Opel Astra, Zafira

Since 1998 of release

Repair and car operation

Opel Astra
+ Cars Opel Astra and Zafira
+ The operation manual
- Routine maintenance
   The routine maintenance schedule
   The general data on options and adjustments
   Check of levels of liquids
   Check of a condition of tyres and pressure of their rating, rotation of wheels
   Replacement of impellent oil and the oil filter
   Check of a condition and replacement of a belt of a drive of auxiliary units
   Removal of a sediment from the fuel filter of the diesel engine
   Check of a condition and replacement of the hoses located in an impellent compartment
   Check of a condition of components of system of cooling
   Check, service and gymnastics of the storage battery
   Check of a condition and replacement of brushes of screen wipers
   Survey of components of a suspension bracket and steering drive, check of a condition of protective covers of power shafts
   Check of brake system
   Electric equipment check
   The control of a condition of an anticorrosive covering of a body and the car bottom
   Greasing of locks, loops and emphasis
   Zeroing of the indicator of intervals of maintenance service
   Replacement of a filtering element of an air cleaner - diesel models of release on 09.2000
   Replacement салонного the filter
   Replacement of the fuel filter - diesel models of release on 09.2000
   Check of turns of idling and structure of the fulfilled gases
   Replacement of a filtering element of an air cleaner - all petrol models and diesel engines of release with 10.2000
   Replacement of the fuel filter - diesel models of release with 10.2000
   Replacement of spark plugs, check of condition ВВ of electroconducting
   Replacement of the fuel filter - petrol models
+ 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

Check of brake system

Remember that developed at functioning of brake mechanisms the dust can contain extremely unhealthy the person asbestos. At all do not blow off a dust the compressed air and do not inhale it, at service of mechanisms put on a protective mask or a respirator. At all do not use for rubbing of components of brake system gasoline or solvents on an oil basis — apply only firm cleaners or methyl spirit!

More detailed illustrative material on brake mechanisms is resulted in the Head Brake system.

The condition of components of brake system, besides regular, stipulated by the schedule of routine maintenance, checks, should be estimated each time at removal of wheels or at occurrence of signs of infringement of functioning of brake system.

The symptoms listed more low can be a sign of malfunction of components of brake mechanisms:

  1. At braking the car loses course stability (there is a withdrawal in one of the parties);
  2. During braking brake mechanisms publish squeal or a scratch;
  3. Excessively the course of a pedal of a foot brake increases;
  4. At squeezing of a brake pedal pulsations are felt;
  5. Traces of leak of a brake liquid (usually on an internal surface of disks of wheels and tyres) take place.


  1. Ослабьте nuts of fastening of wheels.
  2. Поддомкратьте the car also establish it on props.
  3. Remove wheels.

Disk brake mechanisms

The support of each of brake mechanisms is equipped by two колодками (internal and external). End faces колодок are well looked through through a special observation port in the case of a support after wheel removal.

The estimation of a residual thickness of a frictional overlay internal колодки is made visually through a support observation port. If overlays are worn out over an admissible limit (Specifications see), it is necessary to make complex replacement brake колодок.


  1. If visually to estimate a residual thickness колодок it appears inconveniently, or there is a necessity for more detailed survey колодок, remove a support () and take колодки for more detailed studying (the Brake system see the Head).
  2. After колодки will be taken from a support, clear them by means of special means and check up a residual thickness of overlays by means of a ruler or equipped нониусом a calliper.
  3. By micrometer measure a thickness of brake disks. Compare results of measurements to standard requirements (Specifications see). If the thickness any leaves disks abroad an admissible range, replace it (the Brake system see the Head). If a thickness of a disk in norm, check up its general condition. Pay attention to such defects as deep scratches, furrows, teases, overheat traces, etc., in case of need remove a disk and give it in проточку (the Brake system see the Head).
  1. Before establishing to the place of a wheel, examine all brake lines on presence of signs of damages, deterioration, destruction as a result of ageing of a material, traces of leaks, bends, twisting and other deformations (in particular near to points of connection of flexible brake hoses to supports of brake mechanisms — address to an accompanying illustration). Check up reliability of fastening of hoses collars. Make sure that any of brake hoses do not adjoin to acute angles located on the neighbourhood кузовных elements, components of system of release of the fulfilled gases and a suspension bracket (at any positions of a steering wheel). In case of need make corresponding repair or correct a route of a lining of lines. Defective components replace (the Brake system) see the Head.

Drum-type brake mechanisms


  1. At check of back drum-type brake mechanisms make sure that the lay brake is released, then обстучите a drum outside by a hammer with soft brisk for the purpose of landing easing.
  2. Remove brake drums.
  3. Make careful cleaning of brake mechanisms with application of special cleaning structure.

At all do not blow off a brake dust from a surface of components the compressed air and do not inhale it is a dust can contain unhealthy asbestos!

  1. Estimate a residual thickness of frictional overlays of brake boots (forward and back). The thickness of an overlay is measured from an external surface and to a metal substrate (клееные overlays), or to heads of rivets (клепаные overlays). In the first case limiting admissible value makes 3 mm, in the second — 1.6 mm. In case of need make complex replacement of boots. Boots are subject to replacement also in case of revealing of cracks, заполированных to shine of sites of overlays, or traces of hit of a brake liquid.
  1. Make sure of correctness of connection and serviceability of a condition of all springs of assemblage of the brake mechanism (the Brake system see the Head).
  1. Check up assemblage components on presence of traces of leaks of a brake liquid. Cautiously having hooked a finger or a small screw-driver, remove rubber пыльники from the wheel cylinder in the top part of boots. Revealing of any signs of leaks in these parts demands carrying out of immediate regenerative repair of assemblage of the cylinder (the Brake system see the Head). Also check up on presence of traces of leaks all brake hoses and them штуцерные connections.
  1. Carefully wipe internal surfaces of a drum the pure rags impregnated with methyl spirit. Try not to inhale a brake dust containing asbestos.
  2. Examine a working surface of a drum on presence of cracks, задиров, traces of an overheat and other damages. If defects cannot be removed by processing of a surface by a fine-grained emery paper, it is necessary to give a drum for проточки to a car-care centre workshop.
  3. Repeat procedure for components of the opposite brake mechanism. Establish into place drums, fix wheels and lower the car on the earth.

The vacuum amplifier

Check of serviceability of functioning of the vacuum amplifier of brakes is made from a driver's place.


  1. At completely squeezed out pedal of a foot brake start the engine, - the pedal should fail a little more.
  2. At the working engine some times squeeze out a pedal of a foot brake. The size of a course of a pedal should remain a constant.
  3. Squeeze out a pedal, muffle the engine and continue to keep a pedal pressed during about 30 seconds during which it should not neither fail more low, nor rise.
  4. Again start the engine, allow to it to work for about a minute, then again muffle. Again some times firmly squeeze out a pedal, — the course size should be reduced with everyone качком.

In case of negative result of the described check the servo-driver of the vacuum amplifier of brakes is subject to replacement (the Brake system see the Head).

Lay brake

Management of a lay brake is made by means of the lever established between forward seats. Having pulled the lever, cock it against the stop, having counted thus quantity of clicks of the ratchet mechanism. If the quantity of clicks leaves limits of an admissible range (Specifications see), the drive of a lay brake is subject to adjustment (the Brake system see the Head).

Alternatively check of serviceability of functioning of a lay brake can be made by a car parking on a site of road going under a bias and fixing by its motionlessly lay brake at neutral position of a transmission. If the brake does not keep the car at raising of its lever on demanded quantity of clicks, it is necessary to make adjustment (the Brake system see the Head).