Opel Astra, Zafira

since 1998 of release

Repair and car operation



Opel Astra
+ Opel Astra and Zafira Cars
+ Operation manual
+ Routine maintenance
- Engine
   Specifications
   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




Engine assembly order

Before starting engine assembly, make sure available all necessary details, materials and tools to which number the following belongs:

  • Standard set of the metalwork tool;
  • Dinamometrichesky natural a drive on 1/2-inch;
  • The tool for putting on of piston rings;
  • The tool for a staving of piston rings;
  • Short pieces of a fuel hose for putting on on hairpins of covers of shatunny bearings;
  • Measuring set of Plastigage;
  • Set щупов lezviyny type;
  • File with small tooth;
  • Fresh impellent oil;
  • Assembly impellent, or molibdensoderzhashchy greasing;
  • Prokladochny hermetic;
  • Hermetic for fixing of carving connections.

At this stage all subjects to installation components should be absolutely pure and dry. For convenience spread out details on a pure surface as installation.

With a view of economy of time and minimization of volume of arising problems make engine assembly in the following order:

Petrol engines

  1. Piston rings;
  2. Cranked shaft and radical bearings;
  3. Shatunno-porshnevye assemblies;
  4. The oil pump with a maslozaborny tube (see. Procedures of repair of petrol SOHC engines without their extraction from the car or Procedure of repair of petrol DOHC engines without their extraction from the car);
  5. Balancing the assembly / bridge of radical bearings (depending on a complete set if are provided)
  6. The case pallet (including a maslootrazhatelny plate if it is provided) (see. Procedures of repair of petrol SOHC engines without their extraction from the car or Procedure of repair of petrol DOHC engines without their extraction from the car);
  7. Flywheel / a driving disk (see. Procedures of repair of petrol SOHC engines without their extraction from the car);
  8. Head of cylinders with a camshaft (and) and components of a drive of valves (see. Procedures of repair of petrol SOHC engines without their extraction from the car or Procedure of repair of petrol DOHC engines without their extraction from the car);
  9. The case of the gas-distributing mechanism and its cover (see. Procedures of repair of petrol SOHC engines without their extraction from the car or Procedure of repair of petrol DOHC engines without their extraction from the car);
  10. The water pump (see. Head of System of cooling, heating);
  11. Back cover of a drive of GRM (see. Procedures of repair of petrol SOHC engines without their extraction from the car or Procedure of repair of petrol DOHC engines without their extraction from the car);
  12. Components of a drive of GRM (see. Procedures of repair of petrol SOHC engines without their extraction from the car or Procedure of repair of petrol DOHC engines without their extraction from the car);
  13. Forward covers of a drive of GRM (see. Procedures of repair of petrol SOHC engines without their extraction from the car or Procedure of repair of petrol DOHC engines without their extraction from the car);
  14. The inlet pipeline and final collector (see. Head of the Power supply system and release);
  15. Hinged units;
  16. Protective casing of the engine (at the corresponding complete set).

Diesel engines

  1. Piston rings;
  2. Cranked shaft and radical bearings;
  3. Shatunno-porshnevye assemblies;
  4. Components of a drive of GRM with a back cover - engines of 2.0 l (see. Procedures of repair of diesel engines of 1.7 l and 2.0 l without their extraction from the car);
  5. The oil pump with a maslozaborny tube (see. Procedures of repair of diesel engines of 1.7 l and 2.0 l without their extraction from the car);
  6. The case pallet (including a maslootrazhatelny plate if it is provided) (see. Procedures of repair of diesel engines of 1.7 l and 2.0 l without their extraction from the car);
  7. Flywheel / a driving disk (see. Procedures of repair of petrol SOHC engines without their extraction from the car);
  8. Head of cylinders with a camshaft (and) and components of a drive of valves (see. Procedures of repair of diesel engines of 1.7 l and 2.0 l without their extraction from the car);
  9. The water pump (see. Head of System of cooling, heating);
  10. Components of a drive of GRM — all engines, except 2.0 l (see. Procedures of repair of diesel engines of 1.7 l and 2.0 l without their extraction from the car);
  11. The case of the gas-distributing mechanism and its cover (see. Procedures of repair of diesel engines of 1.7 l and 2.0 l without their extraction from the car);
  12. Components of a drive of GRM with a back cover (see. Procedures of repair of diesel engines of 1.7 l and 2.0 l without their extraction from the car);
  13. Forward covers of a drive of GRM (see. Procedures of repair of diesel engines of 1.7 l and 2.0 l without their extraction from the car);
  14. The inlet pipeline and final collector (see. Head of the Power supply system and release);
  15. Hinged units.