plugs (check manual for specific type).
Coolant Replacement:
Initial replacement around 5 years or 100,000 km (62,000 miles), then every 2-3 years or 50,000 km (31,000 miles) thereafter (using correct coolant type).
Fluid Specifications
Engine Oil Type:
Typically SAE 5W-30 or 5W-40 synthetic or semi-synthetic oil meeting GM specifications (e.g., GM-LL-A-025 or GM-LL-B-025 - consult manual for exact spec).
Engine Oil Capacity:
Approximately 4.0-4.5 liters (4.2-4.8 US quarts) for 1.8L and 2.2L engines, including filter (verify with manual).
Coolant Type:
GM-approved OAT (Organic Acid Technology) coolant, typically orange or pink in color (e.g., Dex-Cool compatible).
Brake Fluid Type:
DOT 4
Known Issues
Common Problems:
Oil leaks from rocker cover gasket or sump gasket, minor electrical gremlins (e.g., window regulators, central locking), exhaust system corrosion, occasional cooling system leaks (e.g., radiator, hoses), potential for ABS sensor issues.
Timing Belt Or Chain:
Ecotec engines typically use a timing chain, which generally does not require scheduled replacement unless issues arise (e.g., stretching, tensioner failure).
📚 Vehicle History
Brand Heritage
Holden History:
Holden, an Australian automotive manufacturer with a long and storied history, known for producing iconic vehicles like the Commodore and Monaro. Holden's Astra models were rebadged versions of Opel (GM's German subsidiary) vehicles.
Model Evolution
Astra Ah Origin:
The Holden Astra AH is based on the Opel Astra G platform (internally known as the 'T98' platform).
Generation Details:
This generation of Astra was produced globally by Opel/Vauxhall and sold under various GM brands, including Holden in Australia.
Production
Manufacturing Location:
Primarily manufactured in Europe by Opel for global distribution, including for the Australian market by Holden.
🏆 Awards & Recognition
Recognitions
Safety Awards:
As mentioned, ANCAP safety ratings are a key recognition. Specific awards may vary by market and year of release.
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