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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Check of levels of liquids

Below some special procedures of service demanding performance of additional checks of levels of liquids are described also. Regularly look under the car, checking it on existence of signs of development of leakages of working liquids.


Originators of the real Management recommend to make check of levels of the main working liquids (the impellent oil, cooling liquid, liquid of washing of a windscreen, battery electrolit, liquid of system of hydrostrengthening of a wheel) on a regular basis, is not more rare through each 7500 km of run. The others - according to the schedule THAT (see. Schedule of routine maintenance).

Various hydraulic liquids play a role of working bodies in systems of greasing, cooling, braking, coupling, heating and air conditioning, washing of glasses etc. In view of that all liquids are subject eventually to a razzhizheniye and development, and also during normal functioning of systems gradually become soiled, it is necessary to make their complete replacement periodically. Before starting correction of level or replacement, familiarize with the list recommended for use in the car of grades of liquids (see. Specifications).

At check of levels of liquids the car should be parked on an equal horizontal platform, whenever possible with a firm covering.

Impellent oil

Visual control of leaks

At the greasy engine and a big consumption of oil check places of the most probable development of leaks:

 PERFORMANCE ORDER

  1. Open a cover of a jellied mouth and check consolidation on existence of cracks or damages.
  2. Case ventilation: For example, a ventilating hose from a cover of a head of cylinders to a hose of absorption of air.
  3. Laying of a cover of a head of cylinders.
  4. Laying of a head of cylinders.
  5. Stopper of removal of oil (round ring).
  6. Laying of the oil filter: a filter joint with a flange.
  7. Laying of the pallet of a case.
  8. Forward and back epiploons of a cranked shaft.

As in the presence of thinnesses oil extends on a big surface of the engine, a place of leaks at once difficult to define. For detection of leaks act as follows:

 PERFORMANCE ORDER

  1. Wrap the generator in polyethylene. Spray the engine a usual cold cleaner and through short time wash out water on a car wash.
  2. Joints of components of the engine strew outside with lime or talc.
  3. Check oil level, if necessary add.
  4. Make a trial trip. As oil in the hot engine reduces the viscosity and quicker acts in places of leaks, it is necessary to execute a trial trip on distance about 30 km on the high-speed route.
  5. In summary investigate the engine by means of a lamp and localize places of leaks, having eliminated malfunctions.

Level check

If to start measurement of level of impellent oil right after engine switching off, the part of oil remains in the top part of the engine that will essentially be reflected in accuracy of indications щупа.

Check of level of impellent oil is made by means of measuring щупа, passed in directing tube and lowered in the engine to the bottom point of the pallet of its case. Location measuring щупа is shown on the illustrations showing placement of components in an impellent compartment of the car and placed at the beginning of the present Chapter.

Check of level of oil should be made before the trip first in the present day, or about 15 minutes later after an engine stop. If to execute check immediately after engine switching off, its results will adequately not reflect a situation as the part of oil will appear distributed on internal galleries and engine components.

 PERFORMANCE ORDER

  1. Take measuring щуп from a directing tube and dry wipe its edge pure rags or a paper towel. Insert щуп back into a tube against the stop, then again take. Having examined an edge щупа, estimate size of the site moistened with oil. Level of oil should be between the top and bottom marks in an edge щупа. In case of need add in the engine the corresponding amount of oil of a demanded grade.
  1. For level lifting from bottom (MIN) of a mark on щупе to top (MOVE) is required slightly less than one liter of oil. Level lowering out of limits of the bottom border of an admissible range conducts to development of oil starvation of the engine fraught with serious mechanical damages of the last. Try not to pour also oil above the top mark as it can lead to a pelting of spark plugs or failure of epiploons of the power unit as a result of excessive increase of pressure.
  2. To fill in oil in the engine it is necessary to remove the cover of a jellied mouth equipped with a carving (see illustrations the Scheme of an arrangement of components in an impellent compartment of petrol Astra G models of 1.6 l of SOHC or the Scheme of an arrangement of components in an impellent compartment of petrol Astra G models of 1.6 l of DOHC or the Scheme of an arrangement of components in an impellent compartment of petrol Zafira models of 1.6 l of SOHC or the Scheme of an arrangement of components in an impellent compartment of petrol Astra G models of 1.7 l of SOHC or the Scheme of an arrangement of components in an impellent compartment of petrol Astra G models of 1.7 l of DOHC). In order to avoid an oil razbryzgivaniye during its filling in the engine use a funnel, or a butterdish with a long nouse. Having filled in oil, screw and strongly tighten a cover of a jellied mouth, then start the engine and attentively examine on existence of signs of leaks a drain stopper and a surface of the oil filter interfaced to the block. Muffle the engine, wait about 15 minutes during which oil will merge in the pallet, then once again check its level.

Check of level of engine oil is important preventive procedure of service of the engine. Continuous decrease in level testifies to existence of leakages of oil as a result of failure of epiploons, damage of sealing laying, wear of piston rings or directing plugs of valves. If oil on color or a consistence reminds milk, or at it there are water drops, it speaks about possible damage of laying of a head of cylinders, or formation of cracks to a head body (ok) or the block. Check should be made immediately. During measurement of level of oil always check also its condition. Big and index fingers remove from an edge щупа oil traces — in case of presence at it small metal particles oil is subject to replacement (see. Replacement of impellent oil and oil filter).

Cooling liquid of the engine

Do not allow antifreeze hit on open sites of a body and the painted surfaces of the car. Casual splashes immediately wash away a plentiful quantity of water. Remember that antifreeze is extremely toxic liquid and its hit in an organism even in small amounts is fraught with the most serious consequences, up to a lethal outcome. Never leave antifreeze being stored in leaky closed container, immediately collect cooling liquid spilled on a floor. Remember that the sweetish smell of antifreeze can draw to itself attention of children and animals. About ways utilization of the fulfilled cooling liquid consult with local authorities,-.во many regions of the world special points on different reception of working off are equipped. At all do not merge old cooling liquid in the sewerage and on the earth!


Recently nontoxical grades of antifreeze are developed, nevertheless, they also should to be utilized in the organized order.

All models of cars described in the real Management are equipped with system of cooling of the compensatory type, working at superfluous pressure. The broad tank of system of cooling made of translucent plastic is located in a forward corner of an impellent compartment closely to the battery (see illustrations at the beginning of Head) and connected by a perelivny hose to the basis of a jellied mouth of a radiator. At engine warming up cooling liquid extends, and its surplus flows via the valve which has been built in in a cover of a jellied mouth of a radiator, in a broad tank. In process of cooling, liquid comes back on a hose back to a radiator that allows to support constantly in norm its level in system.

Do not uncover at all a jellied mouth of a radiator / a broad tank at the hot engine!


Level of cooling liquid in a broad tank is checked on a regular basis and at the cold engine should not fall below a mark of KALT/COLD in a wall of the tank made of translucent plastic. In case of need make the corresponding adjustment, having added in a tank demanded quantity of a fresh mix.


For correction of level of liquid use only demanded structure a mix этиленгликоля and the distilled water (about 50/50). Remember that frequent application for this purpose leads idle time of water to a gradual razzhizheniye of antifreeze and an utrachivaniye a mix of frost resistance and anticorrosive properties. It is not necessary to abuse also various type additives.

Continuous falling of level of cooling liquid usually testifies to development of leaks in system. Check on existence of traces of leaks a radiator, connecting hoses, a cover of a jellied mouth, drain jams and the case of the water pump. If it is not possible to reveal any signs of leaks, it is necessary to make check of a cover of a radiator by pressure in the conditions of a car-care center workshop.

Do not uncover at all a radiator / a broad tank at the hot engine!

In need of removal of a cover of a radiator wait complete cooling of the engine, then wind a mouth with a thick layer of rags and slowly unscrew a cover to the first emphasis. If thus there is a steam emission, let's to the engine cool down a little more, after it finally uncover.

Besides level always check also a condition of cooling liquid, - it should be rather transparent. If cooling liquid is painted in henna-red color of a rust, the system of cooling should be emptied, washed out and filled with a fresh mix of antifreeze with water. Even if liquid outwardly is not exposed to any changes, inhibitors of corrosion entering into its structure are exposed eventually to development therefore cooling liquid should be replaced regularly according to the schedule of routine maintenance of the car (see. Schedule of routine maintenance).

Try not to allow antifreeze hits on open sites of skin or the painted surfaces of body components. Casual splashes immediately wash away a plentiful quantity of water.

Liquid for windscreen washing

Liquid for washing of a windscreen is filled in in the special tank made of plastic located in the left forward corner of an impellent compartment between the storage battery and a broad tank of system of cooling (see illustrations at the beginning of Head). In regions with a temperate climate as liquid for washing of glass pure water can be used, however it is not necessary to fill the tank more than on 2/3 for the purpose of compensation of expansion of water at its freezing during frosts. At car operation in severe climatic conditions to use only patent screen wipers providing the corresponding decrease in a freezing point of liquid. In order to avoid a glass obmerzaniye when washing in cold weather previously warm up it a way обдува passed via the heater heat exchanger air.

Rules of configuration of a mix are usually printed to a container label. At all do not apply to addition in liquid of washing of glasses used in cooling system antifreeze, - the last is aggressive in relation to a paint and varnish covering of body panels!

Electrolit of the storage battery

Cars considered in the real Management are completed with the battery of tight type not needing service in which case only ventilating openings are provided. The case of the battery can be made of translucent plastic, - in this case electrolit level in its banks can be supervised for the purpose of obtaining indirect information on serviceability of functioning of system of a charge and current state of the battery. If in use a vehicle the battery for any reason was replaced usual (served type), it is necessary to check from time to time electrolit level in its banks for what it is necessary to remove the top control/jellied jams. Especially attentively it is necessary to watch electrolit level in a warm season. For correction of level of electrolit it is necessary to use only the distilled water.

Hydraulic liquid of brake system and coupling drive

The main brake cylinder (GTTs) is fixed on the block of the servo-driver of the vacuum amplifier of brakes (see illustrations at the beginning of Head). The tank established from above on GTTs is used as a reserve drive in hydraulic paths both brake mechanisms, and coupling (see. Heads Coupling and power shafts and Brake system).

Liquid level in GTTs tanks and a drive of coupling is well looked through through translucent walls of the last and should be supported between marks of MIN and the MOVE, without reaching to top on 8 — 9 mm.

In case of need corrections of level of liquid carefully wipe a cover of the corresponding tank and a surface round it pure rags in order to avoid hit in hydraulic system of dirt.

At a liquid flood in the tank watch that it was not sprayed on the surrounding painted surfaces of body elements. Add in each of systems only liquid of the grade stipulated by standard requirements (see. Specifications), - mixing of two liquids of a various grade by no means is inadmissible and can lead to refusal of the relevant system!

Brake liquid is extremely chemically aggressive, - do not allow hit it in eyes and on the painted surfaces of body panels! Do not use for addition in system the hydraulic liquid which has staid of more than one year, or stored in leaky closed container. Remember that brake liquid is very hygroscopic, i.e. possesses ability to absorb moisture from air therefore efficiency of functioning of brake system can dangerously decrease!

At a stage of correction of level it is necessary to check also attentively a condition of liquid and internal walls of the tank. In case of identification of mud deposits, firm extraneous particles or water drops the system should be emptied and filled with fresh hydraulic liquid (see. Heads Coupling and power shafts and Brake system).

After the tank will be filled to demanded level, densely plant on it a cover.

Remember that level of hydraulic liquid in the GTTs tank in process of operation of frictional overlays of brake shoes gradually falls, however this decrease is always very insignificant. If liquid has to be added too often, therefore, in system the leak which source should be immediately revealed takes place, and the reason is eliminated, - attentively examine all brake lines and their shtutserny connections, including supports, wheel cylinders and the servo-driver of the vacuum amplifier (for more details see. Check of brake system). Falling of level of liquid in the tank of a hydraulic actuator of coupling testifies to development of leaks in a path, including the executive cylinder (see. Head Coupling and power shafts).

If during check of level of liquid in the main cylinders that fact is elicited that its tank is almost devastated, the relevant system should be pumped completely over (see. Heads Coupling and power shafts or Brake system).

Liquid of system of hydrostrengthening of a wheel


Check of level of hydraulic liquid in the tank of the steering pump TRW

1 — Equipped measuring shchupy a carving cover

2 — the Working site щупа
3 — the Filter



Check of level of hydraulic liquid in the tank of the steering pump DELPHI

1 — the Carving cover
2 — Equipped shchupy a filtering element

3 — the Working site щупа

The tank of liquid of system of hydrostrengthening of a wheel is located in a back part of an impellent compartment (see illustrations at the beginning of Head).

The cover of the tank is equipped built in measuring shchupy (see illustrations Check of level of hydraulic liquid in the tank of the steering pump TRW or Check of level of hydraulic liquid in the tank of the steering pump DELPHI). A procedure for test standard for all measurements with the help щупов.

Try not to allow an exit of level of liquid out of limits of the bottom border of an admissible range.

In case of need make the corresponding correction of level, having added in a tank mouth hydraulic liquid of a demanded grade.

If need for correction of level of liquid arises regularly and often, check on existence of signs of leaks the steering pump, a case of reechny transfer, and also all connecting lines of a hydraulic path of system and their shtutserny connections.

RKPP transmission oil

 PERFORMANCE ORDER

  1. Tire out the car on a platform or a viewing hole, or поддомкратьте and establish it on props in strictly horizontal situation. Check of level of transmission oil should be made before a trip, or not less than 5 minutes later after an engine stop, - oil should manage to flow down in the pallet of a case of RKPP.
  1. Carefully wipe a surface of a case of a box round a control stopper. On transmissions of F13, F17 and F18 the stopper is in the left part of a case behind the internal CV JOINT of a power shaft.

On F23 transmissions — in a back part of the case of differential.

  1. Check is made by input in a finger opening — oil should reach the bottom cut of an opening.

    A — the Astra models
    B — the Zafira models

A.

B.
  1. Correction of level of oil is made through an opening under installation of the sensor switch of fires of a backing (F13, F17 and F18), or through a special jellied opening (F23) — turn out a sensor / stopper.

On boxes of F13, F17 and F18 transmission oil is filled in through an opening under installation of the sensor switch of fires of a backing — disconnect electroconducting (4) and turn out the sensor (3)

  1. Continue to fill in oil until it will not start to follow too much a control opening, allow surpluses to flow down, then muffle a control opening a stopper and tighten the last with demanded effort.
  2. Establish into place the sensor-vyklyuchatel/a stopper of a jellied opening and tighten it / it with demanded effort.

Some of boxes of the F23 type have regularly raised level of transmission oil — after reduction of level of oil to the bottom cut of a control opening it is necessary to screw a stopper and to add in a box about 0.5 more l of oil. Control jams of boxes of such execution are usually marked by a yellow label.

ATF

Correctness of level of ATF is one of critical operational parameters of the models equipped with AT. Excessive falling of level of ATF can lead to pro-slipping of the converter of rotation whereas the excessive amount of liquid conducts to its foaming, to formation of leaks and is fraught with a transmission exit out of operation.

Check of level of ATF should be made at the transmission warmed up to normal working temperature (15 — 20 km of run, 72 — 80°С).

It is not necessary to make check of level of ATF right after car operation on high speeds, in the conditions of a city cycle in hot weather, or after trailer towage, - previously let's liquids cool down within about 30 minutes!


 PERFORMANCE ORDER

  1. Park the car on an equal horizontal platform with a firm covering, strongly cock the parking brake. If the engine cold, start it and warm up to normal working temperature on single turns. At the working engine squeeze out a pedal of a foot brake and serially carry out the AT selector lever through all provisions, in summary, having returned it to the situation "R".
  1. Without suppressing the engine, take from a directing tube measuring щуп. Fingers remove from an edge щупа traces of ATF and to the touch estimate its condition.
  1. Carefully wipe an edge pure rags and enter щуп back into directing tube, having densely planted a cover on a mouth.
  1. Again take щуп from a mouth and by length of the moistened site of an edge determine ATF level in a transmission case. In case of need make the corresponding adjustment, through a funnel having added in transmission liquid of a demanded grade — fill in ATF directly in a mouth of a directing tube measuring щупа, try not to fill in in transmission excessive amount of liquid.

    And — Marking for check of level of ATF at working temperature
    In — Marking for check of level of ATF at cold transmission

  1. For lifting of level of ATF from the bottom border of a working range щупа to top about 0.6 l of liquid are required — add ATF in the small portions in stages, each time checking level.
  2. At the same time with level it is necessary to check as well ATF condition. If the liquid moistening the end of an edge щупа has a dark red-brown shade, or smells as ashes, ATF should replace (see. Head Automatic transmission). In the absence of confidence of correctness of an assessment of a condition of transmission liquid compare it on color and a smell to fresh ATF.