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Holden Astra Zafira TS TT 1998 2005 Gregorys Service Repair Manual

The Holden Astra is a compact vehicle advertised by Holden in Australia. Spanning six generations, the first, Australia-only Astra of 1984 was a derivative of the locally produced Nissan Pulsar, because is the 1987 Astra. It was succeeded by the Holden Nova in 1989---another unique-to-Australia design range. From 1995, the Holden Astra name had been found in New Zealand, for a badge engineered form of the Opel Astra, which was sold in your area as an Opel since 1993. The following 12 months, Holden discontinued the Nova range in Australia in preference of the Opel-based Holden Astra. On 1 May 2014, Holden revealed to transfer the Opel Astra J GTC and Opel Astra J OPC with Holden badges to Australia and unique Zealand.

In September 1998, the Astra was replaced again with a German Opel-engineered, Belgium-built variation. Referred to as TS Astra, it had been equipped with either a 90-kilowatt (120 hp) 1.8- or a 2.2-litre petrol system and was available in City, CD, CDXi, SXi and SRi standards. The SRi ended up being three-door hatchback best, and standard Astra was just readily available with a 1.8-litre 16-valve system. Systems with a 5-stud wheel design have the abdominal muscles alternative factory-installed. The Astra CD attained 15-inch alloy rims as standard products in circa 1999, changing the metallic rims with hubcaps formerly standard.

The TS Astra design changes followed that the Opel Astra grams range, including the sedan, hatchback and convertible. However, the coup by Bertone wasn't supplied with a Holden badge. The drivetrain had been just like other vehicles into the Astra lineup, and therefore, had not been a bona-fide low rider. Like Astra F, the Astra grams had been readily available as a wagon in unique Zealand, however Australia. In 2003, a 147-kilowatt (197 hp) 2.0-litre turbo motor became offered. The typical Astra was just readily available with a 1.8-litre 16-valve system, and existed on until 2005 because the Holden Astra Classic, alongside this new design. The viewpoint behind it was for Holden to remain competitive in the market before less expensive Viva model was launched.

In accordance into Monash University's 2008 improvement towards Used Car protection score, TS Astra designs were ranked "better than normal" in neuro-scientific crash security security.
Requirements amount

City: had been the standard TS model, available as a three- and five-door with a six-speaker speakers, double airbags, disc brakes, flexible headlamps, and triple facts screen. The system ended up being the 1.8-litre X18XE1 engine with 85 kW (114 hp) (1998--2000) while the uprated Z18XE with 92 kW (123 hp) (2001--2004).
CD: included town properties, plus 15-inch alloy wheels, a CD athlete, ABS brake system, traction controls, air conditioning, digital mirrors, and power windows. Optional products offered are: forward fog lamps, 16-inch alloy rims, cruise controls, and a rear spoiler.

2005--2006 Holden Astra convertible

CDX: released in December 2002 for MY03 and included across CD variation: cruise controls, front fog lights, weather controls air-conditioning, chrome trim around dials, side airbags (curtain airbags had been in addition an option for MY04 models), hot leather seating and leather upholstery, and a larger, greater quality MFD (multi-info screen) with broadcast tips, date, time, outside temperatures, trip computer system with instantaneous fuel intake and L/100 kilometer, distance to vacant, essential vehicle alerts (check control) and stopwatch.
SXi changed the town three-door for MY03 and offered between December 2002 and 2004. Over the previous City three-door, the SXi included front fog lamps and sports trim. Recommended properties included, a CD athlete, ABS brakes, alloy tires, air-conditioning, and a rear spoiler.
SRi: released in October 2001 and carried the exact same products as the SXi, but had been in line with the CD variation except fitted utilizing the 2.2-litre Z22SE motor.
SRi Turbo: launched in-may 2003 included in MY03 modifications, this model will be based upon the SRi, except fitted using 2.0-litre Z20LET turbocharged motor and contains even more traditional gear.
Convertible: released in December 2001 and fitted with the 2.2-litre Z22SE system. Convertible Turbo brands found its way to might 2003 because of the 2.0-litre Z20LET engine.

Restricted versions

Olympic version: Holden produced Olympic versions of both the City and CD grades edition launched in July 2000, included "Sydney 2000" Olympic badging.
Equipe: had been in line with the Astra town, but included 15-inch alloy tires and different combinations of extra services including cruise controls, power microsoft windows, electric side-view mirrors, fog lamps and rear spoiler. Equipe model were circulated in April 2001, April 2002, April 2003 and September 2003.
Linea Rossa: unique edition for convertible, released in 2004.

Z14XE 1.4 L (1389 cc) 77.6 mm (3.1 in) 73.4 mm (2.9 in) 10.5:1 66 kW (89 hp) 120 N*m (89 lb*ft)

2000-2004 Opel Astra Grams
2000-2003 Opel Corsa C

Z16XE 1.6 L (1598 cc) 79 mm (3.1 in) 81.5 mm (3.2 in) 74 kW (99 hp) 150 N*m (110 lb*ft)

Opel Astra G
Opel Meriva

Z18XE 1.8 L (1796 cc) 80.5 mm (3.2 in) 88.2 mm (3.5 in)

90 kW (120 hp)
92 kW (123 hp)

167 N*m (123 lb*ft)

2006--2008 Chevrolet Niva
2004--2009 Saab 9-3
Opel Astra
Opel Meriva
Opel Tigra
Opel Zafira

Ecotec L61 engine in a Chevrolet Timeless (Malibu)
2003 Pontiac Sunfire Ecotec motor
Ecotec L61 put in in a 2003 Chevrolet Cavalier

This system normally known as a Z22SE in other countries like the United Kingdom and Australian Continent.

The basic household II design was considerably re-engineered in 2000 to be the Ecotec Gen I. Unlike its particularly harsh forerunner, the motor was designed for smoothness. Dual in-block balance shafts were key toward design, the power-steering pump had been attached right to the cylinder mind and driven by the intake camshaft, the water-pump housing had been throw into the block, together with A/C compressor and alternator had been installed right on the block without brackets. The oils filter housing is throw to the block with a removable cover and replaceable paper factor. They would not use an EGR valve. The Ecotec line are manufactured in Tonawanda, nyc and Kaiserslautern, Germany, and was also manufactured for Saturn in springtime slope, Tennessee until Saturn's discontinuation. In the united states this system changed both Quad-4 in addition to GM 122 motors and first appeared in the 2000 Saturn L-Series.

The L61 try a 2.2 L---2,198 cc (134.1 cu in)---version with a lost-foam throw aluminum cylinder mind and block; it features an 86 millimetres (3.4 in) bore and 94.6 millimetres (3.72 in) stroke and often a 9.5:1 compression ratio or a 10.0:1. The engine try 665 millimetres (26.2 in) long, 642 millimetres (25.3 in)in width, 655 millimetres (25.8 in) high and approximately 139 kilograms (306 lb).

The Ecotec 2.2, design L61 initially starred in the 2000 Saturn LS1; the L61-powered Saturn Ion additionally replaced the Saturn-powered Saturn S-Series.

There are many variants to the standard L61. The 2003 Saturn L-Series has actually increased production version with higher (10:1) compression plus aggressive camshaft. The 2004--2008 Chevrolet Malibu uses a version with electric throttle controls and a special unitized fatigue manifold and catalytic converter. The Malibu and Saturn variations in addition make use of return-less fuel shot. The 2002 Saturn VUE had been 1st us variant of L61 to-be loaded with digital throttle controls, whereas other applications would not happen until 2005 in the Saturn ION and Chevrolet Cobalt. For 2007, introduced an updated form of the L61 based on the Gen II design.

The supercharger and inlet manifold from 2.0 Ecotec LSJ motor can be purchased as the official kit from GM and along with modified computer software into the ECM, can make a 2.2 supercharged form of this engine.


The X20XEV may be the earliest household II motor labeled as Ecotec, a mass-market successor towards the C20XE with a Lotus-developed cylinder head. The latest cylinder mind had a smaller sized valve direction when compared to elderly C20XE, that was expected to give more torque in reduced revs. Its a 1,998 cc (121.9 cu in) naturally aspirated system with 16 valves and belt-driven two fold overhead camshafts (DOHC). 86 mm (3.4 in) bore and stroke in cast-iron OHC-derived cylinder block and aluminum cylinder head. The X20XEV is equipped with exhaust petrol recirculation (EGR) to reduce nitrogen dioxide emissions and air injection reactor (environment) to speed up the warming-up associated with the catalytic converter also to reduce unburnt hydrocarbons and carbon monoxide. The engine is capable of making 100 kW (136 PS; 134 bhp). An increased result variation known as the X20XER has also been created that gives 167 hp (125 kW) power and 136 lb*ft (185 N*m) torque.

The Z20LET are a turbocharged form of the X20XEV when it comes to Opel Astra G and functions a 8.8:1 compression, 200 PS; 197 hp (147 kW) and 195 lb*ft (264 N*m) of torque. From 2005, the Z20LET engine had been modified for Astra H and Zafira B, to 3 different design designations, Z20LEL, Z20LER and Z20LEH. The differing designations denote the system power result, 170 hp (127 kW), 200 hp (149 kW) and 240 hp (179 kW). More revisions on original build incorporate under-piston oils air conditioning, a revised turbocharger product additionally the removal regarding the contra-rotating balancer shafts when you look at the 240 hp (179 kW) Z20LEH engine (as found in the Astra VXR), to reduce mechanical losings. The Z20LEH in addition features quality Mahle forged pistons, which are much stronger versus cast pistons suited to the Z20LET, Z20LEL and Z20LER.

In 2008 with Euro 5 emission standard, two motors arrived: the A20NFT that delivered 240--250 hp (179--186 kW) (used in the Astra Zafira and Insignias 4x4) and a higher energy motor known as the A20NHT that delivered 276--290 hp (206--216 kW) (used into the Astra J OPC for 2010--2015).

The 2.0-litre X20SED D-TEC 16 Valve DOHC MPFi is built by Holden and used in the Daewoo Nubira.

The L34 also referred to as the U20SED try a 2.0 L (1,998 cc (121.9 cu in)) engine that has been built until 2009 by Holden in Australian Continent, dubbed D-TEC by GMDAT (the newest Daewoo after the buyout from GM) or E-TEC II by Chevrolet (GM). It offers an 86.0 mm (3.39 in) bore and stroke. Power is ranked at 119 hp (89 kW) in south usa and European countries, 126 hp in Canada, and 132 hp in america; each is at 5400 rpm and torque is ranked at 126 lb*ft (171 N*m). The system has been used regarding the Daewoo Lacetti and it is various rebagded brands, such as for instance Chevrolet Optra, Chevrolet Evanda, Suzuki Reno, and Suzuki Forenza.

The initial generation Ecotec motors tend to be belt-driven 16-valve DOHC machines, with cast-iron cylinder blocks and aluminum cross-flow cylinder heads. They feature sodium-filled exhaust valves, a cast metallic crankshaft, and a spheroidal graphite flywheel. Additionally they function exhaust gasoline recircualtion (EGR), additional atmosphere injection, and Multec M motor controls with sequential multiport fuel injection. The 1.6 L version has also been shipped to be used in the Brazilian Corsa GSi.

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Holden Astra TS series TT series Zafira 1.8 and 2.2 Litre Service and Repair Manual 1998-2005 Gregorys 1999 2000 2001 2002 2003 2004


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