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
   Specifications
   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



Specifications

Recommended greasings and liquids

Greasings and the liquids recommended to application by the company-manufacturer of cars at the moment of drawing up of the present Management are more low listed. Fresher information can be received on firm car repair shops of company Opel.

Type, properties and volumes of working liquids

Fuel

Type

Petrol engines

Neetilirovannyj gasoline is not worse АИ-95

Diesel engines

Diesel fuel with цетановым number not less than 49

Volume of a fuel tank

L

Models Astra

52

Models Zafira

58

Impellent oil

Pay attention to conditions of warranty service of the new car concerning application of synthetic impellent oils!


Petrol engines

All-weather synthetic impellent oil viscosity OW-X, 5W-X, 10W-X on ACEA A3-98/B3-98, where X = 30 and above

Diesel engines

All-weather synthetic impellent oil viscosity OW-X, 5W-X, 10W-X on ACEA A3 - 98/B3-98 or A3-98/B3-98/B4-98, where X=30 and above

Viscosity

See Automobile химикалии, oils and greasings

Volume (with filter replacement)

Engine type

Volume, l

Z12XE/X12XE

3.5

Z14XE/X14XE

3.5

Z16SE/X16SE

3.5

Z16XE/X16XE

3.5

Z16XEP/X16XEP

3.5

Z18XE/X18XE

4.25

Z20LET/X20LET

4.25

X20XEV

4.25

X20XER

4.25

Z22SE/X22SE

5.0

Y17DT/X17DT

4.5

Y17DT (ECO)

4.5

Y20DTL

5.2

Y20DTH

5.2

Y22DTR

5.2

Cooling system

Type of a cooling liquid

Mix of soft water and antifreeze (1:1) for maintenance of frost resistance to-40 C

Antifreeze

Models from 10.2000 red / orange colours

Models on 9.2000 blue / green colours


Do not mix antifreezes of different type!

Volume

Engine type

Volume, l

Without air conditioner

With air conditioner

Z12XE/X12XE

РКПП

5.2

5.5

АТ

-

-

Z14XE/X14XE

РКПП

6.3

6.6

АТ

6.2

6.5

Z16SE/X16SE

РКПП

5.9

6.2

АТ

5.8

6.1

Z16XE/X16XE

РКПП

6.3

6.6

АТ

6.2

6.5

Z16XEP/X16XEP

РКПП

6.3

6.6

АТ

6.2

6.5

Z18XE/X18XE

РКПП

6.5

6.8

АТ

6.4

6.7

Z20LET/X20LET

РКПП

7.0

 

АТ

-

-

X20XEV

РКПП

Data is absent

 

АТ

Data is absent

 

X20XER

РКПП

Data is absent

 

АТ

Data is absent

 

Z22SE/X22SE

РКПП

6.8

7.1

АТ

6.6

6.9

Y17DT/X17DT

РКПП

7.1

7.1

АТ

-

-

Y17DT (ECO)

РКПП

7.1

7.1

АТ

-

-

Y20DTL/X17DTL

РКПП

-

-

АТ

7.8

7.8

Y20DTH

РКПП

7.9

7.9

АТ

-

-

Y22DTR

РКПП

7.9

7.9

АТ

-

-

Transmissionnoe oil for РКПП

Type

Transmissionnoe oil OPEL -   19 40 768 (№   09 120 541)

Volume

L

All models, except 2.0 l

1.6

 L models 2.0  

1.8

РКПП F23

1.55

ATF for АТ

Type

ATF OPEL -  19 40 767 (№   09 117 946)

Volume (at change)

L

All models

4.0


Dexron II and Dexron III not to apply!

Brake liquid / a hydraulic liquid of a drive of coupling

Type

FMVSS116/DOT4, SAE J1703

Liquid of system of hydrostrengthening of a wheel

Type

Oil OPEL -  19 40 766 (№   09 544 116)

Volume

L

Pump TRW

0.7

Pump Delphi/Saginaw

1.1

Liquid of washing of glasses

Type

Any патентованная a liquid for screen wipers

Volume

L

Models with washers of lenses of headlights

4.5

Models without washers of lenses of headlights

2.3

Greasing for the chassis

Universal greasing on литиевой to a basis

NGLI No2

Greasing for polar plugs of the battery

Bosch FT 40 v 1

The engine

In case of a different interpretation with the data resulted on label VECI, should give preference the last.

The oil filter

Type

Petrol engines

  • The filter of not folding design
    • Engines 1.4, 1.6 and 2.0 l

Champion G102

    • Engines of 1.8 l

Data is absent

Turns of idling, mines

Petrol engines (are not regulated, established ЕСМ)

L models 1.2

730—890

L models 1.4

700—930

L models 1.6

690—920 (X16SZR); 730—930 (X16XEL)

L models 1.8

670—1030

L models 2.0

730—960

Diesel engines

Models 1.7 of l SOHC

780—900 rpm (copes ECM)

Models 1.7 of l DOHC

825—875 rpm (copes ECM)

L models 2.0

750—850 rpm (copes ECM)

The maximum turns of the engine at long functioning

Engine type

Frequency of rotation of the engine, rpm

Z12XE/X12XE

6250

Z14XE/X14XE

6400

Z16SE/X16SE

6000

Z16XE/X16XE

6400

Z16XEP/X16XEP

6400

Z18XE/X18XE

6400

Z20LET/X20LET

6400

X20XEV

6400

X20XER

Data is absent

Z22SE/X22SE

6500

Y17DT/X17DT

5100—5300

Y17DT (ECO)

5200

Y20DTL/X17DTL

4750

Y20DTH

4950—5050

Y22DTR

4920—5080

The admissible expense of oil

On 1000 km of run

0.6 l

Klapannye backlashes (only diesel engines of 1.7 l DOHC)

Inlet and final valves

0.4 mm

The static moment of injection (diesel engines)

Engines of 1.7 l SOHC

Copes ECM

Engines of 1.7 l DOHC

0.28—0.33 mm of a course плунжера ТНВД to ВМТ the piston of the first cylinder in the end of a compression step

Engines of 2.0 l

Copes ECM

Ignition system (petrol models)

Type / a backlash of spark plugs

Champion RC10DMC/0.8 mm
Bosh FLR 8 LDСU/1.0 mm
NGK BKR 5 EK/0.8 mm
AC DELCO 41-954 ED, (engine Z22SE)

The power supply system

Petrol models

Type of a filtering element of an air cleaner

Champion U689

Type of the fuel filter

Champion L225

Diesel models

Type of a filtering element of an air cleaner

  • The engine of 1.7 l SOHC

Champion U689

  • Other engines

Data is absent

Type of the fuel filter

  • The engine of 1.7 l SOHC

Champion L111

  • Other engines

Data is absent

Type of candles накаливания

  • The engine of 1.7 l SOHC

Champion CH 163

  • The engine of 1.7 l DOHC

Data is absent

  • Engines of 2.0 l

Champion CH 207

Brake system

The minimum admissible thickness of frictional overlays brake kolodok/boots

Disk brake mechanisms of forward and back wheels

2.0

Drum-type brake mechanisms

1.0

Wheels and tyres

Specifications to the Head Brake system see also.

Pressure of a rating of tyres

Models Astra

All models, except 2.0 l (all the sizes long tyres)

Loading to three persons, including the driver

  • Forward wheels

2.2 bar

  • Back wheels

1.9 bar

Total load

  • Forward wheels

2.4 bar

  • Back wheels

2.8 bar

L models 2.0

Tyres 195/60

  • Loading to three persons, including the driver
    • Forward wheels

2.2 bar

    • Back wheels

1.9 bar

  • Total load
    • Forward wheels

2.3 bar

    • Back wheels

2.8 bar

Tyres 205/50

  • Loading to three persons, including the driver
    • Forward wheels

2.3 bar

    • Back wheels

2.0 bar

  • Total load
    • Forward wheels

2.5 bar

    • Back wheels

2.9 bar

Models Zafira

Loading to three persons, including the driver

  • Forward wheels

2.2 bar

  • Back wheels

2.2 bar

Total load

  • Forward wheels

2.6 bar

  • Back wheels

3.0 bar

High-speed categories of tyres (designation)

The mark REINFORCED in the end of tyre marks means the strengthened execution.


Q

160 km/h

V

240 km/h

S

180 km/h

ZR

Over 240 km/h

T

190 km/h

W

270 km/h

H

210 km/h

Y

Over 270 km/h

Efforts of a tightening of carving connections, Nanometer

Data on efforts of a tightening of fixture is resulted also in the text of the Head and on some illustrations.


Design detail

Value

Bolts of fastening of wheels

110

Petrol models

The oil filter of not folding design

15

Cover of the oil filter of a folding design

15

Bolt of fastening of the case of the folding oil filter to the block

45

Screws of fastening of the module of ignition

8

Spark plugs

25 (the engine of 2.2 l: 20)

Drain stopper of the pallet картера the engine

Engines SOHC

  • Models without system K/V (the stamped pallet)

55

  • Models with К/В (the cast pallet)

45

Engines DOHC

  • Models 1.4, 1.6. And 1.8 l
    • With a head under internal шестигранник TORX (a rubber sealing ring)

10

    • With шестигранной a head (a metal sealing ring)

45

Engines of 2.0 l

10

Diesel models

1.7 l SOHC

The generator

  • Bolts М10 of fastening of the generator to a basic arm

46

  • Bolts М8 of fastening of the generator to a basic arm

25

  • Nut of fastening of a basic arm to the block of cylinders

35

  • Bolt of fixing of the generator on an adjusting lath

35

The central bolt натяжителя a belt of a drive of compressor K/V

45

Nuts of plates of fastening of the fuel filter

25

The oil filter

15

Drain stopper of the pallet картера the engine

10

1.7 l DOHC and 2.0 l

Fastening демпфера крутильных fluctuations to a power shaft

10

Fastening of a support of a suspension bracket of the power unit to a body

45

Fastening of a support of a suspension bracket of the power unit to a stretcher

55

The central bolt of fastening of a cover of the case of the fuel filter

6

Cover of the case of the oil filter

25

Drain stopper of the pallet картера the engine

  • L models 1.7

78

  • L models 2.0

18


The scheme of an arrangement of components in an impellent compartment of petrol models Astra G of 1.6 l SOHC

1 — ShChup of measurement of level of impellent oil
2 — the Cover of a jellied mouth of impellent oil
3 — the Oil filter
4 — the Air cleaner
5 — the Top support of racks of a suspension bracket
6 — Tank GTTS
7 — the Inlet air line
8 — system GUR Tank

9 — the Assembly block of safety locks
10 — the Socket of the main plait of electroconducting of the engine
11 — the Broad tank of system of cooling
12 — the Tank of a liquid of washing wind glasses/lenses of headlights
13 — the Storage battery
14 — the ignition Module
15 — ВВ electroconducting
16 — Top радиаторный a hose


The bottom view on car redock - petrol models Astra G of 1.6 l SOHC

1 — the Oil filter
2 — the Drain stopper of the pallet картера
3 — РКПП
4 — the Reception pipe of system of release of the fulfilled gases
5 — the Power shaft
6 — the Tank of a liquid of washing of wind glass / of lenses of headlights

7 — the Stretcher
8 — the Bottom levers of a suspension bracket
9 — the Back support of a suspension bracket of the power unit
10 — the Steering mechanism
11 — Tips of steering draughts
12 — horn Small horns


The scheme of an arrangement of components in an impellent compartment of petrol models Astra G of 1.6 l DOHC

1 — ShChup of measurement of level of impellent oil
2 — the Cover of a jellied mouth of impellent oil
3 — the Cover of drive ГРМ
4 — the Air cleaner
5 — the Top support of racks of a suspension bracket
6 — Tank GTTS
7 — the Inlet air line
8 — system GUR Tank

9 — the Assembly block of safety locks
10 — the Socket of the main plait of electroconducting of the engine
11 — the Broad tank of system of cooling
12 — the liquid Tank стеклоомывателей
13 — the Storage battery
14 — the ignition Module
15 — Top радиаторный a hose


The bottom view on car redock - petrol models Astra G of 1.6 l DOHC

1 — the Oil filter
2 — the Drain stopper of the pallet картера
3 — РКПП
4 — the Reception pipe of system of release of the fulfilled gases
5 — the Power shaft
6 — the Tank of a liquid of washing of wind glass / of lenses of headlights

7 — the Stretcher
8 — the Bottom levers of a suspension bracket
9 — the Back support of a suspension bracket of the power unit
10 — the Steering mechanism
11 — Tips of steering draughts
12 — horn Small horns


The scheme of an arrangement of components in an impellent compartment of petrol models Zafira of 1.6 l SOHC

1 — ShChup of measurement of level of impellent oil
2 — the Cover of a jellied mouth of impellent oil
3 — the Oil filter
4 — the Air cleaner
5 — the Top support of racks of a suspension bracket
6 — Tank GTTS
7 — the Inlet air line

8 — system GUR Tank
9 — the Assembly block of safety locks
10 — the Socket of the main plait of electroconducting of the engine
11 — the Broad tank of system of cooling
12 — the Tank of a liquid of washing wind glasses/lenses of headlights
13 — the Storage battery
14 — Top радиаторный a hose


The bottom view on car redock - petrol models Zafira of 1.6 l SOHC

1 — the Oil filter
2 — the Drain stopper of the pallet картера
3 — РКПП
4 — the Reception pipe of system of release of the fulfilled gases
5 — the Power shaft
6 — the Forward support of a suspension bracket of the power unit

7 — the Stretcher
8 — the Bottom levers of a suspension bracket
9 — the Back support of a suspension bracket of the power unit
10 — the Steering mechanism
11 — Tips of steering draughts
12 — horn Small horns


The scheme of an arrangement of components in an impellent compartment of diesel models Astra G of 1.7 l SOHC

1 — ShChup of measurement of level of impellent oil
2 — the Cover of a jellied mouth of impellent oil
3 — the thermostat Case
4 — Top радиаторный a hose
5 — the Air cleaner
6 — the Top support of racks of a suspension bracket
7 — Tank GTTS
8 — the Gauge of the expense of air (MAF)
9 — the Fuel filter

10 — the Assembly block of safety locks of system of an electric equipment of the engine
11 — the Main assembly block of safety locks
12 — system GUR Tank
13 — the Inlet air line интеркулера turbo-supercharging systems
14 — the Socket of the main plait of electroconducting of the engine
15 — the Broad tank of system of cooling
16 — the Tank of a liquid of washing of wind glass / of lenses of headlights
17 — the Storage battery


The bottom view on car redock - diesel models Astra G of 1.7 l SOHC

1 — the Drain stopper of the pallet картера, the Oil filter
2 — the Forward support of a suspension bracket of the power unit
3 — РКПП
4 — the Bottom levers of a suspension bracket
5 — Tips of steering draughts

6 — the Back support of a suspension bracket of the power unit
7 — the Reception pipe of system of release of the fulfilled gases
8 — the Steering mechanism
9 — the Power shaft
10 — the Stretcher


The scheme of an arrangement of components in an impellent compartment of diesel models Astra G of 1.7 l DOHC

1 — ShChup of measurement of level of impellent oil
2 — the Cover of a jellied mouth of impellent oil
3 — Compressor K/V
4 — the Air cleaner
5 — the Gauge of the expense of air (MAF)
6 — the Top support of racks of a suspension bracket the thermostat Case
7 — Tank GTTS
8 — the Fuel filter
9 — the Assembly block of safety locks of system of an electric equipment of the engine

10 — the Main assembly block of safety locks
11 — the Socket of the main plait of electroconducting of the engine
12 — the Broad tank of system of cooling
13 — the Tank of a liquid of washing of wind glass / of lenses of headlights
14 — the Storage battery system GUR Tank
15 — the thermostat Case
16 — the Inlet air line интеркулера turbo-supercharging systems
17 — Top радиаторный a hose


The bottom view on car redock - diesel models Astra G of 1.7 l DOHC

1 — the Oil filter
2 — the Drain stopper of the pallet картера the Oil filter
3 — the Reception pipe of system of release of the fulfilled gases
4 — the Forward support of a suspension bracket of the power unit
5 — РКПП
6 — the Bottom levers of a suspension bracket
7 — Tips of steering draughts

8 — the Back support of a suspension bracket of the power unit
9 — the Steering mechanism
10 — the Power shaft
11 — the Stretcher
12 — the Generator
13 — horn Small horns


The bottom view on a car back - models Astra G

1 — Back section of system of release of the fulfilled gases
2 — Torsionnaja a beam of a suspension bracket with longitudinal levers
3 — the pressure Valve-regulator in contours of brake mechanisms of back wheels
4 — the Fuel tank

5 — the Cable of a drive of a lay brake
6 — the Well under storage of a spare wheel
7 — Screw springs of a suspension bracket
8 — Support of shock-absorbers


The bottom view on a car back - models Zafira

1 — Back section of system of release of the fulfilled gases
2 — Torsionnaja a beam of a suspension bracket with longitudinal levers
3 — the pressure Valve-regulator in contours of brake mechanisms of back wheels
4 — the Fuel tank
5 — the Cable of a drive of a lay brake

6 — the Well under storage of a spare wheel
7 — Screw springs of a suspension bracket
8 — Support of shock-absorbers
9 — Hoses of a jellied mouth and ventilation of a fuel tank
10 — Intermediate section of system of release of the fulfilled gases