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



Check of levels of liquids

Some special procedures of service demanding performance of additional checks of levels of liquids are more low described also. Regularly look under the car, checking it on presence of signs of development of leaks of working liquids.


Composers of the present Management recommend to make check of levels of the basic working liquids (the impellent oil, a cooling liquid, a liquid of washing of a windscreen, battery electrolit, a liquid of system of hydrostrengthening of a wheel) on a regular basis, is not more rare through each 7500 km of run. The others - according to the schedule THAT (the routine maintenance Schedule see).

Various hydraulic liquids play a role of working bodies in systems of greasing, cooling, braking, coupling, heating and an air conditioning, washing of glasses etc. Whereas all liquids are subject eventually разжижению and development, and also during normal functioning of systems gradually become soiled, it is necessary to make their full replacement periodically. Before to start updating of level or replacement, familiarise with the list recommended to use in the car of grades of liquids (Specifications see).

At check of levels of liquids the car should be parked on an equal horizontal platform, whenever possible with a firm covering.

Impellent oil

The visual control of leaks

At the greasy engine and the big expense of oil check up places of the most probable development of leaks:

 PERFORMANCE ORDER

  1. Open a cover of a jellied mouth and check up consolidation on presence of cracks or damages.
  2. Ventilation картера: For example, a ventilating hose from a cover of a head of cylinders to a hose всасывания air.
  3. Lining of a cover of a head of cylinders.
  4. Lining of a head of cylinders.
  5. Stopper of removal of oil (round ring).
  6. Lining of the oil filter: a joint of the filter with a flange.
  7. Pallet lining картера.
  8. Forward and back epiploons of a cranked shaft.

As in the presence of thinnesses oil extends on the big surface of the engine, places of leaks at once to define difficult. For detection of leaks operate as follows:

 PERFORMANCE ORDER

  1. Wrap the generator in polyethylene. Spray the engine a usual cold cleaner and through short time wash out water on a car wash.
  2. Joints of components of the engine strew outside известью or talc.
  3. Check up oil level, if necessary add.
  4. Make a trial trip. As oil in the hot engine reduces the viscosity and faster acts in places of leaks, it is necessary to execute a trial trip on distance about 30 km on a high-speed line.
  5. In summary investigate the engine by means of a lamp and localise places of leaks, having eliminated malfunctions.

Level check

If to start measurement of level of impellent oil right after engine deenergizings, the oil part remains in the top part of the engine that will essentially be reflected in accuracy of indications щупа.

Check of level of impellent oil is made by means of measuring щупа, passed in directing tube and lowered in the engine to the bottom point of its pallet картера. The site measuring щупа is shown on the illustrations showing placing of components in an impellent compartment of the car and placed in the beginning of the present Chapter.

Check of level of oil should be made before the trip first in a present day, or after nearby 15 minutes after an engine stop. If to execute check immediately after engine deenergizing, its results will adequately not reflect a situation as the oil part will appear distributed on internal galleries and engine components.

 PERFORMANCE ORDER

  1. Take measuring щуп from a directing tube and dry wipe its edge pure rags or a paper towel. Insert щуп back into a tube against the stop, then again take. Having examined an edge щупа, estimate size of the site moistened with oil. Oil level should be between the top and bottom marks in an edge щупа. In case of need add in the engine corresponding quantity of oil of a demanded grade.
  1. For lifting of level from bottom (MIN) marks on щупе to top (MOVE) is required hardly less than one litre of oil. Level lowering for limits of the bottom border of an admissible range conducts to development of oil starvation of the engine fraught with serious mechanical damages of last. Try not to pour also oil above the top mark as it can lead забрасыванию spark plugs or to failure of epiploons of the power unit as a result of excessive increase of pressure.
  2. To fill in oil in the engine it is necessary to remove the cover of a jellied mouth equipped with a carving (illustrations the Scheme of an arrangement of components in an impellent compartment of petrol models Astra G of 1.6 l SOHC or the Scheme of an arrangement of components in an impellent compartment of petrol models Astra G of 1.6 l DOHC or the Scheme of an arrangement of components in an impellent compartment of petrol models Zafira of 1.6 l SOHC or the Scheme of an arrangement of components in an impellent compartment of petrol models Astra G of 1.7 l SOHC or the Scheme of an arrangement of components in an impellent compartment of petrol models Astra G of 1.7 l DOHC see). In avoidance разбрызгивания oils during its refuelling in the engine take advantage of a funnel, or a butterdish with a long nouse. Having filled in oil, screw and strongly tighten a cover of a jellied mouth, then start the engine and attentively examine on presence of signs of leaks a drain stopper and a surface of the oil filter interfaced to the block. Muffle the engine, wait about 15 minutes during which oil will merge in the pallet, then once again check up its level.

Check of level of engine oil is the important preventive procedure of service of the engine. Constant decrease in level testifies to presence of leaks of oil as a result of failure of epiploons, damage of sealing linings, deterioration of piston rings or directing plugs of valves. If oil on colour or a consistence reminds milk, or at it there are water drops, it speaks about possible damage of a lining of a head of cylinders, or formation of cracks to a head body (ок) or the block. Check should be made immediately. During measurement of level of oil always check also its condition. Big and index fingers remove from an edge щупа oil traces, — in case of presence at it of small metal particles oil is subject to replacement (Replacement of impellent oil and the oil filter see).

Cooling liquid of the engine

Do not suppose antifreeze hit on open sites of a body and the painted surfaces of the car. Casual splashes immediately wash off a plentiful quantity of water. Remember that antifreeze is extremely a toxic liquid and its hit in an organism even in small amounts is fraught with the most serious consequences, up to a lethal outcome. Never leave antifreeze stored in leaky closed container, immediately collect cooling liquid spilt on a floor. Remember that the sweetish smell of antifreeze can draw to itself attention of children and animals. About ways recyclings of the fulfilled cooling liquid consult with local authorities,-.vo many regions of the world special points on any reception of working off are equipped. At all do not merge an old cooling liquid in the water drain and on the earth!


Recently nontoxical grades of antifreeze are developed, nevertheless, they also should to be utilised in the organised order.

All models of cars described in the present Management are equipped by system of cooling of the compensatory type, working at superfluous pressure. The broad tank of system of cooling made of translucent plastic is located in a forward corner of an impellent compartment closely to the battery (illustrations in the beginning of the Head see) and connected переливным by a hose to the basis of a jellied mouth of a radiator. At engine warming up the cooling liquid extends, and its surplus flows through the valve which has been built in in a cover of a jellied mouth of a radiator, in a broad tank. In process of cooling, the liquid comes back on a hose back in a radiator that allows to support constantly in norm its level in system.

Do not uncover at all a jellied mouth of a radiator / of a broad tank at the hot engine!


Level of a cooling liquid in a broad tank is checked on a regular basis and at the cold engine should not fall below mark KALT/COLD in a wall of the tank made of translucent plastic. In case of need make corresponding updating, having added in a tank demanded quantity of a fresh mix.


For updating of level of a liquid use only demanded structure a mix этиленгликоля and the distilled water (approximately 50/50). Remember that frequent application for the given purpose of simple water leads gradual разжижению antifreeze and утрачиванию a mix of frost resistance and anticorrosive properties. It is not necessary to abuse also various type additives.

Constant falling of level of a cooling liquid usually testifies to development of leaks in system. Check up on presence of traces of leaks a radiator, connecting hoses, a cover of a jellied mouth, drain stoppers and the case of the water pump. If it is not possible to reveal any signs of leaks, it is necessary to make check of a cover of a radiator by pressure in the conditions of a car-care centre workshop.

Do not uncover at all a radiator / a broad tank at the hot engine!

In need of removal of a cover of a radiator wait full cooling of the engine, then wind a mouth with a thick layer of rags and slowly turn away a cover to the first emphasis. If thus there is steam emission, allow to the engine to cool down a little more, only after that definitively uncover.

Besides level always check also a condition of a cooling liquid, - it should be concerning transparent. If the cooling liquid is painted in krasnovato-brown colour of a rust, the cooling system should be emptied, washed out and filled by a fresh mix of antifreeze with water. Even if the liquid outwardly is not exposed to any changes, entering into its structure ингибиторы corrosion eventually are exposed to the development, therefore the cooling liquid should be replaced regularly according to the schedule of routine maintenance of the car (the routine maintenance Schedule see).

Try not to suppose antifreeze hit on open sites of a skin or the painted surfaces кузовных components. Casual splashes immediately wash off a plentiful quantity of water.

Liquid for windscreen washing

The liquid for windscreen washing is filled in in the special tank made of plastic located in the left forward corner of an impellent compartment between the storage battery and a broad tank of system of cooling (illustrations in the beginning of the Head see). In regions with a temperate climate as a liquid for glass washing pure water can be used, however it is not necessary to fill the tank more than on 2/3 for the purpose of indemnification of expansion of water at its freezing during frosts. At car operation in severe environmental conditions to use only патентованные the screen wipers providing corresponding decrease of a freezing point of a liquid. In avoidance обмерзания glasses at washing in cold weather preliminary warm up its way обдува passed through the heat exchanger of a heater air.

Rules of configuration of a mix are usually printed to a container label. At all do not apply to addition in a liquid of washing of glasses used in system of cooling antifreeze, - last is aggressive in relation to a paint and varnish covering кузовных panels!

Electrolit of the storage battery

Cars considered in the present Management are completed by the battery of tight type not requiring service in which case only ventilating apertures are provided. The battery case can be made of translucent plastic, - in this case electrolit level in its banks can be supervised for the purpose of reception of the indirect information on serviceability of functioning of system of a charge and a current condition of the battery. If while in service a vehicle the battery for any reason has been replaced usual (served type), it is necessary to check from time to time electrolit level in its banks for what it is necessary to remove the top control/jellied stoppers. Especially attentively it is necessary to watch electrolit level in a warm season. For updating of level of electrolit it is necessary to use only the distilled water.

Hydraulic liquid of brake system and coupling drive

The main brake cylinder (ГТЦ) is fixed on the block of the servo-driver of the vacuum amplifier of brakes (illustrations in the beginning of the Head see). Established from above on ГТЦ the tank is used as a reserve drive in hydraulic paths both brake mechanisms, and coupling (Heads Coupling and power shafts and Brake system see).

Level of a liquid in tanks GTTS and a coupling drive is well looked through through translucent walls of the last and should be supported between marks MIN and the MOVE, without reaching to top on 8—9 mm.

In case of need updatings of level of a liquid carefully wipe a cover of the corresponding tank and a surface round it pure rags in order to avoid hit in hydraulic system of a dirt.

At заливании liquids in the tank watch that it was not sprayed on surrounding painted surfaces кузовных elements. Add in each of systems only a liquid of the grade stipulated by standard requirements (Specifications see), - mixing of two liquids of a various grade in no event is inadmissible and can lead to refusal of corresponding system!

The brake liquid is extremely chemically aggressive, - do not suppose its hit in eyes and on the painted surfaces кузовных panels! Do not use for addition in system the hydraulic liquid which has staid more of one year, or stored in leaky closed container. Remember that the brake liquid is very much гигроскопичной, i.e. possesses ability to absorb a moisture from air therefore efficiency of functioning of brake system can dangerously decrease!

At a stage of updating of level it is necessary to check up attentively also a condition of a liquid and internal walls of the tank. In case of revealing of mud adjournment, firm extraneous particles or drops of water the system should be emptied and filled by a fresh hydraulic liquid (Heads Coupling and power shafts and Brake system see).

After the tank will be filled to demanded level, densely plant on it a cover.

Remember that level of a hydraulic liquid in tank GTTS in process of operation of frictional overlays brake колодок gradually falls, however this decrease is always very insignificant. If the liquid has to be added too often, hence, in system the leak which source should be immediately revealed takes place, and the reason is eliminated, - attentively examine all brake lines and them штуцерные connections, including supports, wheel cylinders and the servo-driver of the vacuum amplifier (Check of brake system more in detail see). Falling of level of a liquid in the tank of a hydrodrive of coupling testifies to development of leaks in a path, including the executive cylinder (Coupling and power shafts see the Head).

If during check of level of a liquid in the main cylinders that fact is elicited that its tank is almost devastated, the corresponding system should be completely pumped over (Heads Coupling and power shafts or Brake system) see.

Liquid of system of hydrostrengthening of a wheel


Check of level of a hydraulic liquid in the tank of steering pump TRW

1 — Equipped measuring щупом a carving cover

2 — the Working site щупа
3 — the Filter



Check of level of a hydraulic liquid in the tank of steering pump DELPHI

1 — the Carving cover
2 — Equipped щупом a filtering element

3 — the Working site щупа

The tank of a liquid of system of hydrostrengthening of a wheel is located in a back part of an impellent compartment (illustrations in the beginning of the Head see).

The tank cover is equipped built in measuring щупом (illustrations Check of level of a hydraulic liquid in the tank of steering pump TRW or Check of level of a hydraulic liquid in the tank of steering pump DELPHI see). The Procedure for test standard for all measurements with the help щупов.

Try not to suppose an exit of level of a liquid for limits of the bottom border of an admissible range.

In case of need make corresponding updating of level, having added in a tank mouth a hydraulic liquid of a demanded grade.

If necessity for updating of level of a liquid arises regularly and often, check up on presence of signs of leaks the steering pump, картер реечной transfers, and also all connecting lines of a hydraulic path of system and them штуцерные connections.

Transmissionnoe oil РКПП

 PERFORMANCE ORDER

  1. Tyre out the car on a platform or a viewing hole, or поддомкратьте and establish it on props in strictly horizontal position. Level check трансмиссионного oils should be made before a trip, or after not less than 5 minutes after an engine stop, - oil should have time to flow down in the pallet картера РКПП.
  1. Carefully wipe a surface картера boxes round a control stopper. On transmissions F13, F17 and F18 the stopper is in the left part картера behind an internal SHRUS of a power shaft.

On transmissions F23 — in a back part of the case of differential.

  1. Check is made by input in a finger aperture, — oil should reach the bottom cut of an aperture.

    A — models Astra
    B — models Zafira

A.

B.
  1. Updating of level of oil is made through an aperture under installation of the gauge-switch of fires of a backing (F13, F17 and F18), or through a special jellied aperture (F23), — turn out the gauge / a stopper.

On boxes F13, F17 and F18 трансмиссионное oil is filled in through an aperture under installation of the gauge-switch of fires of a backing, — disconnect electroconducting (4) and turn out the gauge (3)

  1. Continue to fill in oil until it will not start to follow too much a control aperture, allow surpluses to flow down, then muffle a control aperture a stopper and tighten last with demanded effort.
  2. Establish into place the gauge-switch / a stopper of a jellied aperture and tighten it / it with demanded effort.

Some of boxes of type F23 have regularly raised level трансмиссионного oils, — after reduction of level of oil to the bottom cut of a control aperture it is necessary to screw a stopper and to add in a box about 0.5 l of oil. Control stoppers of boxes of such execution are usually marked by a yellow label.

ATF

Correctness of level ATF is one of critical operational parametres of the models equipped АТ. Excessive falling of level ATF can lead to proslipping of the converter of rotation whereas the excessive quantity of a liquid conducts to its foaming, to formation of leaks and is fraught with a transmission exit out of operation.

Check of level ATF should be made at разогретой to normal working temperature of transmission (15—20 km of run, 72—80С).

It is not necessary to make check of level ATF right after car operation on high speeds, in the conditions of a city cycle in hot weather, or after trailer towage, - preliminary allow liquids to cool down within nearby 30 minutes!


 PERFORMANCE ORDER

  1. Park the car on an equal horizontal platform with a firm covering, strongly cock a lay brake. If the engine cold, start it and warm up to normal working temperature on single turns. At the working engine squeeze out a pedal of a foot brake and serially spend selector AT lever through all positions, in summary, having returned it in position Р.
  1. Without suppressing the engine, take from a directing tube measuring щуп. Fingers remove from an edge щупа traces ATF and to the touch estimate its condition.
  1. Carefully wipe an edge pure rags and enter щуп back into directing tube, densely having planted a cover on a mouth.
  1. Again take щуп from a mouth and on length of the moistened site of an edge define level ATF in картере transmissions. In case of need make corresponding updating, through a funnel having added in transmission a liquid of a demanded grade, — fill in ATF directly in a mouth of a directing tube measuring щупа, try not to fill in in transmission excessive quantity of a liquid.

    And — Marks for check of level ATF at working temperature
    In — Marks for check of level ATF at cold transmission

  1. For lifting of level ATF from the bottom border of a working range щупа to top it is required about 0.6 l of a liquid — add ATF in the small portions in stages, each time checking level.
  2. Simultaneously with level it is necessary to check as well condition ATF. If the liquid moistening the end of an edge щупа has a dark red-brown shade, or smells as ashes, ATF it is necessary to replace (Automatic transmission) see the Head. In the absence of confidence of correctness of an estimation of a condition трансмиссионной liquids compare it on colour and a smell with fresh ATF.