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The only unusual solution is the use of an electric pump to create pressure in the power steering system. This allows not to take away engine power unnecessarily, for example, when driving in a straight line, and also to reduce the number of pipelines by installing an electric pump with a reservoir directly on the steering rack. It should be noted that the location of the power steering reservoir on the steering rack complicates the control and, if necessary, adjustment of the fluid level in the system.
In 1999, the first generation single-volume Opel Zafira (Zafira A) was created on the Astra G platform. The presence of a common platform ensured the identity of the chassis and aggregate parts of these vehicles. The Zafira was created primarily as a family car, and as such, it does not have many competitors. With modest external dimensions, it can accommodate up to seven passengers. The third row seats are foldable. However, it is worth noting that with both seats of the third row unfolded, there is practically no room for luggage. All of the above about the advantages and disadvantages of the Astra model can be safely attributed to the Zafira model, given that the choice in the class of such cars is much more limited. In addition, the cars in question were produced under other brands and names for the markets of individual countries, some of which can be found in Russia.
Video (click to play).
Traditionally, most Opel right-hand drive vehicles are Vauxhall and manufactured in England, with model names corresponding to those of the Opel brand. At the same time, with the exception of the location of the controls and the associated minor changes, the cars are completely identical to those in question.
Multimedia guide. All models of sedan, caravan and hatchback Opel Astra-G, produced since 1998 and Opel Zafira minivan, produced since 1999, with in-line 4-cylinder engines: 8-valve SOHC 1.6 liter engine, 16-valve DOHC 1.4, 1.6 engines, 1.8 and 2.0 liters, diesel 8-valve engines with a volume of 1.7 liters SOHC and DOHC, turbocharged diesel 16-valve engines SOHC with a volume of 2.0 liters, equipped with a 5-speed manual gearbox (manual transmission), or a 4-speed automatic transmission (automatic transmission).
Hundreds of illustrations show the controls and individual stages of work on the device and repair of Opel Astra-G and Opel Zafira cars.Quick and easy troubleshooting sections to help you troubleshoot. The wiring diagrams help to identify faults in the electrical system and facilitate the installation of additional equipment on Opel Astra-G and Opel Zafira vehicles.
Here you will find data on the repair of: engine, power system, exhaust system, clutch, gearbox, suspension, steering, brakes, wheels and tires, body, electrical equipment, as well as recommendations for maintenance and diagnostics of electronic control systems of Opel cars Astra-G and Opel Zafira. Diagnostic codes are given.
A separate section is devoted to operating instructions for Opel Astra-G and Opel Zafira cars and is intended to acquaint the owners of Opel Astra-G and Opel Zafira cars with the device, operation and maintenance of the car. The operating instructions for the Opel Astra-G and Opel Zafira contain important information on how to operate your vehicle safely.
The second generation Opel Astra was first presented in September 1997 at the Frankfurt Motor Show. Serial production began in the spring of 1998, in March. Not a single more or less important detail remained from the former Astra.
The car has been redesigned. The novelty is presented with three types of bodies: two hatchbacks - three- and five-door and a station wagon (in the previous family there was also a sedan and a convertible). The latter usually outlive the basic model for a year or two. So this time - the Astra sedan appeared only a year later.
What has not previously been in the Opel lineup is a compact minivan. "Zafira", to the creation of which the company was prompted by the success of "Renault-Megan Senik", is based on the units of the new "Astra". There are more than enough engines: five engines of the EKOTEC family - from 1.2 to 2 liters, a 2-liter diesel engine and even a well-deserved 1.6 liter engine of the “pre-Ecotech era”. The smallest gasoline engine is new. He is the only one not aggregated with a four-speed automatic transmission - only “manual” with five gears. A wide range of modifications is a major trump card in the struggle for the consumer. One and the same car must change its character: become cheap or foppish, sedate or fast, family or individual. You can't refuse Astra. The mass car - such is the "Astra" - should please many people with different needs.
The body of the new "Astra" is a matter of special pride for its creators. Firstly, it is distinguished by a very thorough aerodynamic study. The drag coefficient - only 0.29 - is a very good result.
Secondly, the high strength of the body. Its torsional rigidity in comparison with the body of the old "Astra" has increased significantly. The power circuit meets all passive safety requirements. In which case the body will crumple “correctly”, saving passengers. The body structure is such that with a weight increase of only 15 kg compared to the old Opel Astra, its angular torsional rigidity is 78% higher than that of the previous model. Note that about 20 grades of steel are used in the body of the new Astra. In part, the "extra" metal was used to increase the size of the car. So, the base has grown by 97 mm, the front and rear tracks have become larger by 54 and 31 mm, respectively.
And the last thing - a 12-year guarantee against perforating corrosion of the body speaks volumes about the quality of the material, technology and applied protective coatings. I don't even want to pronounce the word "galvanized". Today you will not surprise anyone with this. True, the new "Astra" body is heavier and in order for the car not to gain excess weight, something had to be lightened. There are also seat belts with a pyron tensioner, four airbags - two front and two side, hidden in the backs of the front seats. The design of the pedal assembly is similar to that of the Opel Vectra. If, upon impact, the deformation “reaches” the pedals, they do not move, but simply. fall off: the brackets crumple and “release” the pedals. Studies have shown that pedals can seriously injure the ankle in a collision.
The front suspension seems to be ordinary - triangular "in plan" levers, a spring-shock absorber strut, a stabilizer.As is customary today, the suspension elements, the steering rack, the power unit are attached to the subframe, and that, in turn, through elastic cushions, to the body. And yet there are some highlights here. For example, the front pillar, take it in your hands - you will be surprised: it is painfully light. Here it is, the fight against kilograms. Light alloy rack enclosures. But that's not all. The stabilizer struts are made of carbon fiber (made of ultra-light and durable plastic based on carbon fibers). In general, light alloys are widely used in the Astra design - even for the steering wheel frame.
The easiest way to tell about the rear suspension design is like that of “Samara”. Such a suspension of the rear wheels on trailing arms, connected by an elastic transverse beam (otherwise - semi-independent), has proven itself perfectly on cars of this class and is used to this day not only on the Astra. Rear suspension mounts are designed to provide steering effect when cornering.
The peculiarity of the car is the electro-hydraulic power steering. The usual pump, driven by a belt from the crankshaft, is not here: it was replaced by a high-speed electric pump. Advantages - less power loss for the pump drive, the unit is compact (the whole amplifier seems to "hang" on the rail) and, most importantly, excellent vehicle responses.
Gasoline engines of the EKOTEC family: Gas distribution with four valves per cylinder, intake pipes of variable length, modern materials and technologies. The two-liter engine is equipped with balance shafts to combat imbalance. As a rule, balance shafts for in-line “four” are considered redundant, but with them it works smoother - the machine becomes “more comfortable”. Brakes: disc brakes on all wheels, with booster and ABS. Steering: rack and pinion, with an amplifier. Tire size: 195 / 60R15H.
And finally, according to the results of 1999 "Opel-Astra" was recognized as the most bought car in Europe. Even the hit of all times and peoples - "Volkswagen Golf" is pushed aside to the second position: almost 745 thousand Opels were sold, and Volkswagens - 723 thousand. The last copies of the Astra G officially rolled off the assembly line in February 2004. After that, the production of the 2nd generation Astra by Opel was transferred to other manufacturers.
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Color Repair Manual Opel Astra G / Zafira A , as well as operation and maintenance manual , car device Opel Astra / Zafira A 1998-2006 biennium release equipped with gasoline engines 1.4 DOHC, 1.6 SOHC, 1.6 DOHC, 1.8 DOHC. Vauxhall Astra / Zafira, Subaru Traviq (Subaru Travik) and Chevrolet Viva . Opel Astra G / Zafira A , recommendations for routine maintenance and electrical equipment (wiring) of the car. Opel Astra G, Opel Zafira A , mechanics, service station specialists, repair shops and car services.
Format: pdf
In this video instruction, I will show you the process of removing the valve cover gasket and fuel injectors, as well as diagnostics and disassembly of the 2005 Opel Astra G car.
This is the first part of the videos for the repair of this car.
In the following parts you will see:
Subscribe to the channel if you liked the video and leave comments! Good luck to all! 😉
the music was provided by NCS
Video Opel Astra G - Repair. Part 1 - Diagnose, Disassemble. Channel Motor Fix
Opel Astra G cars (1998, 1999, 2000, 2001, 2002, 2003, 2004) got rid of most of the sores of the previous generation and can proudly boast of high-quality assembly and, at the same time, a fairly simple design that allows any driver to carry out many maintenance operations , having elementary ideas about the device of the car. Based on today's prices of our service stations, this is a significant plus for the Opel Astra.
The salon is distinguished by comfortable seats and high-quality finishing materials. And most importantly, on the Astra II (G), Opel designers were finally able to defeat the red plague that was destroying the body of the previous Astra without mercy. Corrosion resistance, like that of the Opel Zafira, is commendable.
But all these advantages could not overcome the antipathy towards the Opel Astra among the majority of the population of our country, so getting rid of it for the desired amount will be problematic.
Manager 1.6i engine electronics are not very reliable ... Periodic failures of various sensors and relays can infuriate any of the most relaxed drivers. Most often, the mass air flow sensor will tear the nervous system, which is enough for only 2 years of operation, and a new one will cost $ 150.
Does not differ in life expectancy and rear muffler decaying from our road salt in 2 years ... The new original will cost $ 600, but if you are not annoyed by the roaring sound of the exhaust, then you can safely put Italian for $ 120.
Astra has a 1.6i engine, which is powerful enough, quite reliable, despite the simplicity of the design, and also economical. Even using 92nd gasoline, its consumption will not go beyond 5 liters on the highway and 9 liters in the city per 100 km, and if refuel with the recommended AI-95 , then the consumption will be even less. Plus there are no problems with cheap used parts. And the engine is not averse to eating oil - up to 300 grams per 1000 km of run, so you will have to constantly monitor the level and carry a supply for refilling with you.
The Opel Astra ignition system, especially its high-voltage part, is not only very delicate, but also cannot be diagnosed. Its tenderness lies in its capriciousness to spark plugs, which must be changed every 30 thousand kilometers and set only those recommended by the manufacturer. The technical documentation indicates for the 1.6i engine: Bosch FLR 8 LDСU / 1.0 mm, NGK BKR 5 EK / 0.8 mm and Champion RC10DMC / 0.8 mm. Incorrect spark plugs damage the ignition coils.
After 150 thousand km from the re-enriched mixture, the EGR valve can jam. This is manifested by a problematic start and an unstable idle - the engine speed is floating. Replacing it will cost $ 800-900 for the original one, but on the market you can find a non-original one for $ 220, and first try to clean the old one, sometimes it helps. At the same time, check and idle valve , which is also not highly reliable.
The same reliable hardy and hassle-free is the suspension , whose resource reaches 100 thousand km on our roads, and silent blocks and ball joints, costing $ 18 per piece. even more durable by 20 thousand km. Most likely, only the rear springs will have to be replaced at a price of $ 70 per pair and after 150 thousand km the current shock absorbers are $ 100 per pair.
After 60 thousand km, the resource of the anti-roll bar struts will end, the cost is $ 18 apiece. The most important and obligatory operation THAT at 75 thousand km of run - replacement of the timing belt with rollers. The price of the kit is a small $ 90 compared to the possible consequences of breaking the belt itself.
The service life of the front wheel bearings of the Opel Astra G ends after 80 thousand km. The problem is that they come complete with a hub, hence the cost of $ 120 for one. The rear ones are even more expensive than $ 170 per unit, but they take care of 20 thousand km more.
It is not less reliable and Manual Transmission , in which you only have to change the oil every 120 thousand kilometers.It is recommended to use GL-4 gear oil with OPEL approval - 19 40 768 (No. 09 120 541).
The steering and braking systems keep up with the reliability of the transmission and suspension. The resource of steering tips with rods ends at 100 thousand km and will cost $ 20 per element. If in steering an electric amplifier is installed, then over time the electric motor may start to howl, and a new one is supplied only complete with a pump and a tank.
Changing the engine oil for the Opel Astra is provided every 12 thousand kilometers, it is recommended to use synthetic oil according to API 5W40 , but you can also semisynthetics 10W40 not lower than API SJ or ACEA A3-98. Replacement of the air and fuel filters is provided annually or every 15 thousand km, the air Champion U689 and the fuel Champion L225 are recommended.
Every 20 thousand km of run, be sure to clean the rear calipers from rust and dirt, otherwise they can jam when using the handbrake and, moreover, greatly reduce the life of the brake discs. The rear brake pads are enough for 45 thousand km, replacing the brake pads with your own hands will cost $ 40. It is recommended to use DOT4 or SAE J1703 with FMVSS116 approval as working fluid.
Antifreeze is changed every 3 years, G11 or Comma Xtream G48, Xtream G05 with BS 6580 approval or FW HEFT R 443 are recommended.
All of the above applies to planned and resource maintenance, but the Astra II has features that require constant monitoring.
For the 1.6i engine, this applies to hydraulic lifters, which are panicky afraid of low-quality oil and will remind of this with an unpleasant knock, as well as a problematic upper support.
The same applies to the ECU sensors (it was already mentioned above), as well as contacts in the connectors under the driver's seat, which are constantly violated.
Freon leakage from the air conditioning system is possible through the compressor oil seal.
In the transmission, you need to keep under control the current stage oil seal and the clutch slave cylinder, which will cost $ 200 to repair a leak.
If you do not want to overpay a lot of money for new serviceable parts, you can change them separately, but only if you buy them as used parts for the Opel Astra. And finally, in the back, I advise you to pay attention to the sills and technological holes in the rear arches. Despite the high corrosion resistance, these places tend to get covered with rust due to close acquaintance with the aggressive road environment.
The Zafira series was launched in June 1999. The Zafira's platform and suspension are borrowed from the Astra, but the bodywork is of the High-Capacity Estate design. Not only does the Zafira have seven seats in three rows, it can quickly transform into a spacious truck thanks to the Flex-7 system, which folds the rear row of seats flush with the floor, creating a spacious cargo area.
The Opel Astra / Zafira model range is distinguished by an extraordinary breadth of the range of engines offered to consumers. A complete list of engines used for completing the considered models is given in the Specifications at the beginning of the Engine Chapter. All engines belong to the class of in-line 4-cylinder units with one or two overhead camshafts (SOHC or DOHC) and are installed in the front of the vehicle, transverse to the centreline of the latter.
The braking system is equipped with a standard vacuum booster. All models use disc brakes on the front wheels, rear brakes can be either disc or drum. In addition to the ABS, which is standard in most models, some models are equipped with a traction control system (TCS), on some Universal / Zafira models a rear axle ride height adjuster is installed (see the Brake System Chapter).
The fully independent front wheel suspension consists of MacPherson struts and wishbones. The rear wheel suspension is semi-independent with a torsion beam and two longitudinal levers (for more details, see the chapter Suspension and steering).
Steering - rack and pinion, with hydraulic booster, the steering mechanism is located behind the engine. The electro-hydraulic steering pump is directly mounted on the steering gear and does not require any maintenance. The reservoir of the hydraulic fluid is built into the pump assembly (see the Head Suspension and steering).
Opel Astra and Zafira cars - abstract
The Opel / Vauxhall Astra-G was introduced in the UK in February 1998 to replace the previous Astra, the "F" model. Models with Sedan, Station Wagon and Hatchback bodies were presented.
The Zafira series was launched in June 1999. The Zafira's platform and suspension are borrowed from the Astra, but the bodywork is of the High-Capacity Estate design. Not only does the Zafira have seven seats in three rows, it can quickly transform into a spacious truck thanks to the Flex-7 system, which folds the rear row of seats flush with the floor, creating a spacious cargo area.
The Opel Astra / Zafira model range is distinguished by an extraordinary breadth of the range of engines offered to consumers. A complete list of engines used for completing the considered models is given in the Specifications at the beginning of the Engine Chapter. All engines belong to the class of in-line 4-cylinder units with one or two overhead camshafts (SOHC or DOHC) and are installed in the front of the vehicle, transverse to the centreline of the latter. Due to the limited space and parsimony of information sources, this Manual covers in detail only the most typical representatives of each class of engines used, namely: a 1.6-liter SOHC 8-valve gasoline engine, a number of DOHC 16-valve gasoline engines with a volume of 1.4 to 2.0 liters, and also 8-valve diesel engines with a volume of 1.7 liters SOHC and DOHC and two representatives of turbocharged 16-valve diesel engines SOHC with a volume of 2.0 liters (for more details see the chapter Engine).
The engines meet all modern requirements for the content of exhaust gases of toxic components.
The transmission of torque from the engine to the front wheel drive shafts is carried out by means of a 5-speed manual gearbox (RKPP) installed on the left side of the power unit, or a 4-speed automatic transmission (AT) (for more details, see the Chapters Manual Gearbox and Automatic Transmission) ...
The braking system is equipped with a standard vacuum booster. All models use disc brakes on the front wheels, rear brakes can be either disc or drum. In addition to the ABS, which is standard in most models, some models are equipped with a traction control system (TCS), on some Universal / Zafira models a rear axle ride height adjuster is installed (see the Brake System Chapter).
The fully independent front wheel suspension consists of MacPherson struts and wishbones. The rear wheel suspension is semi-independent with a torsion beam and two longitudinal levers (for more details, see the chapter Suspension and steering).
Steering - rack and pinion, with hydraulic booster, the steering mechanism is located behind the engine. The electro-hydraulic steering pump is directly mounted on the steering gear and does not require any maintenance. The hydraulic reservoir is integrated in the pump assembly (see.Chapter Suspension and steering).
Both Astra and Zafira series are fitted with full-size driver's airbags as standard equipment. Side and head airbags may be optional. The passenger airbag is installed as standard equipment from January 1999. An engine immobilization system is used to protect against burglary. The head unit is equipped with a security code.
The speed control system (tempostat) can be installed on some models on special order.
For the car enthusiast, Astra / Zafira vehicles are easy to maintain, maintenance costs are kept to a minimum, and most of the parts requiring frequent attention are easily accessible.
With regular and proper maintenance, the Astra / Zafira will serve its owner for many years, remaining reliable and highly economical.
In this video instruction, I will show you the process of removing the valve cover gasket and fuel injectors, as well as diagnostics and disassembly of the 2005 Opel Astra G car.
This is the first part of the videos for the repair of this car.
In the following parts you will see:
Subscribe to the channel if you liked the video and leave comments! Good luck to all! 😉
the music was provided by NCS
Video Opel Astra G - Repair. Part 1 - Diagnose, Disassemble. Channel Motor Fix
Opel Astra G books and manuals for free
Repair and maintenance manual for Opel Astra G
- Opel Astra G repair in photos
Opel Astra G user manual and service manual
- operation manual
Wiring diagram Opel Astra G
- pinout of electrical connectors Opel Astra G
Catalog of parts and assembly units Opel Astra G
- table of interchangeability of car parts Opel Astra G
Repair manual for the Opel Astra G engine
- full technical characteristics of the Opel Astra G engine
Repair manual gearboxes gearbox Opel Astra G
- full technical characteristics of the checkpoint
Opel Astra G injector error codes
- description and diagram of the injector
- tuning Opel Astra G with your own hands
Repair manual and operation of the car OPEL ASTRA G / ZAFIRA A 1998-2006 release in photos
Repair manual for the car Opel Astra G / Zafira A, which were produced from 1998 to 2006 and were equipped with 1.4 DOHC, 1.6 SOHC, 1.6 DOHC, 1.8 DOHC gasoline engines. We present for you a color illustrated practical guide with an abundance of detailed photos of vehicle components and assemblies. Each drawing or photo is provided with detailed comments.
Book release year: 2007
Autoliterature, Manuals for the repair and operation of cars »Opel» OPEL ASTRA G / ZAFIRA A 1998-2006 Color repair manual in the photo
Color Repair Manual for Opel Astra G / Zafira A, as well as a manual for operation and maintenance, the device of cars Opel Astra / Zafira A 1998-2006. release equipped with gasoline engines 1.4 DOHC, 1.6 SOHC, 1.6 DOHC, 1.8 DOHC.
This manual can also be used by owners of twin cars Vauxhall Astra / Zafira, Subaru Traviq (Subaru Travik) and Chevrolet Viva (Chevrolet Viva).
All work operations in the publication are accompanied by photographs and detailed comments, which saves time, effort and money, as well as minimizes the risk of damage to equipment.
The separate sections of the manual include the operating instructions for the Opel Astra G / Zafira A, recommendations for routine maintenance and the electrical equipment (wiring diagram) of the car.
Model: Opel Astra (Opel Astra)
Years of issue: 2004, 2005, 2006, 2007, 2008, 2009
Model: Opel Astra (Opel Astra)
Years of issue: 2004, 2005, 2006, 2007, 2008, 2009
Model: Opel Astra (Opel Astra)
Years of issue: 2004, 2005, 2006, 2007, 2008, 2009
Model: Opel Astra (Opel Astra)
Years of issue: 2004, 2005, 2006, 2007, 2008, 2009
Model: Opel Astra (Opel Astra)
Years of issue: 2004, 2005, 2006, 2007, 2008, 2009
Model: Opel Astra (Opel Astra)
Years of issue: 2004, 2005, 2006, 2007, 2008, 2009
Model: Opel Astra (Opel Astra)
Years of issue: 2004, 2005, 2006, 2007, 2008, 2009
Model: Opel Astra (Opel Astra)
Years of issue: 2004, 2005, 2006, 2007, 2008, 2009
Model: Opel Astra (Opel Astra)
Years of issue: 2004, 2005, 2006, 2007, 2008, 2009
Model: Opel Astra (Opel Astra)
Years of issue: 2004, 2005, 2006, 2007, 2008, 2009
Manual for repair, operation and maintenance of cars Opel Astra G / Zafira 1998-2005. release equipped with diesel engines
Repair book Opel Astra, operation and maintenance manual for Opel Astra G 1998-2005, equipped with diesel engines with a working volume of 1.7 and 2.0 liters.
The generation of the mid-size model Opel Astra G entered the market at the turn of the century. This model was the first to receive a design style with chopped edges among Opel cars. Perhaps this design was the main reason for the incredible popularity of the Opel Astra G model in the European market. Currently, in the secondary market of Russia, there are quite large volumes of offers for the Opel Astra G car with mileage in different bodies. In this article, we decided to combine all the information that will help our readers choose a used Opel Astra G.
At its core, the Opel Astra G is an unremarkable car. She has a rather simple appearance as it is today. The motor range includes simple engines, the chassis consists of conventional types of suspensions. Nevertheless, it was the Opel Astra G model that became one of the first foreign car models, the assembly of which was localized in Russia. The Opel Astra G model was assembled in Togliatti and had its own name - Chevrolet Viva.
The predecessor of the Opel Astra G was the Opel Astra F. It was the successor to the legendary Opel Kadett. The Opel Astra F model also had successful sales in the European market. It is worth noting that in Europe, car enthusiasts did not disdain the Opel car brand.They loved the affordable small cars made in Germany.
The Opel Astra G generation has been developed entirely from scratch. Engineers have built a new platform for this vehicle. During its development, all the shortcomings of the previous model Opel Astra F were taken into account. So engineers eliminated the sluggish corrosion of the body by simple galvanizing of almost all body panels.
Opel Astra G entered the European market in 1998. Until 2001, it was the second most popular model in the C-class, second only to the Volkswagen Golf. Since 2001, the Opel Astra G has lost its place in sales to another very popular new product - the Ford Focus. German production of the Opel Astra G model ended in 2004. However, practical Germans moved its production to Poland and called it the Opel Astra Classic. Under this name, the generation of the Opel Astra G was sold in Eastern Europe until 2009 along with the Opel Astra H.
The Opel Astra G car model had quite a few body types: a three-door hatchback, a five-door liftback hatchback, a sedan, a station wagon, a coupe and even a convertible. In addition, the Opel Zafira minivan and the Opel Astra light delivery van were released on the platform of the Opel Astra G model.
The engine range of the Opel Astra G model began with a 68 horsepower turbodiesel and ended with a 200 horsepower gasoline turbo engine. In Europe, the Opel Astra G engine range consisted of 14 different engines. The design of the Opel Astra G was front-wheel drive.
The Opel Astra G platform has received good reviews for handling and reliability. However, the owners complained that the Opel Astra G has a rather stiff suspension. At the same time, it was thanks to the high rigidity on the track that great controllability was achieved.
Video (click to play).
In the table below, we list the main problems that owners of a used Opel Astra G model may experience during operation.
