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

Check of a condition of components of shatunno-piston group

All engines

Preliminary shatunno-piston assemblages should be carefully cleared. Rings are necessary for removing from pistons.

Piston rings are subject to replacement without fail.


  1. By means of the special adaptation, or several щупов лезвийного type remove rings from pistons, — try not to damage a wall of the last casually.

Remember that rings are made of fragile metal and can break at strong разжимании, - be not wounded!

  1. Scratch out from the bottoms of pistons traces of coal adjournment. After removal of the basic layer of adjournment smooth out a surface manually a wire brush or a piece of a fine-grained emery paper.

At all do not use for зачистки made of a soft material and pistons easily subject to erosion wire nozzles to an electrodrill! After зачистки put on the bottoms of pistons marks should differ clearly.

  1. By means of the special adaptation clean flutes under installation of rings on pistons.

It is alternatively possible to take advantage for this purpose of a fragment of an old piston ring, however be careful, — do not scratch a bottom and walls of a flute and do not cut fingers.

  1. Having removed the basic adjournment, wash out шатунные assemblages by solvent and carefully dry them, whenever possible with application of compressed air. Check up passableness масловозвратных apertures in back walls of flutes under installation of piston rings, and also oil apertures in the bottom heads of rods.

At using the compressed air do not forget to put on goggles!

  1. If walls of pistons and a mirror of cylinders are not damaged and excessively are not worn out, and the engine block was not pierced and not replaced, necessity for replacement of pistons also disappears. Normal deterioration of pistons is shown in the form of vertical traces of development on a persistent surface and a small weak point of landing top компрессионного rings in the flute. Do not forget that replacement of piston rings is made without fail, without dependence from their condition.
  2. Attentively examine each of pistons on presence of cracks in a skirt, round ledges under installation of piston fingers and around an arrangement of rings.
  3. Check up persistent surfaces of a skirt of the piston on presence of scratches, the bottom — on presence of through apertures and прогаров on edge. Presence of scratches on a skirt can be regarded as a sign of long overheats of the engine, or too early ignition of an air-fuel mix, — check up serviceability of functioning of system of cooling. Прогары along the edges of the bottom are the detonation certificate. In any case, the reason of the revealed infringement should be eliminated in order to avoid relapses. As the possible reasons of formation of the listed defects leaks of soaked up air, wrong configuration of an air-fuel mix, infringement of installation of a corner of an advancing of ignition, wrong functioning of systems of ignition and EGR can act also.
  4. Dot corrosion of pistons in the form of cavities speaks about hit in chambers of combustion and-or картер the engine of a cooling liquid. Besides, take care, that the reason of internal leaks has been eliminated.
  1. Estimate size of a lateral backlash of landing of piston rings in the flutes for what enclose a new ring outside in the flute on the piston and щупом лезвийного type measure a remaining backlash. Repeat measurement in two-three points on flute perimetre. Watch to mixing компрессионные a ring, — top differs from the second. If the backlash size exceeds admissible value (Specifications see), pistons are subject to replacement.
  1. Define size of a landing backlash of pistons in the cylinders for what measure diameters of the last (see Cleaning and check of a condition of the block of cylinders) and subtract from them diameters of corresponding pistons. Measurement of diameter of the piston is made on a persistent surface of a skirt at an angle 90 to an axis of a piston finger and on the set removal from the bottom. If the landing backlash of the piston in the cylinder exceeds admissible value (Specifications see), it is necessary to give the block in проточку with a selection of new pistons and piston rings of repair diameter.
  1. Estimate correctness of landing of pistons on rods, having tried повращать components in opposite directions. Presence a little appreciable люфта speaks about excessive deterioration of a joint. For situation correction it is necessary to deliver shatunno-piston assemblages in a car-care centre workshop where necessary regenerative repair and replacement of fingers will be made.

Petrol engines

On all petrol engines piston fingers are planted in the top heads of rods with a tightness and have floating landing in lugs of pistons in view of what performance of procedure of removal of pistons from rods (in case of occurrence of such necessity) also should be entrusted to experts of car-care centre. In parallel, rods can be checked up on presence of signs of a bend, twisting and other deformations with application of the special diagnostic equipment.

Needlessly it is not necessary to remove pistons from rods.

Diesel engines


  1. On diesel engines fingers have floating landing as well in rods and are fixed on pistons by means of lock rings. In case of need, having hooked a suitable screw-driver, remove lock rings and manually squeeze out a finger of assemblage. Mark the removed finger by means of an adhesive tape on an accessory to the shatunno-piston assemblage and clean in a reliable place. Lock rings at assemblage are subject to replacement without fail.
  1. Survey the top head of a rod and a piston finger on presence of signs of deterioration, and задиров other mechanical damages. By a micrometer measure diameter of a finger, compare result of measurement to requirements (Specifications see), in case of need make replacement. If the finger or a rod is worn out, both details, except engines of 1.7 l DOHC where it is possible to replace in an individual order запрессованную in the top head the plug are subject to replacement, — consult on firm car repair shop Opel.
  1. Rods (in the absence of mechanical damages) do not require replacement, — visually estimate their presence of signs of obvious deformations, in the presence of suspicions on a bend / twisting, address for the help to experts of car-care centre, or make replacement of defective components.

  2. Having estimated a condition of all components, prepare replaceable details. Replaceable pistons arrive on the market of spare parts complete with fingers and lock rings.

Lock rings can be got separately.

  1. On engines of 1.7 l SOHC make assemblage of pistons with rods so that the ledge on a rod from outside the bearing has appeared from outside a flywheel, the arrow should specify in the piston bottom in a direction of belt ГРМ of the engine.
  1. On engines of 1.7 l DOHC the dot label on the piston bottom should appear from the same party, as a ledge on a rod.
  1. On engines of 2.0 l pistons with rods gather so that the arrow specified in the piston bottom aside, opposite to those from which the cast label on the bottom head of a rod settles down.

    1 — the Lock ring
    2 — the Piston finger
    3 — the Label in the form of an arrow
    4 — the Piston
    5 — the Rod
    6 — the Acting label on the bottom head

  1. Slightly grease piston fingers with pure impellent oil, and fix them pistons on the top heads of rods. Make sure of freedom поворачивания the piston concerning a rod on a finger axis. Establish new lock rings (locks upwards) and make sure of reliability of their landing in reception flutes.

All engines


  1. Check up rods on presence of cracks and other mechanical damages. Temporarily remove covers of the bottom heads, take loose leaves of old bearings, wipe beds in covers and heads and check up them on presence of agnails, задиров and roughnesses. Having finished check, enclose loose leaves into place, establish covers on the bottom heads of rods, and by hand tighten fixing bolts.

If the engine is under repair for the purpose of elimination of knock of fingers, replace шатунные assemblages.