Opel Astra, Zafira

Since 1998 of release

Repair and car operation

Opel Astra
- Cars Opel Astra and Zafira
   Identification numbers of the car
   Acquisition of spare parts
   Technology of service, the tool and the workplace equipment
   Поддомкрачивание and towage
   Start of the engine from the auxiliary power supply
   Checks of readiness of the car to operation
   Automobile химикалии, oils and greasings
   Diagnostics of malfunctions
+ The operation manual
+ Routine maintenance
+ The engine
+ Systems of cooling, heating
+ The 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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Technology of service, the tool and the workplace equipment

Technology of service

There are some techniques of performance of procedures of maintenance service and car repairs on which the reader will find references in the text of the given management. Following by it will make work of the house mechanic of more effective, will allow to organise in the best way and qualitatively to execute various technical procedures and is pledge of careful and full performance of all works.

Fixture — the general information

As fixture are called nuts, bolts, hairpins and the screws serving for connection among themselves of two or more details. At work with fixture it is necessary to remember some things constantly. Practically in any fixture this or that kind контрящих and fixing adaptations is applied. It can be lock washers, counternuts, lock tags or fixing компаунд for carving connections. All used carving fixture should be absolutely pure and direct, with not broken carving and not rounded corners шестигранных heads which the wrench is put on. It is necessary to take obligatory to make replacement of the damaged nuts and bolts for a rule. Special самоконтрящиеся nuts with nylon or fiber inserts are not subject to a reuse, as at отпускании lose the контрящие properties.

Prirzhavevshie bolts and nuts for simplification of unscrewing and in order to avoid damage before отдаванием should be processed special getting structure. Many mechanics prefer to use for this purpose turpentine which it is convenient to put from the special small canister with a long nouse. After wetting of the "become attached" fixture by getting structure before starting to it отпусканию, it is necessary to give to structure within several minutes properly to impregnate the oxidised contact layer. Strongly rusted fixture can be cut down a chisel, is cut ножовкой or removed by means of special гайколома.

At cutting of a head of a bolt or обламывании hairpins on assemblage, the rest of a carving part can be drilled or taken by means of the special tool. The majority of repair trucks can undertake performance of this, also as well as others (for example, restoration of the broken carving in carving apertures), repair procedures.

Flat and lock washers at assemblage should be established always into place in the same order and the same way, as earlier. The damaged washers always replace new. Between a lock washer and a soft metal surface (for example, aluminium), thin sheet metal or plastic always it is necessary to establish flat washers.

The sizes of fixture

For many reasons manufacturers of cars all apply metric fixture more widely and more widely. It is necessary to understand, however, a difference between used sometimes standard (named also American, or standard SAE) and, more universal in system of measures, metric fixture as, despite external similarity, they are not interchangeable.

All bolts, both standard, and metric are classified on diameter, a step of a carving and length.

For example, the standard bolt 1/2 - 13 x 1 has an inch floor in diameter, 13 coils of a carving on one inch and length of 1 inch.

G — marks of a class of durability
L — length (in inches)
T — a carving step (quantity of coils on inch)
D — nominal diameter (in inches)

Metric bolt М12 - 1.75 x 25 has diameter of 12 mm, a step of a carving of 1.75 mm (distance between the next coils) and length of 25 mm.

P — a durability class
L — length (in mm)
T — a carving step (distance between the next coils in mm)
D — nominal diameter (in mm)

Both bolts are outwardly almost identical, however are not interchangeable.

In addition to the listed signs both metric, and standard bolts can be identified by head survey. To begin with, the distance between лысками heads of a metric bolt is measured in mm, whereas at standard — in inches (the same is fair and for nuts). As consequence, the standard wrench is not necessary for use with metric fixture, and on the contrary. Besides, on heads большей parts of standard bolts usually are available the radial notches defining the maximum admissible effort of a tightening of a bolt (durability degree). The more quantity of notches, the above admissible effort (on cars bolts with degree of durability from 0 to 5 are usually applied). The class of durability of metric bolts is defined by a digital code. Code figures are usually cast, as well as for standard, on a bolt head (on cars bolts of classes of durability 8.8, 9.8, and 10.9 are usually applied).

Marks of a class of durability of bolts

Above - standard/SAE/USS
1 — the Class of durability 1 or 2
2 — the Class of durability 5
3 — the Class of durability 8

Below - metric

Also on labels of a class of durability standard nuts can be distinguished from the metric. Dot labels are applied to identification of durability of standard nuts, проштамповываемые on one of face surfaces of a nut while marks of metric nuts are made with the help besides figures. Than quantity of points, or the above value of a digital code, the above admissible effort of a tightening of a nut more.

Marks of a class of durability standard шестигранных nuts

Shestigrannaja nut
Class of durability 5
Class identification — Three points

Shestigrannaja nut
Class of durability 8
Class identification — Six points

Marks of a class of durability metric шестигранных nuts

Shestigrannaja nut
Class of durability 9
Class identification — Arabian 9

Shestigrannaja nut
Class of durability 10
Class identification — Arabian 10

End faces of metric hairpins also are marked according to a class of their durability. Large hairpins are marked by a digital code whereas marks are put on smaller in the form of a geometrical figure (from left to right):

1 — the Class of durability 10.9
2 — the Class of durability 9.8
3 — the Class of durability 8.8

It is necessary to notice that the considerable part of fixture, in particular a class of durability from 0 to 2, is not marked at all. In this case unique way of difference of standard fixture from metric is measurement of a step of a carving, or сравнивание carvings with unequivocally identified.

Standard fixture often name also, contrary to metric, fixture of standard SAE. Nevertheless it is necessary to remember that under classification SAE only small fixture gets. The large fixture with not metric carving is fixture of the American standard (USS).

As the fixture of the same geometrical size (both standard, and metric) can have various classes of durability, at replacement by the car of bolts, nuts and hairpins it is necessary to pay attention to conformity of a class of durability of established new fixture to a class of durability of the old.

Procedure and order of a tightening of carving connections

The tightening большей should be made parts of carving connections with the efforts defined by requirements of Specifications, resulted in the beginning of each Chapter of the given Management (it is necessary to understand as effort of a tightening of fixture put to it at a tightening a twisting moment). More low the effort of a tightening will be called also as the moment of a tightening of fixture. The tightening with excessive effort can lead to infringement of integrity of fixture whereas недотягивание it conducts to unreliability of connection of interfaced components. Bolts, screws and hairpins, depending on a material of which they are made also diameter of a carving part, usually have strictly certain admissible moments of a tightening, many of which as already it was mentioned above, are resulted in Specifications in the beginning of each Chapter. Strictly adhere to the resulted recommendations about the moments of a tightening of fixture applied on the car. For a tightening of the fixture which has been not mentioned in Specifications, it is necessary to use the map of the admissible moments of rotation resulted more low. The values resulted in the table are focused on fixture of classes of durability 2 and 3 (more high-class fixture supposes a tightening with the big effort), besides, it is meant that the tightening dry (with not greased carving) fixture in steel or cast (not aluminium) a detail is made.

The sizes of metric carvings

The sizes of metric carvings


9—12 Н•м


19—28 Н•м


38—54 Н•м


68—96 Н•м


109—154 Н•м

The sizes of trumpet carvings


7—10 Н•м


17—24 Н•м


30—44 Н•м


34—47 Н•м

The sizes of carvings of the American standard

1/4 - 20

9—12 Н•м

5/16 - 18

17—24 Н•м

5/16 - 24

19-27 Н•м

3/8 - 16

30—43 Н•м

3/8 - 24

37—51 Н•м

7/16 - 24

55—74 Н•м

7/16 - 20

55—81 Н•м

1/2 - 13

75—108 Н•м

Any fixture located on a perimetre detail (such as bolts of a head of cylinders, the pallet картера and various covers), in order to avoid detail deformation should be given and be tightened in strictly certain order. The order of a tightening and отдавания such fixture is resulted in corresponding Heads of the Management. If the special order is not stipulated, in order to avoid a component curvature it is necessary to adhere described below procedure. At the first stage all bolts or nuts should be tightened by hand. Further, each of them should be by turns held on on one complete revolution, and transition of odes of one bolt/nut to another should be carried out in a diagonal order (cross-wise). Further, having returned to the first bolt/nut, it is necessary to repeat procedure in the same order, tightening fixture for a half-turn. Continue to operate in the same manner, tightening each bolt/nut this time already on a turn quarter for one approach until all of them will not appear tightened with demanded effort. At отпускании fixture as it is necessary to adhere to the described procedure, but operating upside-down.

Dismantling of components

Dismantling of all components should be carried out in such manner that at assemblage each detail could be established on the former place and correct image. Remember prominent features of appearance, in case of need make landing marks of the details which installation can be into place made in the ambiguous image (to such elements the persistent washer equipped with a flute on a shaft) concerns, for example. Placing of the removed details on a pure working surface in that order in what their removal was made will be good idea. Useful there will be also a drawing up of the elementary schematic sketches or step-by-step photographing of knot subject to dismantle.

At fixture removal try to make marks of its initial position on assemblage. Often, immediate installation of fixture (in gathering with washers) on a former place after removal of a corresponding detail allows to avoid mess at assemblage. In the absence of such possibility, all fixture should be put in specially prepared for this purpose broken into sections and in appropriate way the marked box, or it is simple on the separate marked capacities. Such approach appears especially useful at work with the knots consisting of set of fine details, such as the generator, клапанный the mechanism, the panel of devices or elements of a decorative upholstery of salon.

At a detachment of electric contacts and sockets it is necessary to pay attention of carefulness of marks of electroconducting by means of an adhesive tape with the digital on it digital or alphabetic code.

Prokladochnye surfaces

On all cars of a lining are applied to hermetic sealing of a place of a joint of surfaces of interface of two or more details and serve for prevention of leaks of oils and liquids, and also maintenance in assemblage of superfluous pressure or depression.

Often such linings before installation become covered liquid or pastelike sealing компаундом (hermetic). Sometimes under the influence of time, temperatures and superfluous pressure can occur so strong прикипание interfaced surfaces to each other that division of details becomes an exigeant problem. With many cases to dismantle of such knots helps обстукивание them outside on perimetre of a place of a joint a hammer with soft the brisk. It is possible to take advantage for this purpose as well of a usual hammer, putting blows through the wooden or plastic prorate.

It is not necessary to make обстукивание cast cases and fragile components! At this sort of occurrence of difficulties always first of all check, whether weigh fixture it is removed.

Avoid поддевания "become attached" a screw-driver or mount for the interfaced surfaces which infringement of integrity can be at the bottom of development of leaks. If подрычаживания it is impossible to avoid "the become attached" elements of assemblage, use for this purpose the handle from old сметки, but remember that all formed in the course of dismantle of components of a chip should be carefully removed from interfaced surfaces and from within assemblage.

After division of details their interfaced surfaces should be smoothed carefully out with full removal of all traces of a material of an old lining by means of a suitable scraper. The hardened fragments of an old lining can be preliminary softened by means of the converter of a rust or a special chemical compound then are removed from an interfaced surface by a scraper. As a scraper the piece of a copper tube with the flattened out and pointed end in this case can be used. Use for this purpose of a copper tube is recommended, as copper usually is softer than materials applied in the car that reduces risk of damage of an interfaced surface. Some linings easily can be removed by means of a copper brush, however, is not dependent on the applied method, interfaced surfaces should become absolutely pure and smooth. If for any reason the interfaced surface has appeared scratched, before assemblage of components fill a scratch прокладочным with hermetic. In most cases it is necessary to use not stiffening (or semistiffening) hermetic.

Councils about removal of hoses

If your car is equipped by air central air, at all do not disconnect from conditioner components any hoses until the system will not be discharged in representation branch of the company-manufacturer of the car or the expert in central airs of air of a workshop of car-care centre.

Measures of precautions which should be observed at removal of hoses, are very close to that at removal of linings. Avoid damage of surfaces of unions and branch pipes which hoses as it can be at the bottom of occurrence of leaks are put on. In a special measure it concerns procedure of removal of hoses of a radiator. Owing to various chemical reactions occurs прикипание rubbers of hoses to interfaced surfaces of unions and branch pipes. For hose removal first of all ослабьте a collar of its fastening on the union. Then nippers with the sliding hinge seize a hose near to a collar and start to rotate it on the union / a connecting branch pipe to the right-to the left. Continue this procedure to a hose outright release, then remove a hose from the union. The small amount of silicone or other greasing will facilitate procedure if it can be entered into a backlash between the union and a hose. For simplification of procedure of installation of a hose grease an internal surface of a hose and an external surface of the union.

As extreme means, or in case of unequivocal necessity of replacement of the hose, its end put on the union for removal can be knifed and then is separated from an union surface. Thus try not to damage a knife union metal / a connecting branch pipe.

Damaged at hose removal the fixing collar is subject to replacement. Collars of braided type usually weaken eventually, therefore, without dependence from a condition, as required it is better to replace them with collars of screw type.

The tool

Selection of the qualitative tool is one of basic requirements for everyone who plans independent performance of procedures of maintenance service or car repairs. At first sight, the expenses connected with acquisition of the demanded complete set of tools, can seem incommensurably big, however at сравнивании them with the expenses interfaced to performance of procedures of routine maintenance and the elementary car repairs on a car repair shop, will appear quite reasonable.

To help the average motorist with a choice of the tool necessary at carrying out of various procedures on care by the car, described in the given Management, the lists of three toolings conditionally entitled as are more low resulted: a tooling for routine maintenance and the minimum repair; a tooling for the general and major repairs and the special tool. The owners of cars who do not have practical experience of carrying out of mechanical works, should begin with performance of the procedures limited to application of tools from the first list, raising thus the qualification and gradually expanding a range of the applied tool. In process of experience acquisition it is possible to pass to performance more challenges, supplementing a tooling available on hands. After a while the received skills will allow to start performance of more difficult works demanding application of the tool from the second list (for the general and car major repairs). When your qualification will start to allow to save considerable means for independent performance of difficult repair procedures, it is possible to think of acquisition of the special tool.

Tooling on routine maintenance and the minimum car repairs

The list resulted more low includes a minimum of procedures of routine maintenance necessary for performance and insignificant car repairs of tools. Acquisition of the complete set of the combined wrenches (with usual рожковой a head on one end and with накидной on other) Is recommended. Despite the big cost of such complete set in comparison with cost of a set usual рожковых keys, expenses will be justified, since the given keys possess advantages of both types.

  • The complete set of the combined keys (1/4—1 inch; 6—19 mm)
  • Adjustable spanner
  • Candle key (with a rubber insert)
  • The tool for adjustment of a candle backlash
  • Set measuring щупов
  • Nippelnyj key for prorolling of brakes
  • Screw-drivers:
    • With a flat sting (150 mm in length and 8 mm in diameter)
    • With крестовым a sting (№ 2 x 6 inches (150 mm in length)
  • The combined flat-nose pliers
  • Ножовка on metal with a set of cloths
  • Manometre for pressure measurement in tyres
  • Lubricant pistol (syringe)
  • The canister under oil
  • Thin emery paper
  • Wire brush
  • The tool for зачистки plugs and contacts of wires of the battery
  • Key for removal of the oil filter
  • Funnel (the average size)
  • Props for car fixing in the lifted condition 2 шт
  • Drain capacity
  • If routine maintenance procedures include carrying out of base adjustments, acquisition of high quality of a stroboscope and the combined tachometre/tool for measurement of duration of the closed condition of contacts of the breaker is required also. In spite of the fact that these tools are a part of the list of special tools, the mention of them here is resulted in a kind of an absolute necessity of their application for carrying out of qualitative adjustment of ignition of the engine, being part of procedures of routine maintenance of the car.

    Tooling for the general and car major repairs

    The given tool is necessary at carrying out of any operations on repair of the engine of the car and it is offered in addition to the first list. The given list includes the complete set of replaceable face heads. At considerable cost, the set of replaceable heads brings invaluable advantage, thanks to the universality and convenience in circulation, — in particular in a combination with entering into the complete set of various type drives. It is recommended to use preferably drives inch section 1/2 (instead of 3/8 inches) since they though are more expensive, can be used practically with any type динамометрических keys (in an ideal, the good mechanic should have at the order both types of drives). Cheaper alternative to the complete set of replaceable face heads is the set of tubular keys.

  • The complete set of replaceable face heads (including type heads Torх) (or tubular keys), the sizes corresponding to the sizes of wrenches from the previous list
  • Ratchet reversive drive (for use with replaceable face heads)
  • Collar in length of 250 mm
  • Universal (карданного type) the hinge (for use with face heads)
  • Dinamometrichesky key (with a drive of the same size, as for replaceable face heads)
  • Hammer with round brisk — 8 ounces (nearby 230)
  • Hammer with soft brisk (plastic or rubber) (киянка)
  • Screw-drivers:
    • With a flat sting (length 150 mm and about 6.5 mm in diameter)
    • With a flat sting (strong № 2, 8 mm)
    • With крестовым a sting (№ 3 x 8 inches (203 mm))
    • With крестовым a sting (strong № 2)
  • Clamping pincers
  • Flat-nose pliers:
    • For electricians (with the isolated handles)
    • Узконосые (nippers)
    • For lock rings (internal and external)
  • Chisel — 1/2 inches (13 mm)
  • Scraper (made of the copper tube flattened out and pointed from one end)
  • Скрайбер (чертилка)
  • Кернер
  • Small beards with a thin sting (1.6, 3.2, 4.8 mm)
  • Steel ruler/measuring instrument of planeness
  • The complete set of keys-shestigrannikov (Allen) (for heads with internal шестигранником)
  • Set of files
  • Wire brush (big)
  • The second complete set of props
  • Jack (hydraulic or ножничного type)
  • One more constantly required tool is the electrodrill with a cartridge on 3/8 inches (to 9.5 mm) with the complete set of high quality of drills.

    The special tool

    The tools being adequately expensive, not required regularly, or demanding at using performance of instructions of manufacturers get to the given list. If the sphere of your activity does not include frequent performance of difficult mechanical operations, acquisition of such tool will be a bad investment of means. It is reasonable to get it by sharing the cost with friends or to hire in car-care centre workshops.

    Those tools which can be found in retail trade or which are issued for distribution on representation branches of firms are brought in the list only. Sometimes in the text of the Management you will find references to such special tools. Usually authors try to offer in parallel the alternative method, allowing to avoid obligatory application of the remote tool. In a case if to avoid application of the special tool it is impossible, and its acquisition in using is problematic, performance of corresponding works is better for entrusting experts of car-care centre.

  • The tool for compression клапанных springs
  • The adaptation for procleaning of flutes of piston rings
  • The tool for обжимания piston rings
  • The tool for installation of piston rings
  • Measuring instrument of degree of compression of gases in cylinders (компрессометр)
  • Vertical drill for processing of edges of cylinders
  • Хон for processing of mirrors of cylinders
  • Measuring instrument of diameter of cylinders
  • Micrometer (micrometers) and-or циферблатный a calliper
  • The tool for removal of hydraulic pushers
  • Separator of spherical hinges
  • Stripper of universal type
  • Shock screw-driver
  • Set циферблатного a measuring instrument
  • Stroboscope (with the inductive gauge)
  • The manual combined pump (vacuum / delivery)
  • Tachometre / the tool for measurement of duration of the closed condition of contacts of the breaker
  • Universal tester for electric measurements
  • Elevating rigging
  • The tool for removal / of installation of brake springs
  • Floor jack
  • Micrometer with the complete set from nozzles

    Tsiferblatnyj measuring instrument with the complete set of clamps and nozzles

    Tsiferblatnyj/noniusnyj calliper

    The vacuum pump with a manual drive


    Measuring instrument of a compression with a nozzle for installation in candle apertures

    Stripper for dempfera/steering wheel removal

    General purpose stripper

    The tool for removal of hydraulic pushers

    The tool for compression клапанных springs

    The tool for compression клапанных springs

    Vertical drill for removal of step deterioration in the cylinder

    The adaptation for procleaning of flutes of piston rings

    The tool for removal/installation of piston rings

    The tool for обжимания piston rings

    Хон for processing of mirrors of cylinders

    The tool for removal of cups of directing springs of brake boots

    Хон for processing of brake cylinders

    The tool for centering of disks of coupling

    Set of taps and лерок

    Tool acquisition

    To the beginner-mechanic in respect of acquisition of the necessary tool for performance of procedures of routine maintenance and car repairs can be offered some practical advice. By preparation for carrying out of procedures of routine maintenance or the minimum car repairs it is reasonable to get the tool separately. On the other hand, in case of planning of wide works, it is easier and more reliable to buy the complete set of the modern tool in shop of a retail network. Complete set acquisition usually manages slightly more cheaply individual purchases and is often supplemented with the enclosed tool box. Further, for choice expansion, separate tools, additional complete sets and a tool box большего can be bought in addition the size. Gradual expansion of the complete set of tools will allow to stretch expenses and to be defined in a choice of really necessary tools.

    Specialised tool shops are a unique source of acquisition of some special tools, but, irrespective of a source, avoid cheap purchases, in particular at a choice of screw-drivers and replaceable face heads as term of their service for certain will appear short. Expenses connected with replacement and restoration of the cheap tool as a result will appear incomparably more considerable, than expenses for unitary acquisition of the qualitative goods.

    Care of the tool and its storage

    The good tool is a valuable investment of means, therefore it is reasonable to take care of keeping it clean and constant availability for service. After using the tool before combining it in a storage place, always carefully wipe its surface pure dry rags, deleting from it traces of a dirt, greasing and the rests of metal particles. Never leave the tool scattered on a workplace. After end of works attentively check space under a cowl and under the car on presence of the forgotten tool.

    For storage of such tool as screw-drivers, flat-nose pliers, hammers the tool comb fixed in a convenient place on a wall of garage, etc. is ideally suited. Sets of wrenches and replaceable face heads should be stored in metal boxes. The measuring tool should be stored in inaccessible to influence of corrosion, dry and pure places.

    Always it is necessary to pay attention to a condition of working surfaces of the tool. The shock part бойка a hammer in the course of work is subject расклепыванию, screw-drivers lose in due course sharpening of the stings. Do not stint to give a few time and attention to that by means of an emery paper or a file to remove расклепы and to put in order cutting edges. It is irreversible the worn out or damaged tool replace.

    At careful leaving the tool will serve to you belief and the truth during very long term.

    The workplace equipment

    Speaking about the tool, it is necessary to recollect the workplace equipment. If carrying out of more serious work, than simple maintenance service is necessary, it is necessary to take care of preparation of the suitable worker of a platform.

    It is necessary to recognise that many motorists are compelled to make removal of the engine and other similar works far not in the conditions of garage or a workshop. In any case the important requirement is roof or awning presence.

    Whenever possible, any procedures on dismantling of parts of systems of the car should be made on a pure flat workbench, or a strong table of convenient height. The workbench should be necessarily equipped by a vice. Presence of a vice with disclosing of sponges to 100 mm and with soft overlays on sponges is sufficient.

    As already it was mentioned above, on a working platform the pure dry place for storage of the tool, lubricant and cleaning liquids, шпаклевок, paint and varnish materials, etc. should be equipped

    It is necessary to notice that absolutely necessary tool is the electrodrill, hence, the working platform should be equipped by the power supply for its connection. Presence of a drill with a cartridge to 9.5 mm and a set of qualitative drills appreciably will facilitate carrying out of many procedures.

    At last, on a workplace always there should be a sufficient stock of old newspapers and pure, not ворсящейся the rags, intended for cleaning of a working platform, the tool and car details.

    It is necessary to hand over working off in the centres on recycling in tight container.

    Never make any works on the barefaced painted surface of the car, use protective overlays on wings, or, at the worst, cover the polished surfaces with old blankets.