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    Holden ASTRA AH 2004-2009 Service Repair Manual

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    This manual covers the Astra, generation code AH, produced between 2004 and 2009. The Astra AH is a compact family car known for offering good value, a comfortable ride, and...
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    Type: Car
    Vendor:
    Sku: 96728
    This manual covers the Astra, generation code AH, produced between 2004 and 2009. The Astra AH is a compact family car known for offering good value, a comfortable ride, and practical interiors, competing in a segment that includes models like the Ford Focus and Toyota Corolla. Available in hatchback, sedan, and wagon body styles, it typically features GM Ecotec inline 4-cylinder engines ranging from 1.8L to 2.2L, producing approximately 125-150 PS. The vehicle's engineering quality and reliability contribute to its reputation as an affordable and dependable transportation option. This comprehensive Service and Repair Manual provides detailed information for DIY enthusiasts and professional mechanics alike. It covers essential areas such as engine mechanicals, fuel and cooling systems, powertrain, chassis components including suspension and brakes, and electrical systems with extensive wiring diagrams. Maintenance procedures, step-by-step repair instructions, and diagnostic troubleshooting guides are included, empowering users to effectively maintain and repair their Astra. The manual is presented in English and is designed to be a definitive resource for ensuring the longevity and optimal performance of the vehicle.
    🏷️ 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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