Opel Astra, Zafira

since 1998 of release

Repair and car operation



Opel Astra
+ Opel Astra and Zafira Cars
+ Operation manual
- Routine maintenance
   Schedule of routine maintenance
   Specifications
   General information about settings and adjustments
   Check of levels of liquids
   Check of a condition of tires and pressure of their rating, rotation of wheels
   Replacement of impellent oil and oil filter
   Check of a condition and replacement of a belt of a drive of auxiliary units
   Sediment removal from the fuel filter of the diesel engine
   Check of a condition and replacement of the hoses located in an impellent compartment
   Check of a condition of components of system of cooling
   Check, service and charging of the storage battery
   Check of a condition and replacement of brushes of screen wipers
   Survey of components of a suspension bracket and steering drive, check of a condition of protective covers of power shafts
   Check of brake system
   Electric equipment check
   Control of a condition of an anticorrosive covering of a body and car bottom
   Greasing of locks, loops and emphasis
   Zeroing of the indicator of intervals of maintenance
   Replacement of a filtering element of an air purifier - diesel models of release on 09.2000
   Replacement of the salonny filter
   Replacement of the fuel filter - diesel models of release on 09.2000
   Check of turns of idling and composition of the fulfilled gases
   Replacement of a filtering element of an air purifier - all petrol models and release diesel engines with 10.2000
   Replacement of the fuel filter - diesel models of release with 10.2000
   Replacement of spark plugs, check of a condition of VV of electroconducting
   Replacement of the fuel filter - petrol models
+ Engine
+ Systems of cooling, heating
+ Power supply system and release
+ engine Electric equipment
+ Manual transmission
+ Automatic transmission
+ Coupling and power shafts
+ Brake system
+ Suspension bracket and steering
+ Body
+ Onboard electric equipment

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Specifications

Recommended greasings and liquids

Below greasings and the liquids recommended for application by the company manufacturer of cars at the moment of drawing up of the real Management are listed. Fresher information can be received at firm car repair shops of the Opel company.

Type, properties and volumes of working liquids

Fuel

Type

Petrol engines

Unleaded gasoline is not worse AI-95

Diesel engines

Diesel fuel with tsetanovy number not less than 49

Volume of a fuel tank

l

Astra models

52

Zafira models

58

Impellent oil

Pay attention to conditions of warranty service of the new car concerning application of synthetic impellent oils!


Petrol engines

All-weather synthetic impellent oil viscosity OW X-th, the 5W-X-th, 10W-X on ACEA A3-98/B3-98, where X = 30 and above

Diesel engines

All-weather synthetic impellent oil viscosity OW X-th, the 5W-X-th, 10W-X on ACEA A3 - 98/B3-98 or A3-98/B3-98/B4-98, where X=30 and above

Viscosity

See. Automobile himikaliya, oils and greasings

Volume (with filter replacement)

Engine type

Volume, l

Z12XE/X12XE

3.5

Z14XE/X14XE

3.5

Z16SE/X16SE

3.5

Z16XE/X16XE

3.5

Z16XEP/X16XEP

3.5

Z18XE/X18XE

4.25

Z20LET/X20LET

4.25

X20XEV

4.25

X20XER

4.25

Z22SE/X22SE

5.0

Y17DT/X17DT

4.5

Y17DT (ECO)

4.5

Y20DTL

5.2

Y20DTH

5.2

Y22DTR

5.2

Cooling system

Type of cooling liquid

Mix of soft water and antifreeze (1:1) for ensuring frost resistance to-40 ° C

Antifreeze

models from 10.2000 red / orange colors

models on 9.2000 blue / green colors


Do not mix antifreezes of different type!

Volume

Engine type

Volume, l

Without the air conditioner

With the air conditioner

Z12XE/X12XE

РКПП

5.2

5.5

АТ

-

-

Z14XE/X14XE

РКПП

6.3

6.6

АТ

6.2

6.5

Z16SE/X16SE

РКПП

5.9

6.2

АТ

5.8

6.1

Z16XE/X16XE

РКПП

6.3

6.6

АТ

6.2

6.5

Z16XEP/X16XEP

РКПП

6.3

6.6

АТ

6.2

6.5

Z18XE/X18XE

РКПП

6.5

6.8

АТ

6.4

6.7

Z20LET/X20LET

РКПП

7.0

 

АТ

-

-

X20XEV

РКПП

Data are absent

 

АТ

Data are absent

 

X20XER

РКПП

Data are absent

 

АТ

Data are absent

 

Z22SE/X22SE

РКПП

6.8

7.1

АТ

6.6

6.9

Y17DT/X17DT

РКПП

7.1

7.1

АТ

-

-

Y17DT (ECO)

РКПП

7.1

7.1

АТ

-

-

Y20DTL/X17DTL

РКПП

-

-

АТ

7.8

7.8

Y20DTH

РКПП

7.9

7.9

АТ

-

-

Y22DTR

РКПП

7.9

7.9

АТ

-

-

Transmission oil for RKPP

Type

Transmission OPEL oil - 19  40 768   (No. 09 120 541)

Volume

l

All models, except 2.0 l

1.6

Models of 2.0 l

1.8

РКПП F23

1.55

ATF for AT

Type

ATF OPEL - 19  40 767   (No. 09 117 946)

Volume (at change)

l

All models

4.0


Dexron II and Dexron III not to apply!

Brake liquid / hydraulic liquid of a drive of coupling

Type

FMVSS116/DOT4, SAE J1703

Liquid of system of hydrostrengthening of a wheel

Type

OPEL oil - 19  40 766   (No. 09 544 116)

Volume

l

Pump TRW

0.7

Pump Delphi/Saginaw

1.1

Liquid of washing of glasses

Type

Any patent liquid for screen wipers

Volume

l

Models with washers of lenses of headlights

4.5

Models without washers of lenses of headlights

2.3

Greasing for the chassis

Universal greasing on a lithium basis

NGLI No2

Greasing for polar plugs of the battery

Bosch FT 40 v 1

Engine

In case of a different interpretation with the data provided on a label of VECI, should give preference the last.

Oil filter

Type

Petrol engines

  • Filter of not folding design
    •  L engines 1.4, 1.6 and 2.0

Champion G102

    • Engines of 1.8 l

Data are absent

Turns of idling, mines

Petrol engines (ESM are not regulated, established)

Models of 1.2 l

730 — 890

Models of 1.4 l

700 — 930

Models of 1.6 l

690 — 920 (X16SZR); 730 — 930 (X16XEL)

Models of 1.8 l

670 — 1030

Models of 2.0 l

730 — 960

Diesel engines

Models of 1.7 l of SOHC

780 — 900 rpm (ECM copes)

Models of 1.7 l of DOHC

825 — 875 rpm (ECM copes)

Models of 2.0 l

750 — 850 rpm (ECM copes)

The maximum turns of the engine at long functioning

Engine type

Frequency of rotation of the engine, rpm

Z12XE/X12XE

6250

Z14XE/X14XE

6400

Z16SE/X16SE

6000

Z16XE/X16XE

6400

Z16XEP/X16XEP

6400

Z18XE/X18XE

6400

Z20LET/X20LET

6400

X20XEV

6400

X20XER

Data are absent

Z22SE/X22SE

6500

Y17DT/X17DT

5100 — 5300

Y17DT (ECO)

5200

Y20DTL/X17DTL

4750

Y20DTH

4950 — 5050

Y22DTR

4920 — 5080

Admissible consumption of oil

On 1000 km of run

0.6 l

Klapannye gaps (only diesel engines of 1.7 l of DOHC)

Inlet and final valves

0.4 mm

Static moment of injection (diesel engines)

Engines of 1.7 l of SOHC

ECM copes

Engines of 1.7 l of DOHC

0.28 — 0.33 mm of a course of a plunzher of TNVD to VMT of the piston of the first cylinder at the end of a compression step

Engines of 2.0 l

ECM copes

Ignition system (petrol models)

Type / gap of spark plugs

Mm Champion RC10DMC/0.8
Mm Bosh FLR 8 LDCU/1.0
Mm NGK BKR 5 EK/0.8
AC DELCO 41-954 ED, (Z22SE engine)

Power supply system

Petrol models

Type of a filtering element of an air purifier

Champion U689

Type of the fuel filter

Champion L225

Diesel models

Type of a filtering element of an air purifier

  • Engine of 1.7 l of SOHC

Champion U689

  • Other engines

Data are absent

Type of the fuel filter

  • Engine of 1.7 l of SOHC

Champion L111

  • Other engines

Data are absent

Type of candles of an incandescence

  • Engine of 1.7 l of SOHC

Champion CH 163

  • Engine of 1.7 l of DOHC

Data are absent

  • Engines of 2.0 l

Champion CH 207

Brake system

Minimum admissible thickness of frictional overlays of brake blocks / boots

Disk brake mechanisms of lobbies and back wheels

2.0

Drum-type brake mechanisms

1.0

Wheels and tires

See also Specifications to Head Brake system.

Pressure of a rating of tires

Astra models

All models, except 2.0 l (all sizes of tires)

Loading to three people, including the driver

  • Forward wheels

2.2 bar

  • Back wheels

1.9 bar

Full load

  • Forward wheels

2.4 bar

  • Back wheels

2.8 bar

Models of 2.0 l

Tires 195/60

  • Loading to three people, including the driver
    • Forward wheels

2.2 bar

    • Back wheels

1.9 bar

  • Full load
    • Forward wheels

2.3 bar

    • Back wheels

2.8 bar

Tires 205/50

  • Loading to three people, including the driver
    • Forward wheels

2.3 bar

    • Back wheels

2.0 bar

  • Full load
    • Forward wheels

2.5 bar

    • Back wheels

2.9 bar

Zafira models

Loading to three people, including the driver

  • Forward wheels

2.2 bar

  • Back wheels

2.2 bar

Full load

  • Forward wheels

2.6 bar

  • Back wheels

3.0 bar

High-speed categories of tires (designation)

«REINFORCED» mark at the end of marking of the tire means the strengthened execution.


Q

160 km/h

V

240 km/h

S

180 km/h

ZR

over 240 km/h

T

190 km/h

W

270 km/h

H

210 km/h

Y

over 270 km/h

Efforts of a tightening of carving connections, Nanometer

Data on efforts of a tightening of fixture are provided also in the text of Head and on some illustrations.


Design detail

Value

Bolts of fastening of wheels

110

Petrol models

Oil filter of not folding design

15

Cover of the oil filter of a folding design

15

Bolt of fastening of the case of the folding oil filter to the block

45

Screws of fastening of the module of ignition

8

Spark plugs

25 (engine of 2.2 l: 20)

Drain stopper of the pallet of a case of the engine

SOHC engines

  • Models without To/in system (the stamped pallet)

55

  • Models with To/in (the cast pallet)

45

DOHC engines

  • Models 1.4, 1.6. and 1.8 l
    • With a head under an internal shestigrannik of TORX (a rubber sealing ring)

10

    • With a six-sided head (a metal sealing ring)

45

Engines of 2.0 l

10

Diesel models

1.7 SOHC l

Generator

  • Bolts М10 of fastening of the generator to a basic arm

46

  • Bolts М8 of fastening of the generator to a basic arm

25

  • Nut of fastening of a basic arm to the block of cylinders

35

  • Bolt of fixing of the generator on an adjusting level

35

Central bolt of a natyazhitel of a belt of a drive of the To/in compressor

45

Nuts of plates of fastening of the fuel filter

25

Oil filter

15

Drain stopper of the pallet of a case of the engine

10

1.7 l of DOHC and 2.0 l

Fastening of a damper of krutilny fluctuations to a power shaft

10

Fastening of a support of a suspension bracket of the power unit to a body

45

Fastening of a support of a suspension bracket of the power unit to a stretcher

55

Central bolt of fastening of a cover of the case of the fuel filter

6

Cover of the case of the oil filter

25

Drain stopper of the pallet of a case of the engine

  • Models of 1.7 l

78

  • Models of 2.0 l

18


The scheme of an arrangement of components in an impellent compartment of petrol Astra G models of 1.6 l of SOHC

1 — Shchup of measurement of level of impellent oil
2 — the Cover of a jellied mouth of impellent oil
3 — the Oil filter
4 — the Air purifier
5 — the Top support of racks of a suspension bracket
6 — the GTTs Tank
7 — the Inlet air line
8 — the GUR system Tank

9 — the Assembly block of safety locks
10 — the Socket of the main plait of electroconducting of the engine
11 — the Broad tank of system of cooling
12 — the Tank of liquid of washing wind glasses/lenses of headlights
13 — the Storage battery
14 — the ignition Module
15 — VV electroconducting
16 — the Top radiatorny hose


The bottom view on a car front - petrol Astra G models of 1.6 l of SOHC

1 — the Oil filter
2 — the Drain stopper of the pallet of a case
3 — РКПП
4 — the Reception pipe of system of production of the fulfilled gases
5 — the Power shaft
6 — the Tank of liquid of washing wind glasses / lenses of headlights

7 — the Stretcher
8 — the Bottom levers of a suspension bracket
9 — the Back support of a suspension bracket of the power unit
10 — the Steering mechanism
11 — Tips of steering drafts
12 — horn Horns


The scheme of an arrangement of components in an impellent compartment of petrol Astra G models of 1.6 l of DOHC

1 — Shchup of measurement of level of impellent oil
2 — the Cover of a jellied mouth of impellent oil
3 — the Cover of a drive of GRM
4 — the Air purifier
5 — the Top support of racks of a suspension bracket
6 — the GTTs Tank
7 — the Inlet air line
8 — the GUR system Tank

9 — the Assembly block of safety locks
10 — the Socket of the main plait of electroconducting of the engine
11 — the Broad tank of system of cooling
12 — the Tank of liquid of stekloomyvatel
13 — the Storage battery
14 — the ignition Module
15 — the Top radiatorny hose


The bottom view on a car front - petrol Astra G models of 1.6 l of DOHC

1 — the Oil filter
2 — the Drain stopper of the pallet of a case
3 — РКПП
4 — the Reception pipe of system of production of the fulfilled gases
5 — the Power shaft
6 — the Tank of liquid of washing wind glasses / lenses of headlights

7 — the Stretcher
8 — the Bottom levers of a suspension bracket
9 — the Back support of a suspension bracket of the power unit
10 — the Steering mechanism
11 — Tips of steering drafts
12 — horn Horns


The scheme of an arrangement of components in an impellent compartment of petrol Zafira models of 1.6 l of SOHC

1 — Shchup of measurement of level of impellent oil
2 — the Cover of a jellied mouth of impellent oil
3 — the Oil filter
4 — the Air purifier
5 — the Top support of racks of a suspension bracket
6 — the GTTs Tank
7 — the Inlet air line

8 — the GUR system Tank
9 — the Assembly block of safety locks
10 — the Socket of the main plait of electroconducting of the engine
11 — the Broad tank of system of cooling
12 — the Tank of liquid of washing wind glasses/lenses of headlights
13 — the Storage battery
14 — the Top radiatorny hose


The bottom view on a car front - petrol Zafira models of 1.6 l of SOHC

1 — the Oil filter
2 — the Drain stopper of the pallet of a case
3 — РКПП
4 — the Reception pipe of system of production of the fulfilled gases
5 — the Power shaft
6 — the Forward support of a suspension bracket of the power unit

7 — the Stretcher
8 — the Bottom levers of a suspension bracket
9 — the Back support of a suspension bracket of the power unit
10 — the Steering mechanism
11 — Tips of steering drafts
12 — horn Horns


The scheme of an arrangement of components in an impellent compartment of diesel Astra G models of 1.7 l of SOHC

1 — Shchup of measurement of level of impellent oil
2 — the Cover of a jellied mouth of impellent oil
3 — the thermostat Case
4 — the Top radiatorny hose
5 — the Air purifier
6 — the Top support of racks of a suspension bracket
7 — the GTTs Tank
8 — the Sensor of a consumption of air (MAF)
9 — the Fuel filter

10 — the Assembly block of safety locks of system of electric equipment of the engine
11 — the Main assembly block of safety locks
12 — the GUR system Tank
13 — the Inlet air line of an interkuler of system of a turbo-supercharging
14 — the Socket of the main plait of electroconducting of the engine
15 — the Broad tank of system of cooling
16 — the Tank of liquid of washing wind glasses / lenses of headlights
17 — the Storage battery


The bottom view on a car front - diesel Astra G models of 1.7 l of SOHC

1 — the Drain stopper of the pallet of a case, the Oil filter
2 — the Forward support of a suspension bracket of the power unit
3 — РКПП
4 — the Bottom levers of a suspension bracket
5 — Tips of steering drafts

6 — the Back support of a suspension bracket of the power unit
7 — the Reception pipe of system of production of the fulfilled gases
8 — the Steering mechanism
9 — the Power shaft
10 — the Stretcher


The scheme of an arrangement of components in an impellent compartment of diesel Astra G models of 1.7 l of DOHC

1 — Shchup of measurement of level of impellent oil
2 — the Cover of a jellied mouth of impellent oil
3 — the To/in Compressor
4 — the Air purifier
5 — the Sensor of a consumption of air (MAF)
6 — the Top support of racks of a suspension bracket the thermostat Case
7 — the GTTs Tank
8 — the Fuel filter
9 — the Assembly block of safety locks of system of electric equipment of the engine

10 — the Main assembly block of safety locks
11 — the Socket of the main plait of electroconducting of the engine
12 — the Broad tank of system of cooling
13 — the Tank of liquid of washing wind glasses / lenses of headlights
14 — the Storage battery the GUR system Tank
15 — the thermostat Case
16 — the Inlet air line of an interkuler of system of a turbo-supercharging
17 — the Top radiatorny hose


The bottom view on a car front - diesel Astra G models of 1.7 l of DOHC

1 — the Oil filter
2 — the Drain stopper of the pallet of a case the Oil filter
3 — the Reception pipe of system of production of the fulfilled gases
4 — the Forward support of a suspension bracket of the power unit
5 — РКПП
6 — the Bottom levers of a suspension bracket
7 — Tips of steering drafts

8 — the Back support of a suspension bracket of the power unit
9 — the Steering mechanism
10 — the Power shaft
11 — the Stretcher
12 — the Generator
13 — horn Horns


The bottom view on a car back - the Astra G models

1 — Back section of system of production of the fulfilled gases
2 — Torsionnaya a suspension bracket beam with longitudinal levers
3 — the pressure Valve regulator in contours of brake mechanisms of back wheels
4 — the Fuel tank

5 — the Cable of a drive of the parking brake
6 — the Well under storage of a spare wheel
7 — Screw springs of a suspension bracket
8 — Support of shock-absorbers


The bottom view on a car back - the Zafira models

1 — Back section of system of production of the fulfilled gases
2 — Torsionnaya a suspension bracket beam with longitudinal levers
3 — the pressure Valve regulator in contours of brake mechanisms of back wheels
4 — the Fuel tank
5 — the Cable of a drive of the parking brake

6 — the Well under storage of a spare wheel
7 — Screw springs of a suspension bracket
8 — Support of shock-absorbers
9 — Hoses of a jellied mouth and ventilation of a fuel tank
10 — Intermediate section of system of production of the fulfilled gases