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Aftersales Training

Participant’s Handout
Opel Agila
V 1.0

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Table of Contents

Topic Page

1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . General introduction of the Opel Agila _______ 4

2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Body and Safety features ______ 13

3. . . . . . . . . . . . . . . . . . . . . . . . . . . Heating, ventilation and air-conditioning ______ 23

4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Suspension ______ 41

5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brakes ______ 47

6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engines ______ 55

7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . European On Board Diagnosis ______ 71

8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission and clutch ______ 97

9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steering _____101

10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical systems _____111

11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service _____129

Elegance (model-code P68) as left hand drive.Base (model-code F68) in the Gliwice plant in Poland and is . General introduction of the Opel Agila 1. With this vehicle Opel is the first European car The Agila is a Sub-S model. which manufacturer ever to built a Mini means that the Agila is placed just People Carrier. Opel introduces the new Agila. but Opel made his own There is only one body version of specific modifications to meet their the Agila available with three quality standards and give the Agila different model variants: its own expression. The Opel Agila is below the Corsa (S-car) in the Opel born out of a corporation with car line.1 Introduction For the model year 2000½. a car that belongs to the so-called Mini People Carrier segment. The Agila is built . Suzuki.1. 4 .Comfort (model-code L68) available as right hand drive as well .

4.2 Car features Active safety: .Anti-lock brakes (optional) Passive safety: . 5 .Electronic power steering .11 1 3 5 Z12XE 2 4 R Comfort: .Third brake light F12 .Air conditioning (optional) .39 1 3 5 Z10XE 2 4 R F12 .Electronic Power Steering .1.0 litre 12V engine (Z10XE) with 58 Hp .Headrests available on all seats . 1.2 litre 16V engine (Z12XE) with 75 Hp The Agila comes with a 5-speed manual transmission (F12) only.Drivers airbag (standard) codrivers airbag (optional) .Pyrotechnical pre-tensioners for the front seat belts .3-point seatbelt on all seats . 1.Power windows (optional) Performance: The Agila is available with two different engines: .Mc Pherson front wheel suspen- sion .4.Body structure .Electrically adjustable mirrors .

emission stands for the internal definition of the compliance . Maintenance free direct ignition system . Catalytic converter welded to exhaust manifold . Plastic intake manifolds for both engines .0 litre engine Z10XE 1.2 litre engine Z12XE 6 . Drive by wire (E-gas) will be effective by 2005. Double oxygen sensor to Euro IV emission regulations. . that .Some engine features: The Z. Maintenance free camshaft drive 1. Return-less fuel system .

7 .1. With the second seat row folded down. second seat row. the volume of the luggage compartment increases to 597 litre. Dimensions of the Agila in mm The luggage compartment has a The Agila has a turning circle of 10.3 Dimensions and weights The different dimensions of the Agila are shown in the picture below.6 volume of 248 litres behind the m from wall to wall.

Black B-pillar Furthermore the following options are available: .Front fog lights .Anti lock brakes . the Agila is Z12XE: 990 Kg (1002 Kg with AC) available in three different model variants.Power mirrors Agila Comfort: . . each with their own Permissible gross vehicle weight of specific equipment level: the Agila: The equipment levels indicated here Z10XE 1325 Kg (1325 Kg with AC) are based on the European specifi- Z12XE 1340 Kg (1340 Kg with AC) cations and may vary from country to country.4 Models Z10XE: 975 Kg (987 Kg with AC) As mentioned before.Driver airbag and seatbelt pre tensioners .Central door locking . 2005 8 .Painted front and rear panelling .14’’ light alloy wheels . The maximum roof load for the Agila is 30 Kg.Electric power steering Litre.Wheel covers Agila Elegance . 2003.Passenger airbag .Load compartment cover .Tinted windows .Power windows .Air-conditioning .Radio CAR 2001. Agila Base: The fuel tank has a capacity of 41 .Weight of the Agila: 1.Manual sunroof .

Turkey 0 12 Serial number: 1 13 14915th vehicle of modelyear 2000 4 14 9 15 1 16 5 17 9 . Y =00 G 11 Manufacturing plant: 1= Rüsselsheim 2 = Bochum 3 = Azambuja 4 = Zaragoza 5 = Antwerp II 6 = Opel Eisenach 7 = Luton 8 = Ellesmere Port B = Bertone D = Chin Chuang. B for Corsa-B etc. Poland H = Halol. Tigra H = Agila T = Astra.5 Vehicle Identification The VIN (Vehicle Identification Number) can be explained using the following table: VIN-number Digits W 1 Defined code for manufacturer of vehicle: O 2 WOL = ADAM OPEL AG L 3 O 4 GM code for manufacturer: zero (or specifically defined letter) H 5 GM code for vehicle type: S = Corsa. Egypt G = Gliwice. A for Agila-A. Zafira E = Speedster J = Vectra V = Omega A 6 Model designation which indicates the version of the model: G for Astra-G. Combo. Poland Z = Izmir. Hungary P = Warszawa.1. X = 99. India J = Bekasi. F 7 GM code for body style 6 8 8 9 Y 10 Model Year: W = 98. Indonesia N = Norwich S = Szentgotthard. Taiwan F = Zamalek.

. . ment on the drivers side. The rear seats are placed a little higher than the front seats to create more leg space and a good all around view.Glove box with open lid. . 10 . The Agila design provides maximum interior space vs. Full-size spare wheel in cargo ment panel on the passenger floor.Storage tray below the instru. The rear seat features 50/50 split and two-seater capacity.Storage tray below the instru.Large front door pockets for the colours are available. . driver and passenger.Cup holder on central floor console.Sliding trays below driver and passenger seat. The height of the Agila offers maximum headroom. the small exterior size. Map pocket on the back of the .1.Storage unit with cup holder for rear passengers on central floor console. Agila offers a generous interior space. side. For the Agila three different fabric . front seat. .6 Interior Thanks to its body shape. . . 50/50 split rear seat Some interior features: . Height adjustable headrests on the front seats are standard. Large pockets on rear doors.

The electrically adjustable outside mirrors are foldable. the front panelling as well as the (optional) fog lights. Currently only pro- duced by the manufacturers Kleber The Agila front design is character- and Michelin. The grille is integrated into size 165/60 R14. 155/65 R14. Foldable outside mirrors 11 .1. Alloy rim The Agila will be available in 10 exterior colours. The Agila has the following features The size of the tyres of the Agila is related to the exterior. The Agila is available with roof railing as well as glued side mouldings. Alloy rims (6 spoke ised by its large headlamps with design) are available as an option integrated side blinkers (orange only in combination with larger tyre bulbs). seven of these exterior colours are two-coat metallic/mica paints.7 Exterior On the rear window a centre high mounted stop light is installed.

8 Accessories The listed items below are some of the accessories to compliment the factory options: • Central armrest • Towing hitch • Fog lights • Opel FIX child seat • Boot storage box • Low profile base carrier • Opel i-line interior and exterior accessories • Sunroof Opel i-line exterior spoiler Sport Interior 12 .1.

2.2 Wings To remove the front wings. With these two scissor-type hinges it is possible to adjust the bonnet perfectly to the body work. Body and Safety features 2. 2.1.1 Body equipment 2. Scissor-type hinges 13 . The front wings are connected to the body with several screws as shown in the picture below. the front bumper and wheel arches must be removed from the body.1 Bonnet The bonnet is connected to the body with two scissor-type hinges.1.

Trunk lid hinge 4 K 0048 2.3 Front/rear doors To increase the passive safety level of the Agila the doors are equipped with side impact door bars. 13 1 2. It is not allowed to adjust or replace these door bars. The trunk lid can be adjusted by replacing the 3 strike plate. 1. Strike plate 1. The hinges are welded to to the body. Rubber stoppers 4. Side impact door beam 14 . The strike plate must be adjusted in such a way that the 1 rubber stoppers have a pre load.1. Mounting points dampers 3. Connector Trunk lid Two dampers support the trunk lid 2 with opening and closing. Check link 3. Hinges 2.

Front member 2. Rear member 2. Self-locking nut 1. of a collision the front and rear members are connected with nuts to the chassis.2. parts mounted behind the bars are easy accessible.5 Bumpers After every disassembly of the front or rear bar new self-locking nuts To reduce repair costs in the event must be used. 1. Self-locking nut 15 . when the front or rear member is removed.1.

Switch for left or right outside mirror 2.2. Fixing points electrically oper. Fixing points ated windows 2. The outside mirror is fixed to the door with three screws. To remove the outside mirror. 1.7 Outside rear-view mirror Electrically controlled outside mirrors are standard on all model variants.1.6 Side windows The Agila will be available with manual operated windows and optional with electrically operated windows.1. Catch nut 16 . The manual operated windows of the front and rear doors are similar. Electrically operated windows are only available on the front doors. The mirror glass is clipped onto the adjusting mechanism. 2. Multi switch for mirror adjust- ment 1. Fixing points manual operated windows 3. 3. the door panel on the inside must be removed.

This sunroof is similar to the sunroof available for the Astra-G. 17 .The front window has positioners to adjust the window in the right position.2.1. the small side windows and the rear window are all glued to the body.8 Outside/Windows The front windscreen. The body mouldings on the Agila are glued and can be removed by heating them with a hairdryer. For the Agila is a sunroof available as an option.

2.1 Freewheeling lock cylin- roof railing is only available as an ders option.g.2 Airbag system Roof railing 2.1. ger seat a storage box is installed.9 Roof railing 2. A passengers airbag two headrests on the front seats is available as an option. The working principal of the freewheeling lock cylinders are the same. Because side airbags are not available for the Agila the control 18 . The roof The front doors and the trunk lid are railing is fixed on the roof with four equipped with freewheeling lock nuts. These freewheeling lock 30 Kg. driver and passenger of the Underneath both driver and passen- Astra-G. but the lock in detail is different from the freewheeling lock cylinders used on the e. With all other model variants the roof railing is standard. The airbag and optional two headrests on the units of the driver and passenger rear seats.2.10 Inside The new Agila comes standard with a drivers airbag and seat belt The Agila is standard equipped with pretensioners. The control unit is manufactured by Siemens and is placed between the two front seats as always with Opel. All headrests are height are similar to the units used for the adjustable and can be removed.2.The maximum roofload is cylinders. 2. cylinders prevent the car from theft and protect the lock against dam- age when the correct key is not used.2 Safety Features On the standard equipped Agila a 2. Astra-G.1.

module can handle max. That the TECH II. The pretensioners also a pyrotechnical load. The tions must be taken very serious. But because the retractor is a Seatbelt pretensioner The control unit must be replaced rotating gear the construction is after 1 airbag ignition or after 3 very different. 19 . So in replaced after each activation. tensioned by turning the axle on sioners. • Airbag configuration • Pretensioner configuration • Driver airbag squib circuit (Ohms) • Passenger airbag squib circuit (Ohms) • Driver pretensioner squib circuit (Ohms) • Passenger pretensioner squib circuit (Ohms) In the event of a rearend collision the seatbelt pretensioners can be activated. four 2. from Opel are all located at the lock seatbelt pretensioners. In this pretensioner the safety belt is ignitions of the safety belt preten. working principal of these seatbelt • System voltage (V) pretensioners is not very different to • Power reserve (V) a seatbelt pretensioner located at • Airbag loops the lock of a safety belt. Control Unit case of a frontal accident the retractor gear is driven by the pyrotechnical load and tensions the safety belt which makes that the occupant is protected.3 Seatbelt pretensioner As written before the working squibs. The data list contains on the safety belts of the Agila are means that al the safety precau- the following parameters: located in the retractor gear. So there is The control unit is serviceable with of the safety belt. The pretensioners must be which the belt is wrapped.2. Two for the front airbags principal of the seatbelt pretensioner and two for the seatbelt The known seatbelt pretensioners of the Agila is similar to the known pretensioners.

Bent iron pipe with pyrotechni- and at the other side by a security cal load and 14 balls inside pin. The security pin will break and release the balls out of their position. So now the retractor axle rotates and makes sure that the safety belt is pulled into the retractor mechanism. If the car is involved in a frontal accident and the deceleration reaches the set values which makes sure that the seatbelt pretensioners are ignited. which is located in the top of the bended iron pipe. the balls 20 . When the balls move out of the tube. kept in place on one side by a smal piston 1.How is the energy of the pyrotech- nical load brought to the axle of the retractor gear? The energy of the pyrotechnical load is not brought to the retractor by a cable like all other seatbelt pre- tensioners Opel uses. This retractor gear has the shape of the balls and that contributes to a maximum energy transmission. they drive a special gear which is mounted on the axle of the retractor right after the iron pipe. will expand and forces all bullets in the same direction: out of the iron pipe. The manufac- turer (Autoliv) of this seatbelt pretensioner invented a new way for this energy transmission. In this iron pipe are also 14 balls. Retractor gear in the shape of is blocked in the pulled position. At the end of the activation the belt 1. Now the pyrotechnical load. The pyrotechnical load is located in the top of a bent iron pipe.

pyrotechnical load. The airbag and the seatbelt pretensioners working closely together.4 Force limiter The forces generated by the seatbelt pretensioners on the belt are very high. To decrease the force on the rear seats have a special the seatbelt we can insert a smaller system to secure a child seat. And now you're able to secure a child seat tightly to the rearseat. belt. The seatbelts with force limiters make sure that the body will hit. The load limiter on the pretensioners af the Agila is created by a torsion The pedal release system is bar in the retractor. cal load creates the force on the The two three point safety belts on seatbelt. we need a certain 21 . this means that it is tension will be delayed. How is the force limiter created? For a quick reaction of the seatbelt pretensioner on the ignition from the control module. Pull pyrotechnical load in the out the belt all the way. The forces are even higher than necessary.2. This pyrotechni. This means not possible any more to pull out the that this is not the right way. force limiters are introduced. that the human body contains in the event of a front collision. the torsion bar will be twisted and the force on the seatbelt will be shortly reduced. To reduce the impact of the seatbelts on the body. So the combination of these systems Force limiter makes sure the injuries of the occupants are minimized. When the standard for the clutch and the safety belt reaches a certain force brake pedal on the Agila. but than the time on release the belt. in the right time and with reduced energy. than slowly pretensioner. needs to be taken by the seatbelts. head are reduced. At this moment the occupant will reach the airbag and Seatbelt pretensioner in this way the injuries on body and 2.You can hear a which the belt reaches its requested clicking sound. that means that not all kinetic energy. the airbag.

22 .

Corsa-B. The control panel for heating and available. 1 2 4222 S Cd0946 1. drive versions. The shape of the • The air distribution knob has five control knobs and sliders and the positions lay-out of the panel resembles the • The air distribution knob cannot ones used on Corsa-B. is simular to the ones used on • The air recirculation can be Corsa-B. ventilation and air-conditioning The Opel Agila is standard equipped 3.3. On both engine versions air conditioning is optionally • A four speed fan is used. 23 . Tigra and Combo). as well for the left hand • Pull the fan speed switch to ventilation looks similar to the panel drive versions as for the right hand switch on the rear screen used on the current S-car (Corsa. • The slider frame cover is not The operation of the temperature prepared for the switches for control knob and fan speed switch seat heating. • Recirculated air can be mixed with fresh air.1 Heating and ventilation The following features can be with a conventional heating and features identified: ventilation system. Heating. defogger. Control Panel Corsa-B • The air recirculation slider ones of the Corsa-B the operation is operates just opposite to the completely different slider of the Corsa-B. adjusted in the position fresh air and the position recirculated air and any position in between. Control Panel Agila Although the controls resemble the 2. The illustra- be rotated completely as on the tion below shows the similarities.

Intake 6. There is no second supplier. Recirculation flap section 7.2 Heating and ventilation of the heating and ventilation operation system have the following features. The distrbution of the air is controlled Centre outlets have no doors. Blower 3. controlling the flaps in the via conventional serial resistors. Cd0957 The following illustration shows a cross section of a LHD heater 1. • The heater housing flaps are mechanically connected to the control panel using non-adjust- able bowden cables. • Currently.The controls and the heater housing 3. The have adjustable doors. with the right knob on the control • The blower motor is controlled panel. Outlets to dashpanel air ducts 5. as shown in the illustration. heater housing. Pollen filter section 24 . • Quick fittings for the coolant hoses are not used. The outer dashboard vents of the Opel Agila has 10 outlets. 2. Heater housing with control flaps 4. Heater core housing. • The dash panel contains 10 air vent outlets. It can only be replaced when the heater housing is removed. The heating and ventilation system able. Calsonic is the only manufacturer of the heater housing. • A pollen filter is located between the recirculation flap and the blower intake on all versions. • The heater core is conventional. The resistors are mounted in the exhaust channel of the fan of the heater housing to cool the resistors. Vent holes for the Dash panel air vent holes rear passengers are not avail.

Temperature control flap 3. Resistor pack 25 . Feet outlets 4. Center outlets 7. Blower 9. Heater core 2.1. Center outlet control flap 6. Defrost outlets 8. Feet outlet control flap 5.

depending on the air distribution control knob position.The following illustrations show the air flow through the heater housing. 26 .

27 .

28 .

29 .

The recirculation flap and pollen filter are located in a separate housing on the passenger side of the heater housing. The upper flap for the dashboard outlets does not regulate the airflow to the outer dashboard outlets. to avoid too much compression of the air trapped in the car when the recirculation slider is in the recirculation position. These channels have separate doors. located in the outlets. 30 . This flap also allows air to escape from the vehicle interior when the doors or the tailgate are closed rapidly. The hatched flap for foot outlets allows a certain airflow to the upper outlets even when the flap is positioned for maximum air flow to the feet. The recirculation flap is equipped with a small additional flap that allows a certain amount of recirculation even when the recirculation slider is in the fresh air position. The centre outlets do not have these doors as with other Opel models.

Body vents The required body vents are located on the rear end of the car. G0792 1. behind the impact limiter (bumper) and on the inside of the rear doorsill panel members. Bulb The control panel bulbs are replace- able separately. 31 . The control panel must be removed to have proper access to the bulbs. The location of the bulbs is indicated in the illustra- tion above.1.

32 . G0793 1. Body vents The additional small flap in the recirculation flap also adds to the decompression during the closing of the doors and the tailgate. The vents contribute to a better airflow in the interior and therefor help to demist the windows.

similar to Corsa-B. The system is designed for the use of R134A refrigerant only.3. The system has a new design. 33 .3 Air conditioning features The air conditioning system of the Opel Agila is an add-on unit. integrated in the temperature control knob on the left. Pull the switch to enable the air conditioning. The air conditioning system of the Opel Agila contains the following compo- nents: • Compressor • Condenser • Evaporator • Expansion valve • Control switch • Receiver / drier • Muffler • ECU with AC-control • Cooling fans • Water drain K 3507 1. accord- ing to the Opel standards. Air conditioning switch The air conditioning switch is.

The com- 3. Condensor used on the Corsa-B X10XE and 5. 6. Linear pressure sensor 8. Pipe connection at the usual locations. Compressor 7. condenser. Low pressure service port located in the engine compartment 2. TXV pressor is the same as the one 4. Receiver / dryer X12XE.Engine compartment The compressor. receiver / dryer and the ECU are 1. High pressure service port. 34 .

This casing also contains the recirculation flap. This means that there are no additional switches in the control panel. The evaporator is positioned between the pollen filter and the blower. The drain hose is routed through the firewall to the engine compartment 35 .Heater housing with evaporator The evaporator is positioned in the plastic casing mounted on the left 1. A coolant cut-off valve is not used on the Opel Agila. the water collector and water drain. Water drain of the heater housing on LHD cars. TXV cars and mounted on the right side 3. the pollen filter. Evaporater side of the heater housing on RHD 2. Underneath the evaporator are the water collector and the water drain.

push the TXV from its recess. To be able to remove the A muffler is installed in the suction TXV the bolt must be inserted after line of the compressor to equalise the pipes have been removed to the pressure pulses. 36 . TXV valve position and disassembly Refrigerant circuit The condenser is mounted behind the radiator. TXV.TXV The service ports are located in the refrigerant lines coming from and The expansion valve type used is a going to the TXV. The linear refrigerant pressure sensor is positioned in the high-pressure liquid line from the condenser to the TXV. The receiver / drier is positioned directly on the con- denser. The valve is located in the firewall. close to the longitudinal front member. The receiver / dryer can be replaced separately. The sensor is similar to the used on from the Opel Astra-G.

4 Air conditioning operation An Engine Cooling Module (MKM) as used on the Opel Astra-G is not used on the Opel Agila. based on the sensor inputs from the coolant temperature sensor. linear refrigerant pressure sensor and the dashboard switch. Instead.3. Circuit diagram airconditioning control 37 . the engine control unit (ECU) controls the cooling fans and the compressor clutch via relays.

left heating •8 A .Heated back •RHD Right.1148 •M12 Motor .Blower.1125 compartment •Air conditioning 1132 . passenger compart Grounding points ment •M19 Motor .Blower.pillar.1 Switch .Blower / Abbreviations Heated back window •S123.1115 •K43 Relay .Heated back window Circuits •K13 Relay .1104 air conditioning •Heating 1111 . •LU Illumination light heating •LHD Left. right •R11 Preresistor .Compressor. air conditioning 38 . left ing •S123 Switch .Blower.Air condition •12 Tailgate. •Heated back heating. •Engine cooling 1102 . front passenger •S47 Switch . •E15 Heated back window nents are shown: •K3 Relay .hand drive window •X4 Body front & Instru ment panel •X5 Body front & Instru ment panel •X6 Instrument panel & Body rear •X14 Body rear & Tailgate •X18 Body front & Air conditioning •X19 Body front & Air conditioning •Y10 Clutch .passenger window 1119 .Radiator fan •K36 Relay .hand drive •S123.The illustration shows the electrical Component codes circuits for air conditioning and cooling fans. •4 Engine compartment.Compressor.2 Switch .Blower. The following compo.Radiator fan •2 Engine compartment.

Air conditioninng block diagram A5 Engine control unit B12 Coolant temperature sensor B19 Accelerator pedal sensor B29 Linear pressure sensor B34 Crankshaft position sensor K13 Relay cooling fan K34 Relay blower K36 Rely compressa clutch M12 Blower motor M19 Fan motor Y10 Compressor clutch S47 Switch 39 . • The ECU controls the compres- sor clutch relay. accelerator position. This feature is an Opel standard. based on the engine speed. circuits: tioning of the Opel Agila. switch and refrigerant pressure. Only one fan is used and only one speed is available. The following control features are vides an overview of the compo. • An anti-icing sensor or switch in the evaporator is not used.The following block diagram pro. • When the air conditioning is switched ON the blower will run at first speed if it was not activated yet using relay K43. used on the air conditioning control nents connected to the air condi. based on the refrigerant dis- charge pressure and the coolant temperature measured. • The engine control unit (ECU) controls the cooling fan relay.

40 .

and equipment on the car (ABS. etc.) requires the same setting too. The stabiliser bar has a constant diameter.1 Front suspension General description The front suspension of the Opel Agila is designed using Mc Pherson type struts in combination with a stabiliser bar used as a trailing rod. Lower control arm 4. air conditioning. The layout and tuning of the front suspension of the Z10XE version is equal to the Z12XE version. Suspension 4.4. Drive shaft 41 . 1. Steering knuckle 3. Mc Pherson strut 2. Stabiliser bar 5. The same springs. shock absorbers and stabiliser bars are used.


1. Lower control arm mounting The lower control arm can only be
2. Lower control arm replaced as an assembly. No
3. Steering knuckle with wheel hub separate parts, such as bushings,
can be ordered. In the illustration
above the stabiliser bar is already
removed. 1. Self-locking nut
2. Nut
3. Ring
4. Support bearing
5. Upper seal
6. Ring
7. Bearing
8. Lower seal
9. Spacer
10. Upper spring collar
11. Spring collar damper
12. Hollow buffer
13. Front spring
14. Shock absorber assembly

The indicated components in the
illustration above can be replaced
separately. The shock absorber
assembly is not equipped with a
separate shock absorber insert.



1. Special wheel bolts
2. Hub
3. KM 6142

The hubs are equipped with four
special bolts(1) to fix the rims, in
combination with nuts. The normal
tightening torque for the nuts is
85 Nm and dry nuts should be
greased slightly. The nuts are
equipped with only ONE conical
side. The conical side should face
the rim. If nuts are not properly
installed accidents could occur.

The special bolts should be removed
and installed using a press and KM
6142. The removed bolts may not
be used again.


4.2 Rear suspension

General description

The rear suspension of the Agila is a
1. Rear spring combination of a semi-independant
2. Panhard rod torsion type rear axle with a
3. Rear axle body with wheel hub Panhard rod. The journals form one
4. Wheel drum with bearing assembly with the axle body. The
5. Trailing link trailing links are replaceable sepa-
6. Shock absorber rately. The damping bushings
cannot be ordered separately. If
bushings must be replaced a
complete link must be ordered. The
bearings in the brake drums are not


max.4. 45 . Camber 0° 00' -0° 30' 0° 30' Toe-in 0° 00' -0° 30' 0° 30' On the rear axle no wheel alignment adjustments are possible. max. Camber -0° 20' -1° 20' 0° 40' Toe-in -0° 10' 0° 00' -0° 20' Caster 3° 40' 1° 40' 5° 40' The rear suspension wheel align- ment values are listed in the tabel below: Wheel alignment Rear Axle All versions Tolerance min.3 Adjustments on the front and rear suspension The front suspension wheel align- ment values are listed in the table below: Wheel alignment Front Axle All versions Tolerance min.

46 .

non-ABS versions. • Bowden cable operated park brake on the rear wheels 1 ABS control unit and hydro-unit (optional) 2 Master cylinder and brake booster 3 Rear drum brakes 4 Front disc brakes 47 . system. • Optional ABS on all versions. • Front disc brakes (non-venti. • A load sensing proportioning lated) and rear drum brakes are valve for the rear brakes on all used. • Safety brace assembly for the • Diagonal split 4-channel brake Pedal Release System (PRS). Brakes The general features of the brake • A vacuum brake booster as system of the Opel Agila are: standard equipment.5.

9 Calliper frame 1 Calliper housing 10 Pad (inner) 2 Bleeder valve 11 Pad (outer) 3 Dust cap 12 Bolt 4 Piston 13 Protector sleeve 5 Seal ring 14 O-ring 6 Protector ring 15 Guide pin 7 Guide pin 16 Bolt 8 Protector sleeve 48 . During brake pad replacements the pistons must be pushed back using the same special tool as used with the brakes of the Opel Astra-G. supplied by Bosch. can be tipped backwards for service. because MID is not available on the Opel Agila. If the calliper is The front brakes are equipped with tipped backwards there is a poten- non-ventilated discs and floating tial risk that the brake hose kinks callipers.1 Front brakes The callipers. The anti-resonance springs are mounted on the brake pads. There are no electrical sensors used. Be careful. and breaks or tears.5. The inner brake pads are equipped with audible wear indicators.

2 Rear brakes Regarding maintenance and repair some aspects have to be taken in consideration. The brake lining is glued to the brake shoes. 1 KM 6145 2 Adjusting mechanism Rear drum brake assembly 1 Anchor plate 2 Wheel brake cylinder 3 Adjuster rod 4 Adjuster lever 5 Retracting spring 6 Brake shoe and lining 7 Adjuster spring 49 . This is system that is alos used on other shown in the illustration below. Instead of coil springs a W- shaped retracting spring is used to return the brake shoes into the normal position.5. Opel cars with drum brakes. The wheel brake cylinders and pistons are aluminium castings. The mechanism if the brake drums are automatic adjustment system is a worn and hard to remove. Special tool KM 6145 Drum brakes are used with an can be used to reset the adjusting automatic adjustment system.

is provided in the anchor plate. nuts must be removed. connecting the brake booster to the master cylinder is not adjustable. Master cylinder overhaul is currently drums. With this tool the pin fixing the bent into a recess in the spindle. The piston rod. reservoir to the master cylinder can enable a quick inspection of the phragm. One for the regular version • Brake booster and one for the ABS version. Load sensing proportioning valve 50 . The with the bearings as with Corsa-B. supported. install and adjust this valve. the ABS version has The brake drums are an assembly • Brake pipes and hoses two brake pipe connections. Instead of a cotter pin (Corsa-B) a special nut is Brake booster To remove of the brake fluid reser- used on the Opel Agila. K 2079 1 Brake Fluid reservoir 2 KM 6144 1. brake linings. an inspection hole with plug Brake booster repairs are not not supported. Load sensing proportioning valve The load sensing proportioning valve is only used on the versions without ABS. • Park brake system piston diameters of both versions To remove the drums the bearing • Maintenance and repairs are different. The valve is located near the fuel tank behind the rear axle. Its vacuum non-return be removed using a hammer. To 8 inch booster with a single dia. To secure voir special tool KM 6144 is neces- the nut the outer edge must be The brake booster is a vacuum-type sary. 5. The Brake drum and bearing asseurbly • Master cylinder regular version has four brake pipe • Load sensing proportioning valve connections.3 Brake actuating components The following items will be explained Master cylinder concerning the brake actuating components: The master cylinder comes in two versions. only assembly replace- ments can be performed. without removal of the valve can be replaced separately. The Service Instructions provide a special procedure to remove.

The brake system should be performed in the car. mentioned in the Service Plan and the Service Instructions. Instructions for the exact procedure. The system is designed using the following compo- nents: • Park brake lever assembly • Park brake cable left • Park brake cable right • Lever assemblies in the rear brakes • Park brake telltale switch Maintenance and repairs Regarding brake maintenance and repairs. Refer to the Service system over-pressure. The centre piece is an 1 Right park brake cable wheel break cylinder overhauls and integral part of the park brake lever 2 Left park brake cable master cylinder overhauls are not assembly. Park brake adjustments Service Plan. Besides the The brake fluid should be replaced park brake telltale switch no sepa- every two years. according to the rate parts are available for the lever regulations of the Opel/Vauxhall assembly. The Opel Agila brake system is Park brake system designed for the use of DOT4 SAE The park brake cable consists of J-1043 brake fluid only. 51 . The left and the right 3 Park brake lever assembly supported. lever assembly via the left and the right park brake cables. Assembly replacement drum brakes are attached to the 4 Adjustment nut should be applied if necessary. Currently three pieces. The following features ensure the safety of the drivers and the occupants. the Opel Agila should be treated similar to the other models in the Opel range. Park brake system The park brake system layout shows similarities with the other Opel passenger cars. not bleeding procedure requires 2.0 bar under the car.

hydraulic modulator in one assem- bly. The sensor gear in rear brake drum can be replaced. Repairs of this assembly are not supported and separate compo- nents are not available.4 ABS This ABS provides driver feedback during ABS intervention by means of pump and solenoid noise and brake Anti Lock Brakes (ABS) is optional pedal vibration. 52 .4 channel cylinder is modified for the use of an system and is equipped with a ABS system. The rear wheel speed sensor gear is mounted on the inner hub part of Traction control is not available. can be used on the Agila too. as used on other Opel vehicles. seen the ABS-versions do not require a from the sensor. This system uses an knuckles are used (no integral integral unit with controller and bearing-hub-sensor assemblies). but will be de- stroyed during removal with a puller. The hydrau- lic modulator comes filled with brake fluid from Parts & Accessories (P&A). The master The ABS is a 4 sensor . TECH 2 diagnostic interface. the brake drum.5. Special tools are necessary. are necessary or possible on any component of the ABS. The ABS is a Nissin speed sensors on the front steering product. This is why teeth radially instead of axially. The hydraulic modulator and control unit are combined in one assembly. The standard bleeding procedure (mentioned in the Service Instruc- tions). No adjustments load sensing proportioner valve. Conventional wheel on all versions. The sensor nose Dynamic rear brake proportioning is measures the speed of the passing integrated in the ABS.

left wheel speed sensor B28 Rr. Circuit diagram ABS (1325-1350) U1 Signal converter module A2 ABS control unit X49 Diagnostic link B25 Frt. The ABS versions are not equipped with a load sensing proportioning valve. When ABS is in emergency mode dynamic rear brake proportioning is not opera- tional. right wheel speed sensor B27 Rr. This will lead to unlimited rear brake pressure and that causes the rear axle to be overbraked. right wheel speed sensor 53 . Electrical and electronic features The ABS of the Opel Agila incorpo- rates dynamic rear brake propor- tioning. left wheel speed sensor B26 Frt.

using the TECH 2 and pin 21. The other control the telltales. The versions an additional controller in the without ABS have a dummy control unit. instead switch on the brake system of the ABS control unit. is used to generate a vehicle speed • The pins 10 and 14 are con. This plug provides an additional blink code request for the ABS and EPS control units. This plug is located on the A-pillar on the passenger side. A right) is used with this configuration. providing more facilities The front right wheel speed sensor to isolate the fault. X49. More about these vehicle speed signals will be explained in chapter 10. Only switched on to verify the correct one wheel speed sensor (front - operation of the telltale. Pin 14 is used for the and EPS) receive this signal from a ABS telltale. TID. because there is a better diagnostic Signal converter module (U1) interface.Regarding the circuit diagram the following features can be identified: • The ABS wheel speed sensors are connected to the control unit by means of twisted pair wiring. • The control unit provides two diagnostic interfaces. signal for the the engine manage- nected to the instrument to ment system only. by grounding the wires. instrument system. The telltales are separate vehicle speed sensor in controlled in the instrument via the transmission (B24). grounded signal wire to the Both configurations use a violet wire instrument causes the telltale to to transfer the vehicle speed signal. 54 . illuminate. Pin 10 is systems on board using a vehicle used for the telltale of the brake speed signal (radio. This controller is able to unit or signal converter (U1). Pin 12 is connected to a diagnostic plug. Opel does not use the blink codes for diagnostic purposes. to generate telltale when the ignition is the speed signal for the ECU.

Engines 6.0 litre 12V petrol Torque 85 Nm at 3800 rpm ECOTEC engine with 43 kW Top speed 142 km/h (58 PS) Acceleration 0-100 km/h 18. 6.2 Changes on Z10XE and 55 . Although there are several new features. the Z10XE and the Z12XE engines are based to the X10XE and X12XE engine out of the Corsa-B.2 litre 16V petrol Fuel consumption (Lt/100km) ECOTEC engine with 55 kW -Urban 7.0 sec • The Z12XE a 1.5 (75 PS) -Country 5.6 -Combined 6.3 These both engines are ready to meet the “Euro 4” emissions regulations.6.1 Engine Types Engine data Z10XE The new New Opel Agila is available with two different engines: Output 43 kW/58 PS at 5600 rpm • The Z10XE a 1.

5 56 .7 -Combined 6.5 sec Fuel consumption (Lt/100 km) -Urban 8.Engine data Z12XE Output 55 kW/75 PS at 5600 rpm Torque 110 Nm at 4000 rpm Top speed 155 km/h Acceleration 0-100km/h 13.0 -Counry 5.

X12XE Z10XE.Z12XE Engine management system Motronic M 1. X10XE. component of the in-tank module pressure regulator on fuel line Intake manifold Aluminium Plastic Exhaust manifold Conventional Welded to catalytic converter Throttle valve control Conventional with cable Electronic throttle body and accelerator pedal position sensor (E-gas) 57 .5 Motronic ME Number of oxygen sensors 1 2 Fuel system X10XE X12XE Fuel supply and Returnless fuel sytem pressure regulator is return and line.

Z12 XE compared with X10XE and X12XE On the new Z engines is the cata- lytic converter welded onto the ex- haust manifold. Exhaust manifold with catalytic converter 58 . Heatshield 3. K3407 1. Heated oxygen sensor controls the mixture 2.

This check must be done with a cold engine. For installation of the cooling fluid increases the cap a special grease should be used valve will open and the fluid flows to (Cat. control 2. this one controls the mixture. One is placed on top of the catalytic converter. When the temperature available: KM-6129.Oxygen sensors The new Z engines are ready for the EOBD regulations. When the 397) temperature of the fluid decreases a vacuum is created. Oxygen sensor checks catalytic The cooling systems on the Z10XE For removal and installation of the converter and Z12XE are so called open cool- oxygen sensor. Nr. 90 295 the cooling fluid reservoir. these regulations require that the catalytic converter is controlled on its function. The level of cooling fluid in the sys- tem can be checked on the cooling fluid reservoir. Correc- tions on the cooling fluid level are only allowed via this cooling fluid 19 48 602/Part. The second oxygen sensor is placed after the catalytic con- verter and evaluates the oxygen storage capacity (OSC) of the 1. Oxygen sensor for mixture Cooling system catalytic converter. the cap valve opens in the other direction and the cooling fluid is sucked back into the system. 59 . For this reason there are two heated oxygen sensors placed on the exhaust system of these Z engines. a special tool is ing systems.

This is achieved by making the fuel Tap to releas cooling fluid of sytem. The fuelsystem operates under a pressure of 3. the intank module.8 Bar. 1 Pressure regulater 2 Fuel pump 3 Tank content sensor 4 Filter unit 60 . To fill up the cooling system use the pressure regulator a component of service documentation group J. Fuel system On both engines in the Agila is a return less fuel system used. This means that where normally two fuel lines (supply and return) were mounted between engine and fuel tank now only one fuel line con- nects the fuel tank with the engine. instead of mounting it on the engine.To release all the cooling fluid out of the system a special tap is fitted on the lower half of the radiator.

Accelerator pedal position sensor .Fuel level indicator . Brake light switch • M42 Intank module • M2. Throttle body .5 engine management system.5. The in tank module is connected to Engine management system the engine management system with four wires. two for the fuel pump and two for the Fuel tank Both engines in the Agila are content sensor.Fuel pump . Throttle body . equipped with the Motronic ME 1.The intank module contains the following components: . the Z10XE and Z12XE are also equipped with E-gas. Second oxygen sensor after catalytic converter E-gas In addition to the Y16XE and the Y22XE. Accelerator pedal position sensor .2 Level indicator Cd0959 61 . EGR valve . The main components of the E-gas system are: .Pressure regulator .Filters All components of the in tank module are maintenance free.1 Fuel pump • M2. this engine management is able to let the engines pass the emission regulations. The following compo- nents are new or modified: .

EGR valve . Accelerator pedal position sensor .5 engine management system. The signal of both 'Euro 4'emission regulations.5.3 Engine management The working principal of the sensor position potentiometer 2 signal motronic ME 1. management system with a six pins this engine management is able to connector (3 wires for each let the engines pass the potentiometer). The sensor pedal equipped with the Motronic ME position is connected to the engine 1. The pedal position or modified: potentiometer 1 signal ranges from 0 to 5 Volts. Both engines in the Agila are idle switch. This one used on the Y engines. Accelerator pedal position sensor Cd0935 Sensor pedal position 62 .6. Throttle body . The pedal .5 system pedal position is the same as the ranges from 0 to 2.5 Volts. the Z10XE and Z12XE are also equipped with E-gas. It potentiometer checks contains two potentiometers and no potentiometer 1. Throttle body . Second oxygen sensor after catalytic converter E-gas In addition to the Y16XE and the Y22XE. potentiometers increases with pedal The following components are new actuation.5. The main components of the E-gas system are: .

This is and power supply for both of the potentiometers. The signal voltage range of this potentiometer is 0 to 5 Volts. with a six pins connector. never equal.During normal operation the signal The throttle body contains the different to the throttle bodies of the voltage of both potentiometers is throttle valve. The signal of (motor) and two potentiometers. 63 . the throttle positioner Y16XE and the Y22XE engine. Throttle body The voltage of throttle potentiometer 1 increases as the throttle valve opens. these have an eight pin connector. potentiometer 1 must always be The throttle body is connected to The throttle body of the Z10XE and higher than the signal voltage of the motor management system the Z12XE uses the same ground potentiometer2.

The ECU then calculates the required output signal for the throttle positioner.Where as. same way as the one used on the the ECU receives a signal from the Y16XE and Y22XE. 64 . The movement of the throttle valve is monitored by the throttle body potentiometers. the valve rests at a preset position. throttle potentiometer 2 shows a decrease in signal voltage when the throttle valve opens. In the event of a fault arising it is possible for the throttle positioner to be switched off When the throttle positioner is switched off. The signal voltage range of this potentiometer is 5 to 0 Volts. The throttle positioner works in the When the accelerator is operated. pedal position sensor potentiometers.

So first. On acceleration the valve must first go back to the preset position in which the spring forces it. the throttle good engine breaking on overrun. as connector are very small they mentioned before the throttle valve weren’t able to connect this output is forced into a preset position when on one pin for this reason they used it is switched off or disconnected two pins. Because the recieves from the ECU is a PWM connections to the wiring harness (Pulse Width Modulation) signal. After this position the valve must be opened to reach the speed the driver demands. allowing an engine directions. opening at idle speed (800 RPM). For the engine run at idle speed the valve must be closed a little. positioner is connected to the ECU with two wires.The throttle valve is forced into this The opening and closing of the preset position by a spring. 65 . At this position the also with the connection of the valve opening is greater than the pintel positioner of the EGR valve. In this throttle valve is carried out by the preset position the throttle valve is throttle positioner that works in two partially open. the valve must be closed a little. and when accelerating. This is to drive the vehicle and ensure a In the circuit diagrams. This is done for The signal the throttle positioner technical reasons. We can see this feature (1000 RPM). speed of 1000 RPM (approx). the valve must be opened.

For this reason the pulses widths are reduced in comparison to at idle speed. site direction. 1000 – 1100 RPM On light acceleration the throttle valve is approaching the preset position. This graph shows the PWM signal after the valve has opened a little further than the preset position. This signal makes sure that the throttle valve is closed a little untill the programmed idle speed is reached. neutral.both of the connector on Y29. The graphs of the throttle positioner The spring pressure becomes are made with use of the Tech 31. For the throttle valve to The ground probe is connected to open further. This graph shows the PWM signal from the ECU to the throttle positioner at idle speed. 66 . This is achieved by changing the PWM signal from negative to positive.PWM signals 900-1000 RPM On further acceleration the throttle valve reaches the preset position. For this to happen the throttle positioner needs to work in Idle speed the opposite direction. the throttle positioner pin 1 and the signal probe to pin must force the spring in the oppo- 4. The throttle positioner works in the other direction and the signal changed from negative to positive. The force required to maintain the throttle valve in this position is low (low spring pressure).

This graph shows the PWM signal during hard acceleration. RPM. the width will now change to achieve throttle valve opens further untill the this as additional force is required to engine reaches the demanded open the throttle valve.RPM On acceleration the throttle valve position must be changed. This signal is consistent for all throttle valve positions above the preset position.1100 . 67 . This PWM signal maintains the throttle positioner in position. the pulse On increased acceleration. The pulse widths are very wide due to de- mand for fast throttle valve opening. Hard acceleration tion (cruise position). The throttle positioner main- tains the throttle valve in this posi.

nent enables precise control of the Because of this the pressure sensor exhaust gas recirculation. The exhaust gas recirculation valve consists of the following compo- nents: Solenoid valve The valve opening is dependent on the coil current and is controlled by a pulse-width modulated (PWM) signal from the control unit. informs the driver about malfunc- The control unit measures engine tions in the engine electronics and parameters such as speed. which air-conditioning is directly connected reduces emission of nitrogen oxides. relay. that the ECU sends a signal to a This electronically controlled compo. The piston position sensor is required for assessing the exact position of the solenoid valve. The quantity of exhaust The telltale for engine electronics gas is checked by the control unit. condition and temperature via the sensor input signals and calculates the required exhaust gas quantity. is applied via a spiral spring.Exhaust gas recirculation Fan control The Z10XE and Z12XE engines are To reduce the components the fan equipped with a modified linear is controlled by the ECU. this means exhaust gas recirculation valve (1). 68 . The solenoid valve is not dependent on the vacuum and can therefore Telltale for engine electronics be opened or closed in all load conditions. which switches on the fan. Piston position sensor This sensor tells the control unit how wide the valve is opened. The restoring force required to keep the Telltale for engine electronics exhaust gas recirculation valve closed when it is dead. to the ECU. load immobilizer.

69 .Emission control telltale (MIL) The emission control telltale informs the driver about malfunctions that lead to increased emissions or malfunctions that can damage the catalytic converter. This telltale is required by EOBD.

70 .

2 History of On Board Diagnosis (OBD) With the introduction of the Mini People Carrier Agila for MY 2000 ½. Part of the measures taken to improve the air quality in Europe In Model Year 1996. On Board Diagnosis was introduced Opel was obliged to incorporate the in the early 80’s using flash codes. This ity of this component has been means that for the next Model Year recognised. This was the introduction passenger cars up to 2500 kg’s as of the OBD l. storing DTC’s of its petrol engines. The system is capable Opel must incorporate EOBD into all of recognising DTC’s. Board Diagnosis system is manda. The a system. increases.1 Introduction 7. At the same time these standards • the amount of trucks remains were set for OBD ll and in 1996 all the same but the amount of car manufacturers were required to driven km’s of each truck meet these standards.7 European On Board Diagnosis 7. Speedster will have to comply with This system stores a DTC if an these regulations. or the components connected to tory for newly type approved this ECU. European On Board Diagnosis In 1988. 71 . For Opel. OBD stand- was the introduction of the EOBD ardisation was introduced for all cars system by the European Union. • the amount of driven km’s increases. that could identify a fault appliance of the European On in an Electronic Control Unit (ECU). in regards to the indication of DTC’s on certain components. As of 01-01-01 all electrical defect is detected on a newly sold vehicles will have to component or a reduced functional- comply with these regulations. of 01-01-00. Further- This despite the fact that: more the communication protocol between diagnostic tester and ECU • the amount of automobiles was standardised as well as a 16- increases. as well as displaying the DTC and its status. pin diagnostic link. the California State (USA) (EOBD) system into this car’s required all manufacturers to provide engine management system. OBD was introduced in For Opel the Agila and later on the 1985 on the C13LZ in the Corsa A.

HC CO NOx HC+NOx EWG 1992 2.72 0.2 0.0 0. If the emissions were to rise above 1-1 ½ times the FTP (Federal test procedure) standards.97 EG 1996 2.3 0. for a given period.1 1.5 EURO III 2000 0. then a malfunction indicator lamp (MIL) must be illuminated. at this moment not decided yet.OBD ll is required to monitor and perform diagnostic tests on vehicle emission systems.2 2. The next step was to create a system that not only reduces the emissions. The DTC’s were also standardised as of Model Year 1996. Also the EOBD compels an in-field conformity so the cars must be monitored for a period of 5 years or 80000 km.08 72 . but also check emission relevant components. How this in-field conformity is going to take place is.15 EURO IV 2005 0.

73 . The objective is to reveal emission failures in an early stage. diagnosed components and 7. respective legislative requirements.7. • Catalytic converters are moni- tored for HC and NOx conver- sion. industry and environmental activation of the MIL. Phases of reducing the exhaust emissions in Europe are shown in the next column.3. and by recognis- malfunction thresholds.1 European Union the list of defects with the potential to trigger the MIL. This is achieved by checking the These points include: exhaust emission relevant compo- • Different calibrations for many nents constantly. during the car’s lifetime.3 EOBD EOBD and OBD ll (USA) are broadly similar in the areas of emission limits. The European comity has made an • Freeze frame data covering the objective in corporation with trans- distance travelled since the last port. ing. Remember that in earlier days the emission failures only were detected when the car was serviced. ing and indicating emissions increas- • No evaporative leak system. by lighting a control lamp. One of the measures taken by European Union (EU) to improve air Minor differences relative to the quality was a further reduction of OBD ll system are rooted in the allowable exhaust emissions. organisations.

3.AIR No Yes No Yes 74 .7.2 EOBD & US OBD requirement comparison US US Typical Industry European OBD I OBD II Standard OBD MIL Yes Yes Manufacturer Yes Dependent Standard Yes Yes No Yes codes Connector No Yes No Yes & Communica tion Protocols Misfire No Yes No Yes Cataytic No Yes No Yes converter Comprehen No Yes Yes Yes sive Component Monitor O2 No Yes No response test Yes response test EGR No Yes No intrusive test Yes intrusive test EVAP No Yes No Yes No leak test Fuel Yes Yes Manufacturer Yes Dependent Sec.

More (standardised) DTC codes The exact circumstances for storing are used. “lll”) with the engine not running now on long terms too.06. The regulations are compelled for Europe (newly sold cars) as of • The self-test of the ECU has Model Year 2001: failed. (lamp check) 2.7. Protects the catalytic converter. the MIL will flash as long system.3 The features of the EOBD Remark. • An emission related fault occurs 3.3. The EOBD system is not capable of checking the exhaust gas quality. MIL (Malfunction Indicator Lamp) Malfunction Indicator Lamp (MIL) management is submitted to legislative requirements. 75 . Enables service personnel to discussed at 7. read the DTC’s and their supplemental information. If within this frame the ECU calcu- lates a deviation. than the ECU will inform the driver by illuminating the MIL. More infor- mation about the circumstances is covered in a later stage. as the fault is present. a DTC and illuminating the MIL is 5. The MIL will be illuminated if: • The level of misfire is sufficient to result in catalytic converter damage at the current operating conditions. the emission-standards. 4. Sets Default Tracing Codes in two or three consecutive (DTC’s) if the emissions exceed trips. but can only check the components that are responsible for the exhaust gas quality. Checks the exhaust emissions. An acoustic signal is allowed as well. • Ignition is switched on( position 1.

(formerly known as the Service Vehicle soon SVS lamp) Control lamp for engine electronics 76 . called defect arises which is not emission the engine electronics telltale relevant.EOBD uses an additional telltale for This telltale illuminates when a not emission-related defects.

4. dynamometer. 77 . • Effective running time: 195 For Euro 4 the period just after the 7. to be run 4x in a The test for Euro 4 is changed row) compared to Euro 3 considering the period immediately after the start.6 km/h The test contains of the following steps. to be run running. The • Effective running time: 400 manufacturer has to prove that this seconds test is run through two times • Distance travelled: 6.013km Note: Consider that the Euro 3 The method for analysing exhaust • Average speed: 19 km/h method begins to measure 40- gases for the European type second after the engine starts approvals are done at a Step 2 (extra urban cycle. • Average speed: 62.955km without exceeding the prescribed • Maximum speed: 120 km/h emissions and without defects.7.1 European Type approval seconds start is measured as well. The test consists of 1x) imitated lifelike drive cycles on which exhaust gas is being analysed. • Distance travelled: 1.4 Test cycle for EUR0 III Step 1 (city cycle.

Therefore not all checks will be • Misfire detection. Warm-up cycle Those systems that are checked Warm-up cycle conditions are For EOBD. decelerating and occurs the emission telltale will be verter switching of the engine. will only fulfilled if the engine temperature is components will be checked once a registrar the defect if certain circum. Be aware of the fact that under The following graph shows the drive The following systems are checked some driving conditions not all cycle in which all EOBD relevant permanently. Therefore it is 710C).4. are temperature once a drive cycle: dependent and will be checked A driving cycle consists of starting immediately after a 200 C start. impossible to check the system. above a certain temperature.2 EOBD Cyclic test. permanently. using the back-up value. tests are passed. some systems and upon once a drive cycle. exceeding the idle defect on one of these systems • Working of the catalytic con. off again. The systems that are checked The following systems are checked Driving cycle. speed (driving). (Opel drive-cycle others are checked stances have passed. • Exhaust emission relevant components. by If the sensor is damaged the starting the engine and switching it temperature must be calculated Permanent check. • Injection time. 78 . passed. illuminated.7. required conditions are passed. permanently. If a • Working of the oxygen sensors the engine.

3000 rpm. Driving at constant speed Checked: Catalytic converter. erator Pedal Position (APP).S. Cold start. between 40 –50 km/h . One driving cycle 79 . Only used in the U. In between • The engine speed exceeds air system. 3 3. approx. Driving at constant speed Note: the test will be interrupted if. Checked function: Secondary approx.1. 15 minutes. Checked: oxygen sensor. tected. oxygen sensor monitor voltage • The vehicle speed exceeds 100 4 minutes: and response rate. minutes: between 60 – 100 km/h. • Strong variations of the Accel- 2. km/h. (If present) sufficient deceleration is de. idle speed. approx. monitor voltage and response 4. These tests can be executed at a rate. dynamometer or test-track.

In order to reproduce faults. sensors. 2 short to B+ 3 interruption Each of these tests is performed under certain conditions. purified exhaust gases.5 EOBD tests 7. This is done by using two oxygen EOBD tests the following systems. It therefore monitors the catalytic 1 short to ground converter efficiency.2 Catalytic converter: moni toring requirement 7. • Catalytic converter The first oxygen sensor (control • Misfire detection sensor) is installed directly to the • Fuel system exhaust manifold in front of the • Oxygen sensors catalytic converter and determines • Operation of the secondary air the remaining oxygen content of the system non-purified exhaust gases.7. • Tank fillings • Electronic Control Unit The second oxygen sensor (monitor sensor) is installed behind the Also the ECU runs tests on the catalytic converter and determines components of the before men- the remaining oxygen content of the tioned systems. Monitor sensor 80 . drive cycle.5. the criteria for the tests must be met.5.1 Tests of systems and According to the new EOBD components that are regulations. The component test consists of The ECU will compare the signals three tests. The new EOBD regulations pre- scribes the function test of the following systems: 1. Control sensor 2. The • Evaporation system ECU uses this sensor to control the • EGR system air-fuel ratio. from the two oxygen sensors. the catalytic converter’s exhaust emission rel efficiency must be monitored once a evant. one before and one after the catalytic converter.

Therefore the voltage of the second In case of deterioration of the oxygen sensor will be relatively catalytic converter the OSC will constant at a high level of approx. greater voltage area. In case of deceleration the the monitor sensor will vary in higher catalytic converter will store oxygen. This causes the This will be recognised by the ECU second oxygen sensor to vary in a and a DTC is stored. the oxygen is fully consumed. amplitudes. G0850 G0851 The graph on the left was made using a two-channel oscilloscope with ground as a reference and terminal 8 on channel A and termi- nal 57 on channel B of connector X47. reduce and therefore the voltage of 0. Capacity (OSC). 81 .7 V.In case of an optimal functioning catalytic converter. The signals of the two because of its Oxygen Storage oxygen sensors will look alike.

the • Upon detection. EOBD requires misfire detection under the following criteria: The phenomenon misfire detection is when an ignition (combustion) in a 1. principle that the crankshaft rota- tional velocity fluctuates as each • Detects misfire within 200-1000 cylinder contributes power input. the MIL will stay ON rotational velocity using the crank. A level of misfire resulting in exceed- ing emission levels. The camshaft sensor is used for 2. crankshaft revolutions When the engine misfires. sets a DTC and crankshaft slows down momentar. steady shaft sensor. • When catalytic converter damaging misfire is no longer The ECU monitors crankshaft present.7.Catalytic converter damaging certain cylinder does not take place. 82 . flashes the MIL.5. a catalytic converter damage at the Monitoring misfire is based on the current operating conditions.3 Misfire detection EOBD requirements. • This DTC can be set and the MIL will illuminate on a non- consecutive trip if the misfire occurs under the same operating conditions (within 375 RPM of engine speed and 20% of engine load and similar coolant temperature) within 80 trips. Emission threatening cylinder identification. ily. caused by either a fuel or ignition A level of misfire sufficient to result in system problem. sets DTC in history and MIL will illuminate. • Detects misfire within 1000- 4000 crankshaft revolutions • First trip arms the DTC • Third consecutive trip fails.

but can cause the emission level to exceed the thresholds. Misfire amount during 1000 revolutions à No damage to Catalytic converter. • Crankshaft revolution speed If within this given record circum- • Engine speed stances as in 1 or 2 occur. Misfire amount during 200 revolution of the crankshaft (meas- revolutions ured at every 180 degrees crank- à Overheat and damage to shaft). Catalytic converter. a DTC • Cylinder number will be set and the MIL will flash or will stay ON steady depending on the severity of the misfire.(MIL flashes) • 2.The ECU monitors the following The ECU maintains a record of a parameters: certain amount of crankshaft revolutions. (MIL steady ON) 83 . Conditions for misfire detection The misfire is detected in one • 1.

The injection time is being monitored Monitoring of the misfire will not be for EOBD depending on engine executed if the fuel tank amount is speed. to 4500 RPM above the positive torque line.4 Fuel system chains.5. Note. The air-fuel ratio is constantly being adapted by the ECU depending on the control sensor signal. 7. The crankshaft sensor recognises rough road conditions. load and oxygen quantity in less than 10 litres. the exhaust. misfire detection will not be executed.• NOTE: No misfire detection on rough road. measured by the Monitor the presence of misfire up control sensor. To detect misfire correctly. misfire will not be executed while vehicle is travelling on a rough road. If a car is driving with snow. 84 .

Time to activity. for this and is being adjusted by increasing or decreasing the The adaptation is only capable to amount of fuel injected.5 Fuel trim diagnostics 7. B1 2. also separately on the following func- known as long-term trim. composition of the exhaust gases. Some of the conditions to check the oxygen sensors are. Response time.7.6 Heated Oxygen sensors (2HO2S) For maintaining the ideal air-fuel The air. tions: These parameters are shown in the 1.fuel ratio is constantly kept ratio the ECU is capable to adapt within the optimal area. short-term fuel trim.5. the engine is warmed up and that there is no Limp home situation. long term fuel trim. During driving under high load As a part of the EOBD all oxygen and engine speed the multiple sensors have to be checked adaptation is executed. under all circumstances.5. In case of a registered malfunction. 85 . Sensor voltage. fuel trim. At idle and load and a partial order to decrease the injected engine speed the additive amount of fuel. also known as short-term trim. humidity. adaptation is executed. the misfire detection. that everything has to operate correctly. Used are a multiple adaptation and an additive adaptation. This is done by measuring the For instance the altitude. 2. fuel quality The amount of oxygen is normative etc. correct small deviations. TECH 2 as. B2 short-term 3. outside temperature. catalytic converter efficiency control and the air-fuel ratio check are being postponed. for different Example: If the monitor sensor circumstances: reports a rich mixture than the ECU will decrease the injection time in 1. Obvious is.

test. This test concerns the wiring. • Inactive sensor. activity will increase and the test will calibrated fail parameters in the • Short to ground conditions. fail. Response time To enable the oxygen sensor to This test is executed permanently The ‘Time to activity’ test. heater circuit is failing. before servicing the oxygen sensor. also samples sensor be illuminated. 86 . the MIL will voltage test. voltage over a period of time and detects a fault if the voltage is Note: The vehicle operating condi- beyond the threshold calibrations in tions. such as an exhaust leak. the test will fail. requires to become active and lean-to-rich and the rich-to-lean The test looks for the following: compares this result to calibrated fail transition times of the pre-catalytic parameters in the ECU.1. the under normal driving conditions. Check for warned by the MIL. The Heated Oxygen Sensor (HO2S) If one of these tests fail. If the time between the system. Time to activity (warm-up time) 3. Sensor Voltage test 2. measuring the time the sensor Response time test monitors the connectors or signal abnormalities. the sensor’s heater system by sensor needs to be heated. the time to Transition times are compared to • Shorted to voltage. monitors measure the oxygen content. quality of the fuel used and the ECU for a specified time period. This test can only be run ECU to determine fail or pass of the • Rich and lean shifts of the fuel following a cold start. possible conditions. the condition of the catalytic con- Therefore the deterioration can be verter can affect the operation of spotted and the driver will be the oxygen sensors. transitions is to long. If the converter Heated Oxygen sensor.

fuel vapour from the fuel tank. The ECU can recognise this by using the MAF sensor and a pintle sensor as known in several sys- tems.5. This is called 7. or a change in the EGR flow rate results in the vehicle exceeding the calibrated fail param- eters in the ECU. the MIL will system.g. 7.8 Fuel level System The tank level sensor measures the The EVAP system is used to collect fuel level of the tank.9 Electronic Control Unit canister purging since the vapours (ECU) are purged from the canister.7. The EGR system is considered malfunctioning when an EGR component fails.5. This information is used for misfire These vapours are stored in a detection.5. canister and routed to the intake manifold or throttle body during certain operations. The linear EGR Flow rate detects a reduction in EGR flow.5.10 Exhaust Gas Recirculation (EGR) EOBD requires that the EGR system be monitored for abnormal low and high flow rate malfunctions. canister filled with activated carbon. such as open circuits. X20DTL. 87 . EOBD requires only the testing of the The ECU carries out an internal electrical operation of the EVAP test. The misfire detection is ignored The EVAP system allows the when the content is less than 20 vapours to be drawn from the percent. The linear EGR pintle diagnostics detects the “component hard failures”. If a failure occurs. short circuits and stuck valves.7 Evaporative Emissions 7. e. be illuminated.

1 Diagnostic scan tool The Diagnostic Trouble Codes At this moment three different (DTC’s) are transmitted from the protocols for transmitting data are engine control unit to the generic used.7. the readout device itself must recognise the format in which 1. ISO protocol (International entrance for monitoring emission Standardising Organisation) related Defective Trouble Codes 3. Research Board) An important demand is a universal 2.6. 88 . CARB protocol (California Air the communication takes place. scan tool in digital form by way of standardised data transmission Form of data protocols in CARB and formats.6 DTC memories and types 7. Keyword 2000 protocol (to be (DTC’s) by using a generic scantool introduced from 2000) or the TECH 2. Three formats are currently ISO versions: in use.

Immobilizer) up. Position 1 Position 3 • P Powertrain System • B Body • C Chassis • 0 Overall system • 1 Secondary-air system/mixture Position 2 preparation • 2 Fuel system Determination • 3 Ignition system/misfires • 4 Additional exhaust-gas moni- • 0 Standardised code as per toring SAE/ISO • 5 Cruise control/idle-speed • 1 Manufacturer-specific control Failure Type • 6 Input/output signals. N/A Off 89 . For EOBD. the DTC’s were adopted accordingly after being internationally standard- ised. not critical (eg. The DTC’s can be identified by means of their alphanumeric structure.7. control IIIumination MIL units Engine • 7 Gearbox/transmission Positions 4/5 Counter for MIL Electronics Serial numbering of individual com- ponents or systems Telltale • The DTC’s are not only stored when the indicator lamp lights OBD I.2 Diagnostic Trouble Codes (DTC) The Society of Automotive Engi- neers (SAE) compelled the diagnos- tic trouble codes for the OBD II systems (USA).6.

A hard fault detected over 200 revolutions and an intermitted fault detected over 1000 revolutions.6. be stored. EOBD distinguishes between two different misfire faults. the catalytic converter is highly jeopardised.7. open detected the first time. This DTC shall be stored immediately. with a blinking MIL. later trip. stands the detection of a clear To read out DTC’s which are detectable electronic problem. driving cycle. the data will circuit short to battery. if the same DTC will not and the MIL shall be illuminated. To make sure that no wrong • Normal Fault detection will occur. If misfire is detected. When the DTC occurred For this types of DTC’s it is not the first time. or if a misfire DTC When the DTC is stored. without circuit. This freeze frame can be The DTC is stored in the memory overwritten. a safe and clear detection is four different fault types: difficult. • Misfire detection One of the exceptions of the EOBD DTC’s is the misfire monitoring. the ECU must store a necessary to wait until a later trip or freeze frame. this fault shall be stored finally up to the end of a Under a normal fault.3 DTC Types • Emission Fault For fault detection priority and For emission faults defined for storage. Opel under. circuit short to ground and activation of the MIL. 90 . the ECU occurs. must store a freeze frame. Opel distinguishes between EOBD. be stored.

91 . How- ever. A Freeze Frame is not updated if the test fails a second time. Freeze Frame data is Fault detection Flow Chart stored for the first failed test that sets the DTC and illuminates the MIL. The ECU after the second trip.6. only stores one type of Freeze Frame record. the third drive cycle will be accepted as the consecutive drive cycle. the MIL illuminates stored as a history DTC.• Limp home failures 7. Any previous infor- mation related to DTC’s stored in the Freeze Frame that are overwritten due to a priority DTC setting is lost. If the second drive cycle is not com- pleted.4 DTC Freeze Frame I f one of the emission systems The Diagnostic Executive in the comes into a limp home or back up ECU records certain vehicle operat- mode. fuel trim and misfire DTC’s take priority over all other DTC’s. The MIL will illuminate if the three consecutive drive cycles detect the same fault. the ing conditions when an emission telltale engine electronics illuminates related Diagnostic Trouble Code is immediately. a DTC will be stored. Fuel trim and misfire DTC’s always overwrite the Freeze Frame record unless a fuel trim or misfire DTC is already stored.

If misfire is detected the MIL will be flashing with the frequency of 1 Hz.7. (Value can be calibrated) 92 . MIL ON The MIL will illuminate if any emis- sion fault is clearly detected and stored.6. A DTC can also be cleared using a delete command from a generic scan tool.6. w/o Missfire (O2 esnsor's) 3rd On On and the DTC was no longer de- Missfire 1st Flashing Off tected. Vehicle Speed) N/A Off On free warm-up cycles have passed. OBD II. critical (eg. 7. MIL OFF The MIL can be switched OFF after two or three driving cycles.6 Deletion of DTC nics illumination overview On A DTC can be deleted if 40 failure- OBD I. The procedure for the Freeze Frame is identical.5 MIL/telltale engine electro.

average customer is not environ- In case of an illuminated telltale. the mental minded. 93 . more expensive parts and environ- mental friendly fuel.7 Consequences of EOBD The customer can be faced with for the customer two different kinds of telltales. for that the emission control indicator comfort reasons. On the other hand the customer will experience reduced running costs due to maintenance-free features. It is a fact that the can either flash or illuminate steady. But nevertheless the customer will have to pay the price for research. in some countries “EOBD tax The customer is advised to never reduction” the customer might carry out any repairs or adjustments become more environmental- and maintenance work on the conscious. control indicator for emission control and the control indicator for engine electronics. The consequences for the customer The customer will have to know are to be kept to a minimum.7. engine. The customer can only use unleaded fuel to refill the tank to avoid damage to the catalytic converter and oxygen sensors. customer will have to consult the With the introduction of EOBD and Opel dealer.

will stop the flashing and the MIL will be steady ON. 7. MIL (Malfunsction Indicator Lamp) Case 2 Blinking of the MIL during driving indicates danger of catalytic con- verter damage. compared to the fixed values. a corresponding DTC will be stored in the ECU memory.8. When an emission related faillure has been detected for the third time. the MIL will be illuminated and a DTC is stored in the ECU. The Malfunction Indicator Lamp indicates two different failures. In both cases the driver will be advised to visit an Opel service station. The Malfunction engine control lights has been Indicator Lamp (MIL) and the telltale Indicator Lamp informs the driver changed. tion of the emission control system exceeding of emission standards or must be guaranteed for 5 years or catalytic converter damage. Reducing the eingine load. Case 1 When the ignition is switched on and during cranking the MIL illumi- nates for a function control. about emission relevant failures.8.1 Engine control lights When an emission related DTC The after-sales service organisation would be recognised three times. Control lamp engine electronics 94 . 7. Correct opera. once the engine is running at idle the MIL extinguishes. When deviations will be recognised. With the introduction of the Z10XE has to inform the customer about the Malfunction Indicator Lamp will and the Z12XE the function of the the importance of the Malfunction be activated. engine electronics.2 Malfunction Indicator Lamp 7.8 Consequences of EOBD for the after-sales organi sation. 80000 km’s.

Repeated turbine-geometric. illumination of the control light • Direct fuel injection. • Optimise the intake manifold.7. most informs the driver to visit an Opel important and viable one. In an attempt to minimise the illuminates when a system or engine exhaust emissions. failure.4 Future developments The telltale. or even engine control unit. engine performance. engine electronics. If the control light flashes when the ignition is on there is a fault in the immobiliser system. which results in higher • Optimising the combustion fuel consumption and a reduced chamber. Switching the engine off and on • Turbo-charger with variable again can reset a failure. the emergency program takes over.8. lots of innovative failure will be recognised by the ideas have been released.8. 95 . service station. If it lights up briefly and goes out again this is of no significance.3 Telltale engine electronics 7. Illumination of this telltale informs the driver of an engine management Some of them are described below. already taken in production. • Variable valve opening times.

96 .

Reverse switch 2. Shift housing 6. Transmission housing cover equipped with a new transmission. Transmission description manual transmission. Input shaft and mainshaft with available. Oil plug 1. Lock plate automatic transmission is not cable operated. 13. Serial number The F12 transmission is a five speed 7. Vehicle speed sensor 5.8. The 10. the reverse 9. The clutch is also 12. Final drive 3. The transmission code shift forks area reveals the following informa- tion. Countershaft 5th gear coded with the designation F12. transmission is operated using 11. An bowden cables. Drain plug gears are synchronised. Oil collector All Opel Agila versions will be gear is not synchronised. Transmission housing 4. 97 . The forward 8. Transmission and clutch 8.1 The new F12 transmission 1. Clutch housing 2.

Z10XE F12 .39 4.4.11 1 3 5 2 4 R The transmissions with clutch for the Z10XE and Z12XE versions are the same. the left hand bearing of the input shaft (1).39 1 3 5 2 4 R Z12XE F12 . the countershaft (2) and the shims.4.11 4. 98 . except the final drive gears.

comparing This means that repairs and re- the Z10XE to the Z12XE version: placements of major transmission components is currently not possi- • Clutch cable length ble. except the transmission joint on the long (right) drive shaft. This Sealing of all external components. The cable 3. This joint is a tripod type joint. Adjustment nut bowden cable system.000 km or two years. and the fact on the F12 transmission are that the front right engine mounts of Replacement and adjustments of the Z10XE and the Z12XE are the bowden cable system. 1. difference requires changes in the following components. After this replacement the transmission oil is maintenance free. Adjuster system should be adjusted when the transmission has been removed or when there are complaints about shifting quality. Tripod joint on right drive shaft 4.1. the transmission is mounted Replacement and sealing of the a few centimetres more to the right gear shift guide assembly. Lock nut 2. Adjuster 99 . 1. If such a component should be • Drive shaft lengths replaced or repaired the transmis- • Shift cable lengths sion assembly should be replaced. Lock nut The transmission is operated using a 2. Filler plug All joints on the drive shafts are constant velocity joints. of the vehicle on the Z10XE. • Drive shafts 8. the only repairs possible block of the Z10XE.1 Transmission 1. Oil drain plug 2. The transmission oil is sched- uled to be replaced after 30. equal. Constant velocity joint on left drive shaft 3.1 Adjustments on transmis- sion and clutch 8. Adjustment nut 3.As a result of the shorter engine Currently.

Adjustment bolt cial procedure should be used to check and adjust these values.To be able to check the correct adjustment of the cable system: The transmission must be in neutral position.2 Clutch The clutch pedal height and clutch pedal free play can be checked and 1. If the actual gearshift position is out of range the cables can be adjusted using the adjustment nuts.1. Deviations from the nominal values within 10 millimetre are acceptable. Lock nut adjusted on the Opel Agila. 8. The gear lever must be in the lateral centre position (gearshift lever con- sole as reference). 100 . Then the clutch pedal free play can be adjusted. The gear lever must have a nominal longitudinal distance from the centre dash panel console. First the clutch pedal should be ad- justed to the same level as the brake pedal. A spe- 2.

Contact unit airbag 5. Steering 9. Clamping bolt 8. Steering wheel 4. Steering shaft 9. The steering system consists of the following components: 1. Airbag unit 2. Sealing ring 10. The Agila is standard equipped with Electric Power Steering (EPS).1 Introduction The Agila has a conventional rack and pinion steering system.9. Steering gear 101 . Steering column 6. Steering bolt 3. Intermediate shaft 7.

Version 2.6 mm/ the steering gear. For the assembly and drive or RH-EPS for right-hand disassembly of the tie-rods special drive.6:1. 1. The production date is tool KM-6004-1is required. reflected in a calendar week and year of production.An identification plate is located on The only difference in version is left. this can be revolution and the total steering ratio following information: identified by LH-EPS for left-hand is 17. The steering ratio is 37. Part number 3. Production date KM-6004-1 102 . it contains the or right-hand drive.

9.2 Electric Power Steering

The new Opel Agila will be intro-
duced with an Electric Power
Steering system. The designation
"Electric Power Steering" is abbrevi-
ated as EPS, which appears on the
control light on the instrument
Torque sensor EPS

Motor EPS

Compared to hydraulic power
steering, EPS has the following
• Fuel saving
• Weight saving
The EPS is positioned at the steer-
• Absence of all hydraulic compo-
ing column and consists mainly of
the following components:
• Absence of "Oil level-power
• EPS control unit
steering" maintenance point
• Torque sensor (or deviation
• No need for hydraulic oil disposal
when recycling old vehicles
• Electric motor with electric-
magnetic clutch
The following picture shows an
overview of the components used
EPS control unit on the EPS steering column:


1. Steering column jacket
9.3 Working principle EPS,
2. Steering spindle
3. Worm gear
4. Electric motor
5. EPS control unit The Electric Power Steering system
mainly consists of two components,
the steering shaft assembly and the
electric motor assembly.

A. Steering wheel side 3. Spring
B. Steering joint side 4. Bearing balls
C. Worm side 5. Spindle
1. Steering shaft 6. Worm gear
2. Contact ring 7. Locking pin


When the front wheels experience
much resistance during turning the
driver wants steering assistance. To
detect wheel-turning resistance, the
EPS system is equipped with a
torque sensor.
In case of wheel-turning resistance
a certain torque in the steering shaft
occurs. This torque causes the
contact ring to move up- or down-
wards, depending on the steering
direction, because of the bearing
balls that are underneath and slide
over the spindle. The torque sensor
moves via a little pin with a small
bearing in a groove on the contact

1. Electric motor
2. Worm

When necessary the worm of the
electric motor assembly will be
driven by the electric motor, which a. Steering shaft steering wheel
will result in the turning of the worm side
gear. The worm gear can be b. Contact ring
considered as one assembly with c. Spring
the steering shaft. If the worm gear d. Spindle
turns, the steering shaft turns and e. Worm gear
its turning movement will assist the f. Steering shaft joint-side
steering wheel. g. Worm
h. Steering column


The electric motor unit consists of an electric motor and an electric- magnetic clutch. Electric-magnetic clutch The electric-magnetic clutch is not A.or down wards the a trouble code and the electric- potentiometer turns. The electric- magnetic clutch engages the electric motor with the worm gear when the engine is running and disengages as soon as the engine stops running. detected by the EPS control unit. 106 . 1. which will be magnetic clutch disengages. Torque sensor • Trouble code present in EPS The torque sensor is a double This also means when the electric potentiometer that can move in two motor for any reason blocks during directions. Normal steering will be possible. Contact ring • Engine not running 2. Electric motor 2. If the contact ring moves driving. Steering wheel side engaged under the following cir- B. the EPS control unit will set up. Steering joint side cumstances: 1.

Not used 2. White wire DIAG Diagnostic link INS Instrument A48 Control unit-EPS B101 Sensor-steering deviation M50 Motor-EPS 107 . • EPS control unit • Torque sensor (Deviation sensor) The torque sensor has 4 wires with • EPS motor with electric-mag- the following functions: netic clutch Red wire: 5 Volts power supply • Input and output signal connec- Green wire: ground tions Black wire: signal White wire: signal 1. Green wire 4. Black wire 5. Red wire 3.9. Terminal 5 of the EPS control unit electrical leads to the telltale in the instru- ment.4 Working principle EPS. at terminal 7 the vehicle speed signal enters the EPS control The circuit diagram of the EPS unit and at terminal 6 the engine system shows the following compo- revolution signal enters the EPS nents: control unit.

108 . means that the current through the resistance. central position and the EPS control The required steering assistance is If the steering wheel turns and the unit must be supplied with 2.8 V X50) the engine speed signal. Red wire (1.25 mm²) 2. The regulation of this current lost! is achieved by a Pulse-Width- Modulation (PWM) signal.75 mm²) The maximum voltage on terminals wanted the torque sensor is in its 4 and 5 of connector X52 is 5 Volts. to one direction and because of the coming from the terminals 4 and 5. 3. For instance: will set a trouble code and the EPS X52 the signal from the torque Terminal 4 of connector X52/black system does not function anymore. sensor and via terminal 6 (connector wire: 3. the white wire (terminal 5 of con- nector X52) to the EPS control unit. only turns if the steering the EPS control unit via connector system experiences resistance.25 mm²) Torque Sensor If there is no steering resistance. Black wire (1. Due Terminal 5 of connector X52/white Note: according to the service to these signals the EPS control unit wire: 1. via connector white wire.75 mm²) thus no steering assistance is 4.5 Volts will motor and the other 2 (black) wires be supplied via both the black wire are used for the power supply to the (terminal 4 of connector X52) and electric-magnetic clutch. the torque sensor is in the power supply to the electric its central position and 2. which steering system experiences of terminals 4 and 5 of the connec. Two thick the steering system experiences no wires (red and black) are used for resistance. If X51 and contains 4 wires. or deviation The electric motor is connected to sensor. the torque sensor turns tor X52. In case of a deviant value electric motor must be regulated.1 V instructions it is not allowed to determines the direction and level of slacken or remove the torque the current through the electric sensor because the pre-set will be motor.5 Volts vehicle speed dependant. Black wire (0. Black wire (0. the EPS control unit vehicle speed signal. The EPS control unit receives via double potentio-meter the 5 Volts in the situation no steering assist. 1. terminal 7 (connector X50) the are divided between the black and ance wanted.The torque sensor.

g. the current turning the steering wheel clockwise is set back to a minimum value to or anti-clockwise. The pulse-width ensure safe steering. parking vehicle is stationary. 109 . thermal overload and a drained battery. or negative. if full lock is be higher in case of more resistance applied for some time when the in the steering system (e.This PWM-signal can be positive. both. <0 Volts. for example. overload protection. This prevents the vehicle). This is the becomes wider as the current must case. If the electric depending of the desired current motor current exceeds a limit for a flow through the electric motor specified period of time. > The EPS system is fitted with 0 Volts.

110 .

Steering (EPS) and Central Door Locking System with deadlock feature. signalling and instrument The Agila which is the smallest car The Opel Agila has plastic headlight in the Opel range contains the lenses. One of the items concerning Pre Delivery Inspection (PDI) is to adjust the headlamp levelling. Indicator • Immobiliser 2. Width-adjustment points The indicator bulbs of the front and rear lights have an orange colour.2 Lighting. It is systems such as a 2nd generation only allowed to clean them with car Immobiliser system. Electric Power shampoo.1 Introduction 10. Anti-lock Brake System (ABS) and a Vehicle speed con- verter module. which may not be cleaned following sophisticated electrical with abrasive or caustic agents. signalling and instru- ment • TID & Audio systems • Power windows • Central locking 1. Relays and Grounding 5. The headlamp levelling switch is power supplied via terminal 15 (switch voltage). Height-adjustment • Fuses. Power Windows. 111 . double LCD odometer. Parking lamps Module 4. Electrical systems 10. The following features will be mentioned in this chapter: • Lighting. Dipped head-light and high • Vehicle Speed Sensor beam (H4 12V 60/55 Watt) • Vehicle Speed Converter 3.10. Some other electrical features are Triple Info Display (TID).

The prepared fog lights connectors can be found behind the bumper close to the built-in location for fog lights. Head lamp levelling • ILU Illumination light • S75 Switch-Headlamp levelling • X5 Body front & Instrument panel connector • Y14 Headlamp levelling-Left • Y15 Headlamp levelling-Right The Agila has no single parking light feature but does contain a prepara- tion for additional fog lights in the wiring harness. Ep1014 112 .

Reset knob trip odometer 4. An instrument with tachometer is moved to replace the bulbs. optional for the Agila. Tachometer 113 .The rear light units must be re. Indicator coolant temperature 6. The instru- ment of the Agila contains double trip odometer. LCD odometer 5. Fuel indicator 3. 1. Electronic speedometer 2.

At the back of the instrument the The following Diagnostic Trouble warning buzzer is mounted. The ‘key. Control Unit (ECU). light warning. If memory. the lights are still ON and the door • B0055 Replace Electronic opens. • ABS Telltale test • EBD Telltale test • Odometer LCD test • Key-in warning • Light-On warning Programming • Code index programming • Odometer programming ECU control • Coolant temperature control • Instantaneous tank content control • Engine speed control • Vehicle speed control (km/h) • Vehicle speed control (m/h) 114 . • B0168 Tank gauge voltage Actuator tests: high input. • B0164 Coolant temperature in’ warning has priority over the incorrect signal. • B0165 Coolant temperature signal low input. the EEPROM failure. following TECH 2 software features • B0167 Tank gauge voltage concerning instrument are available: low input. duces a constant beep. this are possible: buzzer warns the driver when the key is still in the ignition switch or DTC when the lights are still ON. the warning buzzer pro. As soon Codes (DTC) concerning instrument as the driver opens his door. • B0021 Trip reset button stuck • B0051 Replace Electronic When the door is opened with the Control Unit (ECU)- key still in the ignition lock. The instrument of the Agila is • B0166 Coolant temperature accessible for TECH 2. warning buzzer creates a beep with • B0052 Reprogram program an interval of approximately 2 Hz. For the signal high input.

This connec- tor is fixed on the wiring harness. right • EMP Radio • FCx Fuse • HWS Hazard warning • K37 Relay-Tail lamp switch • S2 Switch unit-light • HZG Heating • X1 Body front & • IMO Immobiliser Insrument panel • INS Instrument • X23 Splice connector • LWR Headlamp levelling • NSL Fog lamps. • AC Air conditioning • E2 Parking lamp.3 Triple Info Display & Audio systems The optional Triple Info Display (TID) of the Agila is the same as used on the Astra-G with the exception of splice connector X23. rear • NSW Fog lamps. These 5 power supply wires provide Abbreviations Component codes power for the illumination of different components when the lights are • AB Airbag • E1 Parking lamp. front • TFL Daytime running light • TID Triple Info Display • WA Washer • ZIG Cigarette lighter 115 .10. close to the instrument and leads along the cross member behind the dash panel. 2. Collecting point for 7 ground wires. left switched ON. Distribution points for 5 power Ep0991 supply wires. G0785 The connector X23 has two func- tions: 1.

a CD player and also treble. in case of a CAR 2003 or CDR 2005. Another feature of the CDR 2005 is the speed dependant volume control. a cassette recorder. base and fade control. used in the Astra-G. The R2001 has its own display and therefore it will not display informa- tion on the TID. All available radios for the Agila have in the rear roof trim. 116 . 6 pre-settings. treble. 5 pre-settings.The standard audio system of the Agila exists of the radio R2001 with two 7-Watt front speakers and 4 pre-settings. All other optional radios will display information on the TID. The speakers are located in the R 2001 corners of the dash panel and. Optional. base and fade control. CAR 2003 The CAR 2003 comes with four 7- Watt speakers. CDR 2005 The CDR 2005 comes with four 20- Watt speakers. The antenna double DIN connectors and with internal amplifier is the same for telephone mute. the CAR 2003 and the CDR 2005. two other all radios and is similar to the one radios can be ordered in the Agila.

If the battery has been discon- nected it is not necessary to reprogram the memory.10. 117 . The switch for the window lifters is supplied via terminal 15a and the ground for the power windows motors is shared with the central door locking system. Therefore the switch unit of power windows is combined with the lock/unlock button for the central door locking system. The power window system does not include a pinch-guard feature and a comfort closing feature (closing the windows from the outside).4 Power windows The front windows of the Agila can be equipped with power windows and are always combined with central door locking.

•` S17. • S17. • M9 Motor-window lifter. Cd0944 Power windows-Left-hand drive 118 . • M8 Motor-window lifter. • S18 Switch-window lifter.1 Switch-window lifter. driver door. • X9 Instrument panel & Front passenger door.2 Switch-window lifter. • X8 Instrument panel & Driver door. front passenger door.6 Switch-central lock` ing. • ZV Central door locking. front passenger door. • X7 Instrument panel & Driver door. driver door. • S17 Switch-window lifter. front passenger door. If the battery has been disconected it is not necessary to reprogram the memory. • S17.

1.10. It is also possible to lock or unlock all doors simultaneously using the lock/unlock switch in the door panel. Latch assembly 2. The central door locking system. The central door locking system is operated by the key for the driver's and the passenger's door. together with the switches for the power window system. also called central locking. Protector 119 . consists of the following components: G0789 • Control unit central locking • Motors central locking/door lock Control unit Central locking units • Switch lock front doors The control unit of central locking is • Door contact switches located nearby the fusebox at the • Lock/unlock switch A-pillar inside the vehicle. The door contact switches of the front doors are mounted in the B-pillar and for the rear doors in the C-pillar. The lock/ unlock switch is mounted in the front door trim. it is possible to lock and unlock all doors simultaneously. The motor • Car key and the door lock unit form an assembly that is mounted inside each door.5 Central door locking system With the help of the central door locking system of the Agila.

When this is repeated within The fuel filler flap cannot be locked. The fuel filler cap can be locked via a separate lock operated The central door locking system of by the ignition key. the Agila has no overload protec- tion. Turning the key anti-clockwise once results in opening of that particular door only. ±3 seconds. system. This second command is not limited in time. When this command is been repeated all doors will be unlocked. all motors except the it is no part of the central locking tailgate motor will be deadlocked. When the key is turned anti-clockwise only that particular Turning the key clockwise once door will be unlocked. results in simultaneously locking all doors. the system. it is also possible to close and lock the driver’s door manually. This is realised by first pushing the door- knob down. If one of the door switches is operated (grounded) because one of the doors is open or not fully closed. it is possible to lock all doors simul- taneously but not possible to unlock all doors simultaneously or deadlock 1. lifting the door handle and then closing the door. After unlocking and opening the driver’s door using the key. 120 . Lock/unlock switch.

lock front right • M4 Motor-Central locking. passenger door • X16 Body rear & Roof rear rear door. left • M3 Motor-Central locking. • S74 Switch-Central • X12 Body rear & Rear door front passenger door locking. left • S102 Switch-Central locking • X25 Body rear & Tailgate • M5 Motor-Central locking. Central door locking • ASP Outside mirror • M54 Unit-Lock tailgate/lid • X7 Instrument panel & • FH Window lifters trunk Driver door • IRL Interior lamp • M54. right Body rear 121 .1 Motor-Central locking • X8 Instrument panel & • TKS Door contact switch • M54. locking. lock driver • X11 Body rear & Rear driver door door door.2 Switch-Lamp. pas Driver door • A12 Control unit-Central senger compartment • X10 Instrument panel & locking • S14 Switch-Central Front passenger door • M2 Motor-Central locking. • X6 Instrument panel & rear door.

The signal for lock. Note: be aware that the circuit diagram of the central door lock system is drawn in the dead- locked position! Cd0954 On path number 532 the control On path number 531 the interior unit of central locking is connected. 122 .the motor (M54) on the hatch door (tailgate) has an internal switch for the lock/unlock switch (S102) is shared with the ground for power windows. only the direction of current through the motor changes. Diode V9 This way the control unit detects if prevents the control unit of central one of the doors is open with the locking from detecting the interior result of an improper functioning light switch as closed and consider central door locking system (as this as a ‘door-open-signal’. light switch is connected. described before). unlock and deadlock is the same.When central locking is availabe.

Wheel speed sensor input signal at 100 km/h Wheel speed converter module output signal at 100 km/h Vehicle Speed Sensor 123 . Wheel speed sensor 10. steering. a Hall-type sensor. which is used to provide the vehicle the Immobiliser speed signal to the Anti-lock Brake The immobiliser system from the System (ABS) and the Motronic Agila is of the 2nd generation. It provides a 12 This sensor generates 25. The Control Unit. module is enforced on the non-ABS versions. in the New Technical Features of For this reason a signal converter Astra-G. is an inductive-type operation of this system is described sensor and produces a sine curve. This signal converter Vehicle speed sensor module converts the speed sine The vehicle speed sensor is Vehicle speed output signal signal into a block signal that is sent mounted on the transmission and is to the Motronic control unit. pulses/km (±5%) with the standard the control unit for electronic power size tyres installed on the Agila.6 Electrical features The wheel speed sensor. the radio and the triple info display.714 Volts block signal to the instrument.

This module and/or the ABS gener-
ate 8844 pulses/km. This value is
also the K-factor of the instrument.
This programming parameter can
be displayed using the odometer
display of the instrument. If the
odometer-reset button is pressed
for a period of 5 seconds or longer,
the programming display appears.
The code index and the code
version are displayed for 2 seconds.
The next 2 seconds the K-factor is
displayed. After this, the display
returns to the odometer display

B26 Sensor-wheel speed, front
U1 Signal converter module-
vehicle speed
X1 Body front & Instrument


Fuses & Relays

In the circuit diagram 3 abbre-
viations can be found for the fuses:
Fc, Fb and Fl. The fuses indicated
as Fc are located inside the vehicle.
The abbreviation Fb indicates to mini
fuses that are located in the engine
compartment. The abbreviation Fl
indicates to maxi fuses that are
located in the engine compartment.

Relays can be found in the engine
compartment, nearby the A-pillar
(fuse box) and behind the glove

Interior Engine compartment

1. K3, Heated back window 1. K12, Trumpet horn
2. K5, Fog lamp rear 2. K13, Radiator fan
3. K37, Tail lamp 3. K16, Fuel pump
3. K31, Flasher unit 4. K18, Engine control unit
5. K36, Compressor air condition
7. K4, Fog lamp front


1. K45, Interval wiper, windscreen
2. K43, AC Blower 1st speed
3. U1, Speed signal converter


1. right 6. right 2. Engine compartment. Engine compartment. Engine compartment. left 5. Engine compartment. left 3. left 4. Flywheel housing 127 .Ground points The following pictures indicate the 15 grounding points of a Left Hand Drive-Agila. Engine.

Transmission housing 10. Tailgate centre 128 . D-pillar.7. passenger’s side 12. right member 8. Tunnel 15. driver’s side 11. Chassis under seat. A-pillar. Bracket steering column/cross 13. A-pillar. left 9. Tailgate. left 14.

KTA-2266.4 New features for servicing the current version KTA-2049 and the Agila its supplement KTA-2143 lose their validation. With this new version 11. • Changed adjustment of clutch pedal In the new version the emission • Parking brake is adjusted on the data of the Agila is added and these fourth tooth engine are tested according the • Air cleaner cartridge change on demands of EOBD (European On- 60000 Km (??) Board Diagnosis). X16XE. X18XE1 from 2000 ½) exhaust emission test brochure MY98 till MY2000 ½ . Y16XE. KTA 1924/6. 16 Valves engines specific data. can be to MY 99 till MY 2000 ½ and used for all passenger cars contains Agila and Astra-G Coupe. There is a new version of the tions and checklists. • Gearbox F12 oil change at 30000 or 2 years once • Wheels tightened with torque of 85 Nm 129 .version 12.2 Pre-delivery inspection Coupe. tables. (X14XE. including Agila and Astra-G The service plan brochure KTA- 11.5 Service plan brochure Modelyear 2000 ½ The service plan for the Agila is There is a new service plan bro- almost similar to the service plan of • The service brochure modelyear chure KTA-2348 which is valid from the Corsa-B 2000 ½. X16XEL. edition 8/99 was only valid till inspection of the Agila and the end 99. work instruc.11. 2265 valid from MY 99 till MY 2000 • The service brochure KTA-1942/ is not valid anymore. Service 11.99. This form contains Fam I.6 Exhaust emission test current valid pre delivery inspection periods for the timing belt of the brochure brochure.3 Opel service booklet 11.1 Service 11. A new form for the pre delivery 5. the reason for this are Astra-G Coupe is added to the the changed maintenance 11.

• Triple Info Display (TID) • Radio CAR 2003 • Radio CAR 2005 • Airbag • Immobilizer • Instrument Chassis systems: • ABS (Anti-lock brakes) • ESP ( Electronic power steering) The diagnostic plug is located under MKM-846-29 the storage box on the driver’s side Knife for removal of the small side window 130 .11.5 Hybrid For activation of airbag units and seatbelt pretensioners when fitted in Body systems: the car.8.1 Body nosed with the TECH 2: KM-799-11 Motormanagement system: Adapter cable • Motronic ME 1.7 Techline 11.5. 11.8 Special Tools The following systems can be diag.

8.11.2 Front wheel suspension. KM-6142 wheel and tyres Fixing point Support wheel hub when pressed in KM-6138 or pressed out Fixing point Support of steering knuckle when wheel bearing is pressed in with KM-6139 KM-6139 Press tool for pressing wheel bearing in steering knuckel with KM-6138 KM-6140 Fixing point Support wheel bearing with pressing wheel hub in steering knuckle KM-6141 Fixing point Support splash shield brakes and steering knuckle with KM-6118-1 with removing wheel hub from steering knuckle with KM-466-5 131 .

KM-6133 Installation tools Installation ABS sensor on hub of drum brake KM-6143 Adapter Removal ABS sensor of rear hub with KM-161-B KM-6144 Punch To remove spring pin brake fluid reservoir KM-6145 Reset tool To reset the adjusting mechanism of the drum brakes 132 .

11.8. KM-6129 Installation an removal tool for Oxygen sensor with MKM-611 KM-6130 Pin for blocking poly V belt tensioner (only with AC) KM-6131 Installation tool for tensioning poly V belt KM-6132 Adapter for testing the cooling system with KM-471 133 .3 Engine KM-6054 For removal and installation of engine with KM-904 and KM-6056 KM-6056 Supports the engine with removal and installation with gearbox with KM-6054 KM-6103 Supports engine with installation and removal of cylinder head and for maintenance on ECM side.

4 Clutch and gearbox KM-6135 Centre pin for clutch plate KM-6133 Installation tool for sealing of crank shaft left with KM-523-1 KM-6134 Installation tool for sealing of crank- shaft right with KM-523-1 134 .8.11.