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

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Trial start and engine running in after major maintenance

At primary start of the engine after completion of its regenerative repair near at hand without fail it is necessary to have the class B fire extinguisher!

After installation of the power unit on the car, check levels of impellent oil and cooling liquid. Once again make sure that all lines of communication (cables, hoses and electroconducting) are connected and properly fixed. Clean from an impellent compartment all tool, rags and other extraneous subjects.

Petrol models

 PERFORMANCE ORDER

  1. Disconnect ignition system by an electroconducting detachment from the ignition module (see. Head engine Electric equipment). Turn out spark plugs.
  2. Take from the assembly block of the relay of the fuel pump located in an impellent compartment (see. Head of the Power supply system and release).
  3. At the turned-out candles and temporarily disconnected systems of ignition and a food, turn the engine, having lifted pressure of oil in it so that there was an operation of the corresponding control lamp on an instrument guard of the car.
  4. Screw spark plugs, connect VV electroconducting and restore functioning of systems of ignition and a food.

Diesel models

 PERFORMANCE ORDER

  1. Include ignition and at once, without waiting warming up of candles of an incandescence, start to turn the engine a starter till shutdown of a control lamp of emergency pressure of oil.

All models

 PERFORMANCE ORDER

  1. Start the engine in the usual way. Start can occur to the small delay necessary for lifting of pressure of fuel, however no special difficulties should arise.

At emergence of flashes in the case of a throttle check correctness of adjustments of klapanny gaps (where it is required) and a corner of an advancing of ignition (see. Head engine Electric equipment).

  1. After start it is necessary to warm up the engine on single turns to normal working temperature, in the course of a warming up checking it on existence of signs of leakages of the oil, cooling liquid and transmission oil/ATF. Let's to the engine work within 15 minutes on single turns that is especially important after replacement of shatunny bearings.

It is not necessary to worry at emergence of a smell of burning or emergence of the small smoke which reason of emergence it becomes inevitable process of burning out of assembly greasings.


The first some minutes the engine of m to work at single turns it is not so stable that speaks a choice the electronic block (ECM) of optimum algorithm of functioning of control systems (see. Head of the Power supply system and release).

  1. Having waited warmings up of the top hose of a radiator, muffle the engine, and let's to it cool down.
  2. Once again check levels of oil and cooling liquid. On the diesel models equipped with the engine of 1.7 l of SOHC make a dotyagivaniye of bolts of fastening of a head of cylinders on demanded corners (see. Specifications).
  3. Now it is possible to start trial runs and an engine running in. Deduce the car to the area where intensity of traffic is minimum and sharply disperse it till speed of 50 — 80 km/h (30 — 50 miles/h). Then dump speed to 30 km/h, having completely closed for this purpose a butterfly valve. Repeat procedure of 10 — 12 times — arising cyclic loadings will help a usadka of piston rings in relation to walls of cylinders. Again check the engine on leaks.
  4. The first 800 km (500 miles) run try to maintain the engine in a sparing mode, regularly and often checking thus level of engine oil. The raised consumption of oil in a running in of the engine is the normal phenomenon.
  5. Approximately through 800 — 1000 km (500 — 600 miles) run replace impellent oil and the oil filter.
  6. The following the car can be maintained some hundred kilometers of run in a normal mode.
  7. Through 3200 km (2000 miles) again replace impellent oil and the oil filter. Now it is possible to consider the engine rolled finally.