🏷️ Basic Information

Make:

Holden / Opel

Model:

Astra AH / Astra H

Generation:

AH / H

Model Years Covered:

2004, 2005, 2006, 2007, 2008, 2009

Chassis Code:

AH (Holden) / H (Opel)

👋 Introduction

Segment:

Compact car segment (Holden Astra AH derived from Opel Astra H platform)

Competitors Era:

Competed against vehicles like Ford Focus, Mazda 3, Toyota Corolla, Volkswagen Golf during its production run.

Platform Sharing:

Shares platform with Opel Astra H, indicating a global engineering basis.

Manual Usability:

Designed for ease of use with step-by-step instructions and visual aids, making complex tasks accessible.

Value Proposition:

Cost-effective solution for maintaining and repairing the vehicle, saving on dealership service costs.

📋 Manual Details

Main Coverage:

Workshop Service and Repair

Additional Coverage:

Owner's Manual

Estimated Pages:

Comprehensive (exact count not specified, but indicated as extensive)

Type:

Electronic PDF Workshop Service Manual

Language:

English

Format:

PDF Download

📖 Manual Coverage

Engine Mechanical:

Complete engine overhaul, disassembly, assembly, component testing, specifications

Engine Management:

Electronic Control Module (ECM) operation, diagnostics, fuel injection, EGR systems

Cooling System:

Radiator, hoses, thermostat, water pump, fan, coolant specifications

Fuel System:

Fuel tank, pump, lines, injectors, pressure testing, evaporative emissions control

Lubrication System:

Oil pump, oil filter, oil pan, oil specifications, pressure testing

Exhaust System:

Exhaust manifold, catalytic converter, mufflers, emissions control components

Clutch System:

Clutch operation, inspection, replacement, fluid specifications

Transmission Manual:

Manual transmission overhaul, repair, fluid specifications, gear selection

Transmission Auto:

Automatic transmission overhaul, repair, fluid specifications, shift control

Propulsion Mechanism:

Drivetrain components, driveshafts, CV joints

Axles Front Rear:

Front and rear axle assemblies, differential, bearing specifications

Suspension System:

Struts, shocks, springs, control arms, bushings, alignment specifications

Steering System:

Steering rack, power steering pump, fluid, tie rods, alignment

Brake System:

Brake calipers, rotors, pads, lines, master cylinder, fluid specifications, bleeding procedures

ABS:

Anti-lock Brake System components, sensors, hydraulic unit, diagnostics

Electrical System Main:

12V system, battery, charging system, starting system, wiring harness overview

Electrical Diagrams:

Detailed circuit diagrams for all vehicle systems

Body Systems:

Body panel removal/installation, doors, windows, interior trim

Wiper Washer:

Windshield wiper and washer system components, operation, troubleshooting

Instrument Cluster:

Dashboard instrumentation, gauges, warning lights, diagnostic indicators

Generator Starter:

Alternator and starter motor testing, removal, installation

Can Communication:

CAN (Controller Area Network) communication system architecture and troubleshooting

Speaker Antenna:

Audio system components, speaker wiring, antenna systems

General Maintenance:

Routine checks, fluid changes, filter replacements, lubrication

Troubleshooting:

Diagnostic procedures for common and complex issues across all systems

Repair Rebuild:

Detailed step-by-step instructions for component repair and complete system rebuilds

Removal Installation:

Procedures for removing and installing major components like engine, transmission, suspension, etc.

Diagnostics Testing:

Techniques for diagnosing faults using onboard diagnostics (OBD-II) and specialized tools

Specifications Data:

Torque values, clearances, fluid capacities, electrical values, performance data

Depth:

Comprehensive (from basic maintenance to complete engine/transmission rebuilds and advanced diagnostics)

Target Audience:

DIY enthusiasts and professional mechanics

📊 Manual Specifications

Format Details:

Searchable PDF, printable pages

Quality:

High-resolution, includes detailed illustrations, pictures, and diagrams

Binding:

N/A (Digital Download)

Paper Type:

N/A (Digital Download - Printable)

⚙️ Engine Specifications

Engine 1 4L:

1.4L 4-Cylinder Inline, Z14XE, DOHC Petrol. Typically around 89-90 PS (88-89 hp / 65-66 kW) and 125-130 Nm (92-96 lb-ft) torque.

Engine 1 6L:

1.6L 4-Cylinder Inline, Z16XE, DOHC Petrol. Typically around 104-105 PS (103-104 hp / 76-77 kW) and 150-152 Nm (111-112 lb-ft) torque.

Engine 1 8L:

1.8L 4-Cylinder Inline, Z18XE, DOHC Petrol. Typically around 125 PS (123 hp / 92 kW) and 170 Nm (125 lb-ft) torque.

Engine 2 0L Turbo:

2.0L 4-Cylinder Turbo Intercooled, Z20LE DOHC Petrol (e.g., Z20LEH, Z20LER variants). Power outputs varied significantly by specific 'GSi' or 'VXR' trim, ranging from 170 PS (168 hp / 125 kW) to 200 PS (197 hp / 147 kW) and higher for performance variants.

Horsepower Range:

Approximately 89 hp (1.4L) to 200+ hp (2.0L Turbo variants).

Torque Range:

Approximately 92 lb-ft (1.4L) to 180+ lb-ft (2.0L Turbo variants).

Injection Type:

Multi-point fuel injection (MPI) or sequential fuel injection (SFI), depending on engine variant.

🔧 Transmission

Manual Gearbox:

Typically a 5-speed manual transmission for most engine variants.

Automatic Gearbox:

Optional automatic transmission, likely a 4-speed or 5-speed unit depending on engine and market.

Gear Ratios:

Specific gear ratios would be detailed within the manual for each transmission and engine combination.

Clutch Type:

Hydraulically operated single dry plate clutch.

📐 Dimensions

Body Styles:

Hatchback (3-door and 5-door), Saloon (4-door), Estate/Wagon (5-door) depending on specific market/Opel Astra H variants.

Curb Weight Range:

Approximately 1200 kg - 1400 kg, varying by engine and body style.

🛡️ Safety Features

Euro Ncap Rating:

Opel Astra H achieved a 5-star Euro NCAP safety rating for adult occupant protection, indicating a robust safety structure.

ABS Esp:

Anti-lock Braking System (ABS) and Electronic Stability Programme (ESP) available on many models.

Airbags:

Front airbags, side airbags, and curtain airbags were typically offered.

💡 Technology Features

Audio System:

Factory fitted radio/CD player with multiple speaker configurations. Options for upgraded head units and sound systems.

Cruise Control:

Cruise control was an option on many models.

Can Bus:

Utilizes a CAN bus system for communication between various ECUs, enabling advanced diagnostics and system integration.

🔧 Maintenance

Oil Change Interval:

Typically 10,000 km or 12 months, whichever comes first. Consult manual for specific engine and oil type.

Timing Belt Interval:

For Z16XE and Z18XE engines, timing belt replacement is critical, typically around 60,000-90,000 miles (96,000-144,000 km) or 6 years. Crucial to check manual for precise intervals.

Engine Oil Spec 1 8L:

API SG/SH/SJ/SL or ACEA A3/B3/B4, viscosity typically 5W-30 or 5W-40. Check manual for exact specification.

Coolant Spec:

GM Dex-Cool (Orange) or equivalent silicate-free ethylene glycol-based coolant. Typically 50/50 mix with distilled water.

Brake Fluid Spec:

DOT 3 or DOT 4 brake fluid.

Transmission Fluid Manual:

API GL-4, SAE 75W-80 or 75W-90 gear oil. Manual will specify exact type and capacity.

Coil Packs:

Ignition coil pack failure is a common issue, leading to misfires and rough running.

Thermostat Housing:

Plastic thermostat housing can become brittle and crack, leading to coolant leaks.

Eon Engine Management:

Some models with the Ecotec engines can suffer from various sensor issues or ECU problems, often flagged by engine warning lights.

Rear Axle Bushes:

Wear in rear axle suspension bushes can lead to poor handling and alignment issues.

📚 Vehicle History

Holden Astra:

Holden Astra AH was a rebadged version of the Opel Astra H, reflecting Holden's strategy of using GM's global platforms.

Astra H Platform:

The Opel Astra H (the basis for the Holden Astra AH) was the third generation of the Astra family, replacing the Astra G and produced from 2004 to 2009 (in most markets).

Manufacturing Locations:

Opel models produced in Germany (e.g., Bochum), and Holden variants assembled in Australia for the local market.

🏆 Awards & Recognition

Safety Awards:

The Opel Astra H platform upon which the Holden Astra AH is based received a 5-star Euro NCAP safety rating, indicating a high standard of passive safety.