Opel Astra, Zafira

since 1998 of release

Repair and car operation

Opel Astra
+ Opel Astra and Zafira Cars
+ Operation manual
+ Routine maintenance
- Engine
   Check of kompressionny pressure in cylinders
   Diagnostics of a condition of the engine with use of the vacuum gage
   + Procedures of repair of petrol SOHC engines without their extraction from the car
   + Procedures of repair of petrol DOHC engines without their extraction from the car
   + Procedures of repair of diesel engines of 1.7 l and 2.0 l without their extraction from the car
   - General and major maintenance of the engine
      Removal of the power unit from the car - methods and precautionary measures
      Removal, separation and engine installation
      Alternative versions of schemes of regenerative repair of the engine
      Sequence of dismantling of the engine
      Dismantling of a head of cylinders
      Cleaning and check of a condition of a head of cylinders
      Assembly of a head of cylinders
      Removal of shatunno-piston assemblies
      Removal of a cranked shaft
      Cleaning and check of a condition of the block of cylinders
      Honingovaniye of mirrors of cylinders
      Check of a condition of components of shatunno-piston group
      Check of a condition of a cranked shaft
      Check of a condition of radical and shatunny bearings of a cranked shaft
      Engine assembly order
      Installation of piston rings
      Installation of a cranked shaft and check of working gaps of radical bearings
      Installation of shatunno-piston assemblies and check of size of working gaps in shatunny bearings of a cranked shaft
      Trial start and engine running in after major maintenance
+ 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

Cleaning and check of a condition of the block of cylinders



  1. Remove from the block everything the components established outside and sensors.
  2. Упершись a stupid drift to the region of a vyzhimny stopper, develop it in the landing nest under 90 °. After all jams will be developed, they will need to be taken from the engine by means of nippers.
  3. Scratch out from an interfaced surface of the block all traces of a material of old laying — try not to leave scratches and задиров.
  4. Turn out all carving caps of oil galleries. Caps can appear tightened very hardly up to that they should be drilled with the subsequent restoration of a carving in the block. At assembly of a cap are subject to replacement.
  1. On diesel engines shoot sprays of supply of oil with pistons. On engines of 1.7 l sprays are pressed in the block and their removal can be made only with use of the special Opel adaptation, on engines of 2.0 l sprays are fixed by bolts.
  1. Remove from the block of a cover of all radical bearings and take from the beds loose leaves of the last. At once mark the taken loose leaves by means of an adhesive tape on accessory to the bearing and a bed in it (the block or a cover), then put them aside.
  2. At strong external pollution of the engine it is necessary to deliver it in a car-care center workshop for carrying out steam or thermal processing.
  3. After block return from a workshop once again carefully clean all oil openings and galleries — for this purpose special cylindrical brushes of a special form (ask in shops of automobile accessories) are issued. Wash out cavities and channels warm water — continue washing until from the opposite side of the block pure water will not start to follow. Carefully dry the block, then slightly grease all pierced surfaces with liquid oil for protection them from corrosion. In the presence of access to a source of the compressed air use it for acceleration of process of drying of the block and a purge of remote cavities and channels.

At work with the compressed air do not forget to put on goggles!

  1. At strong pollution or a zashlakovyvaniye of the block it is necessary to resort to shchetochny cleaning by hot water with soap. It is not necessary to try to save time at the expense of neglect care of cleaning of the block. Regardless of the chosen way, track care of pro-cleaning of remote cavities, channels and openings. In summary dry the block and grease the pierced surfaces with liquid oil for protection them from corrosion.
  2. Banish all carving openings in the block a tap of the corresponding size for the purpose of providing a guarantee of compliance of indications of the indicator of a dinamometrichesky key to really developed efforts of a tightening of fixture at engine assembly. Whenever possible, blow then the openings banished by a tap the compressed air, having removed from them all small garbage and shaving. Having finished processing of openings, walk a thigh by a carving part of bolts of fastening of covers of bearings and heads of cylinders.
  3. Establish to the place of a cover of radical bearings, having by hand tightened their fixture.
  4. Grease sealing surfaces of new vyzhimny jams with hermetic of the Permatex No 1 type and establish them on the regular places in the block. Track perpendicularity of landing of jams — it will be most correct to use a special cylindrical opravka, however the face head of the suitable size which should rest only against an internal part of a face surface of a stopper (not in a fillet can quite replace it!).
  5. Grease with not hardening hermetic of the Permatex No 2 type a carving part of new caps of oil galleries (alternatively wind them with a tape FUM). Screw caps on the regular places and tighten as it is possible more strongly.
  1. On diesel engines press / приболтите on the places sprays of supply of oil on pistons.
  1. If are not going to start at once engine assembly, place the block in a big plastic bag for protection of its pollution.



  1. Previously the block should be very carefully cleared (see. Removal of a cranked shaft).
  2. Make external survey of the block about identification of traces of corrosion, cracks and other damages. Check a condition of carving openings. It will be reasonable to make also testing of the block for existence of the hidden cracks in the conditions of a car-care center workshop with use of the special diagnostic equipment. In case of detection of defects the block is subject to regenerative repair or replacement.
  3. Check a condition of mirrors of cylinders.
  1. Estimate sizes taking place a konusnost and ovality of cylinders:
    1. Measure diameter of each of cylinders in top (directly under limit of step wear), the central and bottom sections in the plane of a parallel axis of a cranked shaft;
    1. Now measure diameters at the same three levels, but in the plane, a perpendicular axis of the block;

    And — Under limit of step wear
    In — In an average part
    With — In the lower part

    1. The size of a konusnost of the cylinder is defined by a difference between results of measurements in the top and bottom sections. (In this section of the cylinder) the difference of diameters measured in a parallel and perpendicular axis of a cranked shaft the planes is called as ovality.
  1. Compare results of check to requirements (see. Specifications). Operating in the described manner, serially check all cylinders.

Remember that there are some groups of standard diameters of the cylinders resolving various production admissions. Marking of dimensional group is usually put on the top cut of the block of cylinders.

  1. At detection of appreciable defects or a deviation of results of measurements from standard requirements, the block of cylinders is subject to regenerative machining in the conditions of a car-care center workshop. If in the course of regenerative repair boring of cylinders was made, the engine should be completed with new pistons repair (with excess) the size.

Pistons of the repair size (with excess of 0.5 mm) are made for all engines, except engines of 1.7 l of DOHC (petrol and diesel).

  1. If the condition of mirrors of cylinders during performance of check is found satisfactory at simultaneous observance of standard requirements to a form of cylinders and gaps of landing of pistons in them (see. Check of a condition of components of shatunno-piston group), need for a pro-point of cylinders disappears — will execute only honingovany their mirrors (see Honingovaniye of mirrors of cylinders) enough.
  2. Check planeness of a surface of the block interfaced to a head — check is made in the manner similar to described for interfaced surfaces of a head of cylinders (see. Cleaning and check of a condition of a head of cylinders). Compare result of measurements to requirements (see. To the specification), in case of need give the block to a pro-point.