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




Alternative versions of schemes of regenerative repair of the engine

During independent performance of major maintenance of the engine the reader will face the need of a choice of the scheme of actions defining total amount and nature of the forthcoming work most acceptable for it. Need of replacement of the block of the engine, shatunno-piston groups and a cranked shaft is defined by a set of various factors the main thing from which is the block condition. To number of the other parameters defining a choice of structure of the forthcoming works, temporary and material inputs, existence of necessary spare parts, and also own qualification of the owner of the car, as mechanics belong.

It is possible to allocate the following main schemes of carrying out major maintenance of the engine:

Repair and replacement of components in an individual order. If the condition of the block and the main internal components of the engine in the course of survey is found the satisfactory, most reasonable decision there will be a carrying out their service in an individual order. Thus it is necessary to check carefully a condition of the block, a cranked shaft and shatunno-piston groups. Even at very insignificant degree of wear of the block, a mirror of its cylinders without fail are subject to a honingovaniye.

Use ремкомплекта cranked shaft. The set consists their pierced cranked shaft and a set of repair rods with the pistons established on them. Also piston rings and loose leaves of bearings are applied. The set can be intended for installation as in the block with cylinders of the standard size, and in the pierced assembly.

Use of the reduced set of the block of the engine. The reduced set includes the block of cylinders with already established in it cranked shaft and shatunno-piston groups. Thus all bearings of a cranked shaft are completed with new loose leaves, and their working gaps are precisely adjusted. Further such set is equipped additionally with the camshafts removed from the old engine, components of the klapanny mechanism, a head of cylinders and hinged units without any global mechanical works.

Use of an expanded set of the block of the engine. The expanded set represents the reduced set, plus the oil pump, the case pallet, a head of cylinders with a cover, a camshaft, components of the klapanny mechanism and GRM drive (cogwheels with a gas-distributing belt) with covers. All provided bearings, epiploons and laying are new, gaps are adjusted. It is necessary to connect only to the block the inlet pipeline with a final collector and hinged units.

The option of replacement of the engine assembled is possible also. Many firm car repair shops offer similar service on exchange base changing the become unfit for use units on new or restored.

Before stopping the choice on any of the listed schemes of performance of major maintenance of the engine and to start acquisition of the corresponding replaceable components, consult with specialists of firm car repair shop of the company manufacturer of your car and more skilled motorists.