I decided that Andy was doing so much How 2 Stuff that it warranted
a page on it's own, so here it it is..
Engine fault code list which includes Ecotec
Fault code list for ABS and 4x4 codes Mark Craft sent in. And also Alarm and Automatic gearbox and fuel computer info
Fuel Computer Fault Codes and information
How to change the transfer box oil, rear diff,
gearbox and bleed the
PAS/4x4 By Andy Kirwan & John Wild.
Transfer Box oil change.
Undo the drain
plug under the transfer box and drain. 8mm allen key
Leave to drain to get
as much muck out the bottom as possible.
Refit drain plug.
Then
remove the temperature sensor/level plug in the side of the
box (14mm spanner late models).
Then fill via the breather hose in the top of the transfer
box.
This should be located by the coolant tank, cable tied to the top
coolant hose.
Straighten it out and fit a small funnel to it. Pour the
fluid in.
Fill with Vauxhall synthetic 90 443 530 approx œ6.50 0.6
l
Refit temperature sensor/level plug.
6 speed gearbox
oil change
Undo the drain plug under the gearbox and drain. 8mm allen
key
Refit drain plug.
Remove the filler vent completely, located at the
top of the gearbox.
It has a plastic cover on it. Unscrew with a
spanner.
Fill with 1.9 l (for the 6 speed box).
Remove the level check
plug in the side and check.
Replace filler/vent.
1.9 l SMX or
Mobilube 1 synthetic
Rear Diff oil change
Jack up
from drivers side.
Loosen the rear diff cover to let the fluid
out.
Reseal.
Then fill with a tube through the level check
plug.
0.8 l of SYNTRAX or EP80 or Mobilube 1
synthetic
PAS/4x4 fluid change
The PAS / 4x4 oil
should be changed if black or grey.
About 1 litre of Dextron II or
III
Undo jublie clip under the front radiator in the pipe that runs
to the PAS pump. Disconnect.
A load of fluid should pour out.
Then
switch on ignition and press brake pedal 25 times. More fluid
should come
out.
Refit and seal hose.
Remove Fuse 19
Open bypass screw
on shift valve approx 3 turns. (This is the
alan key on the top of the
brass block next to the accumulator)
Fill tank to MAX mark and start
engine
Top up subsiding fluid level immediately to MIN mark (no more
than 1.1 litres) and allow engine to run for approx 5 minutes.
Turn
steering to stop and hold in this position for approx 5 seconds
repeat
process to left and right.
Close bypass screw for 20 seconds and open
again
After another 20 seconds close bypass screw.
Switch off
engine.
Insert fuse and switch on ignition (do not start)
Actuate brake
pedal approx 25 times. (this opens and closes the
pressure switch to
transfer box)
Check fluid and top up if necessary
Start engine and run
for 1 minute and stop
Check fluid. (press brake pedal 25 time with ign
on)
Thanks to
Bob Rawle.
Remote Deadlocking Instructions By Andy Kirwan
Hints on fitting an alarm By Andy Kirwan
Problem with your oxygen sensor? Don't need a CAT for the MOT?
Wiring a cavalier engine into your Astra Mk2
Fitting Astra GSi bonnet vents to your Cavalier Mk3
Fitting a Fuel Computer
Aux Driving Lights Cav Mk3
Radio Connections
Vectra Sunroof total closure
What the 4x4 ECU does
Fitting an Omega Wiper Switch
Changing your 4x4 accumulator
