Opel Astra, Zafira

Since 1998 of release

Repair and car operation

Opel Astra
+ Cars Opel Astra and Zafira
+ The operation manual
+ Routine maintenance
- The engine
   Check компрессионного pressure in cylinders
   Diagnostics of a condition of the engine with vacuum gauge application
   + Procedures of repair of petrol engines SOHC without their extraction from the car
   + Procedures of repair of petrol engines DOHC 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
   - The general and engine major repairs
      Removal of the power unit from the car - methods and safety measures
      Removal, separation and engine installation
      Alternative variants 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
      Assemblage of a head of cylinders
      Removal of shatunno-piston assemblages
      Removal of a cranked shaft
      Cleaning and check of a condition of the block of cylinders
      Хонингование 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 radical and шатунных bearings of a cranked shaft
      Engine assembly order
      Installation of piston rings
      Installation of a cranked shaft and check of working backlashes of radical bearings
      Installation of shatunno-piston assemblages and check of size of working backlashes in шатунных bearings of a cranked shaft
      Trial start and обкатка the engine after major repairs
+ 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

Cleaning and check of a condition of the block of cylinders



  1. Remove from the block all components established outside and gauges.
  2. Упершись stupid выколоткой in edge выжимной stoppers, develop it in the landing nest under 90 . After all stoppers will be developed, they will be simple enough for taking from the engine by means of nippers.
  3. Scratch out from an interfaced surface of the block all traces of a material of an old lining, — try not to leave scratches and задиров.
  4. Turn out all carving заглушки oil galleries. Заглушки can appear tightened very hardly up to that they should be drilled with the subsequent restoration of a carving in the block. At assemblage заглушки are subject to replacement.
  1. On diesel engines remove sprays of giving of oil on pistons. On engines of 1.7 l sprays запрессованы in the block and their removal can be made only with application of special adaptation Opel, on engines of 2.0 l sprays are fixed by bolts.
  1. Remove from the block of a cover of all radical bearings and take from the beds loose leaves of the last. At once mark the taken loose leaves by means of an adhesive tape on an accessory to the bearing and bed in it (the block or a cover), then will put them aside.
  2. At strong external pollution of the engine it is necessary to deliver it in a workshop of car-care centre for carrying out of steam or thermal processing.
  3. After return of the block from a workshop once again carefully clean all oil apertures and galleries — for this purpose special cylindrical brushes of the special form (ask in shops of automobile accessories) are issued. Wash out cavities and channels warm water, — continue washing until from an opposite side of the block pure water will not start to follow. Carefully dry the block, then slightly grease all pierced surfaces with liquid oil for their protection against corrosion. In the presence of access to a source of compressed air take advantage of it for acceleration of process of drying of the block and a purge of remote cavities and channels.

At work with compressed air do not forget to put on goggles!

  1. At strong pollution or зашлаковывании the block it is necessary to resort to щеточной to cleaning by hot water with soap. It is not necessary to try to save time at the expense of neglect carefulness of cleaning of the block. Without dependence from the chosen way, track carefulness of procleaning of remote cavities, channels and apertures. In summary dry the block and grease the pierced surfaces with liquid oil for their protection against corrosion.
  2. Banish all carving apertures in the block a tap of the corresponding size for the purpose of maintenance of a guarantee of conformity of indications of the indicator динамометрического a key to really developed efforts of a tightening of fixture at engine assemblage. Whenever possible, blow then the apertures banished by a tap the compressed air, having removed from them all small dust and a shaving. Having finished processing of apertures, walk лежкой by a carving part of bolts of fastening of covers of bearings and heads of cylinders.
  3. Establish to the place of a cover of radical bearings, by hand having tightened their fixture.
  4. Grease sealing surfaces new выжимных stoppers with hermetic of type Permatex 1 and establish them on the regular places in the block. Track perpendicularity of landing of stoppers, — will take advantage most correctly special cylindrical оправкой, however the face head of the suitable size which should rest only against an internal part of a face surface of a stopper (not in a fillet can quite replace it!).
  5. Grease with not hardening hermetic of type Permatex 2 carving part new заглушек oil galleries (alternatively wind with their tape ФУМ). Screw заглушки on the regular places and tighten as it is possible more strongly.
  1. On diesel engines zapressujte/приболтите on the places sprays of giving of oil on pistons.
  1. If be not going to start at once engine assemblage, place the block in the big polyethylene package for protection of its pollution.



  1. Preliminary the block should be very carefully cleared (Removal of a cranked shaft) see.
  2. Make external survey of the block about revealing of traces of corrosion, cracks and other damages. Check up a condition of carving apertures. It will be reasonable to make also testing of the block for presence of the latent cracks in the conditions of a workshop of car-care centre with application of the special diagnostic equipment. In case of revealing of defects the block is subject to regenerative repair or replacement.
  3. Check up a condition of mirrors of cylinders.
  1. Estimate sizes taking place конусности and ovality of cylinders:
    1. Measure diameter of each of cylinders in top (directly under border of step deterioration), the central and bottom sections in a plane of a parallel axis of a cranked shaft;
    1. Now measure diameters at the same three levels, but in a plane, a perpendicular axis of the block;

    And — Under border of step deterioration
    In — In an average part
    With — In the bottom part

    1. The size конусности the cylinder is defined by a difference between results of measurements in the top and bottom sections. As ovality (in the given section of the cylinder) is called the difference of diameters measured in a parallel and perpendicular axis of a cranked shaft planes.
  1. Compare results of check to requirements (Specifications see). Operating in the described manner, serially check up all cylinders.

Remember that there are some groups of standard diameters of the cylinders resolving various industrial admissions. Marks of dimensional group are usually put on the top cut of the block of cylinders.

  1. At revealing of appreciable defects or a deviation of results of measurements from standard requirements, the block of cylinders is subject to regenerative machining in the conditions of a car-care centre workshop. If in the course of regenerative repair has been made расточка cylinders, the engine should be completed by new pistons repair (with excess) the size.

Pistons of the repair size (with excess of 0.5 mm) are made for all engines, except engines of 1.7 l DOHC (petrol and diesel).

  1. If the condition of mirrors of cylinders during check performance is found satisfactory at simultaneous observance of standard requirements to the form of cylinders and landing backlashes in them of pistons (Check of a condition of components of shatunno-piston group see), necessity in проточке cylinders disappears, — will execute only хонингование their mirrors (Honingovanie of mirrors of cylinders see) enough.
  2. Check up planeness of a surface of the block interfaced to a head, — check is made in the manner similar described for interfaced surfaces of a head of cylinders (Cleaning and check of a condition of a head of cylinders see). Compare result of measurements to requirements (Specifications see), in case of need give the block in проточку.