The Astra G, produced from 1998 to 2009, is a significant model in the compact car segment, known for its versatility and value. Available as a Hatchback, Saloon, Estate, Coupe, and Convertible, this generation represented a substantial evolution from its predecessors, offering improved safety and styling. It was powered by a range of Inline 4-Cylinder Petrol engines, typically from the Ecotec series, with power outputs varying from approximately 75 PS to 160 PS, including a turbocharged option in the Astra GSi. The Astra G was a strong performer in its class, competing with major players like the Ford Focus and Volkswagen Golf, and was recognized for its balance of comfort, practicality, and affordability, becoming one of Europe's best-selling cars.
This comprehensive workshop service repair manual provides extensive coverage for the Astra G, designed to assist owners and technicians. The manual details all major systems, including powertrain, transmission, chassis, and electrical components, alongside body and interior aspects. It offers in-depth maintenance procedures, such as scheduled servicing, oil changes, and critical timing belt replacements, as well as troubleshooting guides for common issues and detailed repair instructions for component removal and installation. Technical specifications, torque values, and wiring diagrams are included to facilitate accurate diagnostics and repairs across all body styles and engine variants covered.
Make:
Opel / Vauxhall / Holden
Generation Years:
1998-2009 (facelifted extensively in 2004)
Internal Generation Code:
Mk.IV / G
Segment:
Compact/Small Family Car
Designation:
One of Europe's best-selling cars during its tenure.
Key Competitors:
Ford Focus, Volkswagen Golf, Honda Civic, Toyota Corolla, Peugeot 307
Versatility:
Offered in multiple body styles catering to diverse customer needs.
Value Proposition:
Known for offering a good balance of comfort, practicality, and affordability.
Geographical Markets:
Europe (Opel), United Kingdom (Vauxhall), Australia (Holden)
Model Variants Covered:
Hatchback, Saloon, Estate (Caravan), Coupe, Convertible
Estimated Page Count:
2000+
Type:
Workshop Service Repair Manual
Digital Format:
Downloadable PDF
Powertrain:
Engine Mechanical, Fuel System, Ignition System, Exhaust System, Cooling System, Lubrication System
Transmission:
Manual Transaxle, Automatic Transaxle (with detailed shift control and hydraulic/electronic operation)
Chassis:
Suspension (Front & Rear), Steering System, Braking System (including ABS/ESP where applicable)
Electrical:
Body Electricals, Lighting, Instrumentation, HVAC Controls, ECU Diagnostics, Wiring Diagrams (comprehensive)
Body And Interior:
Body Panels, Doors, Windows, Seats, Trim, Safety Restraints (Airbags, Seatbelts)
Maintenance:
Scheduled Maintenance, Oil Changes, Filter Replacements, Tune-ups, Fluid Checks
Troubleshooting:
Diagnostic Flowcharts, Symptom-based Troubleshooting Guides, Fault Code Interpretation
Repair:
Component Removal & Installation, Rebuild Procedures, Adjustments, Calibration
Technical Data:
Specifications, Tolerances, Torque Values, Electrical Schematics
Depth:
Comprehensive (from basic maintenance to full engine/transmission rebuilds and complex electrical diagnostics)
Searchability:
Searchable Text
Printability:
High-Resolution, Printable Chapters or Full Manual
Binding Format:
Digital Download (Printable)
Digital Paper Type:
N/A (Digital)
Engine Type Range:
Inline 4-Cylinder Petrol (Ecotec series)
Power Output Range:
Approximately 75 PS (55 kW) to 160 PS (118 kW) depending on engine variant.
Torque Range:
Approx. 115 Nm to 210 Nm
Fuel Delivery:
Multi-Point Fuel Injection (MPI) or Sequential Fuel Injection (SFI)
Common Engines:
X14XE (1.4L), X16XEL (1.6L), X18XE1 (1.8L), X20XEV (2.0L), Z22SE (2.2L)
Turbocharged Options:
Astra GSi (2.0L Turbocharged - Z20LET)
Manual Transmission:
5-Speed Manual Gearbox (e.g., F17, F23)
Automatic Transmission:
4-Speed Automatic Gearbox (e.g., AF13, AF17, AF22)
Clutch Type:
Hydraulically Operated Single Dry Plate Clutch
Manual Fluid Type:
API GL-4, SAE 75W-80 or 75W-90 Synthetic Gear Oil (e.g., GM 1940182 or equivalent)
Automatic Fluid Type:
Dexron III (e.g., GM 93160393 or equivalent)
Length Range:
Approx. 4200 mm - 4300 mm (depending on body style)
Wheelbase:
Approx. 2600 mm
Curb Weight Range:
Approx. 1150 kg - 1350 kg
Euro Ncap Rating:
4 Stars (for 1999/2001 models, variations exist based on equipment)
ABS:
Available on most models, standard on higher trims.
Esp Tc:
Optional or standard on some higher-performance variants.
Airbags:
Frontal airbags standard, side airbags optional on many models.
Seatbelts:
Pre-tensioned seatbelts with load limiters.
Audio Systems:
Factory-fitted radios with CD players, cassette players, and optional premium sound systems. Steering wheel audio controls on higher trims.
Navigation:
Optional factory satellite navigation systems available on later models.
Cruise Control:
Available as an option on many models.
Parking Sensors:
Optional rear parking sensors on some higher-specification models.
Oil Change Interval:
Typically every 15,000 km (9,300 miles) or 12 months, whichever comes first.
Spark Plug Replacement:
Varies by engine, typically 60,000 km (37,000 miles) for standard plugs, 90,000 km (56,000 miles) for platinum/iridium.
Timing Belt Replacement:
Critical for many petrol engines. Typically 90,000 km (56,000 miles) or 5-6 years. Consult manual for specific engine. Failure can cause catastrophic engine damage.
Engine Oil Spec:
API SL/SM, ACEA A3/B3 or A3/B4, SAE 5W-30 or 5W-40 (e.g., GM-LL-A-025 or GM-LL-B-025, check specific engine requirements).
Coolant Type:
G12 or G12+ (Purple/Pink) Antifreeze/Coolant, ethylene glycol-based, mixed 50/50 with distilled water. (e.g., GM 1940643 or equivalent)
Brake Fluid Type:
DOT 4 (e.g., GM 1929949 or equivalent)
Common Electrical Faults:
Issues with the Body Control Module (BCM), intermittent dashboard warning lights, power window regulators.
Common Engine Problems:
Oil leaks (e.g., crankshaft seals), ignition coil failures, thermostat housing leaks, EGR valve issues (diesel, but relevant for common Astra issues).
Common Suspension Wear:
Front wishbone bushings, anti-roll bar drop links, rear shock absorbers.
Common Exhaust Issues:
Corrosion on exhaust sections, catalytic converter failure.
Opel Legacy:
Opel has a long history of producing popular compact cars in Europe.
Astra Lineage:
Successor to the Opel Kadett and Vauxhall/Holden Astra Mk.III (F). The Mk.IV (G) represented a significant redesign with improved safety and styling.
Production Period For This Manual:
1998-2004
Manufacturing Locations:
Various GM plants across Europe (e.g., Germany, UK, Poland, Spain) and Australia.
European Car Of The Year:
While the Astra G itself didn't win European Car of the Year, subsequent Astra generations have been strong contenders and winners in various markets.
Safety Awards:
Various safety accolades and high ratings in crash tests from independent organizations.
Owner Satisfaction:
Generally well-regarded for reliability and cost of ownership in its class during its production run.
