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Opel Astra, Zafira

since 1998 of release

Repair and car operation



Opel Astra
+ Opel Astra and Zafira Cars
+ Operation manual
+ Routine maintenance
- Engine
   Specifications
   Check of kompressionny pressure in cylinders
   Diagnostics of a condition of the engine with use of the vacuum gage
   + Procedures of repair of petrol SOHC engines without their extraction from the car
   + Procedures of repair of petrol DOHC engines 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
   + General and major maintenance of the engine
+ Systems of cooling, heating
+ 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

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Engine

General information


The general scheme of functioning of system of greasing of the engines used for a complete set of Opel Astra/Zafira cars

1 — Shesterenchaty (rotor) oil pump
2 — Maslozabornik
3 — the case Pallet
4 — Polnopotochny the oil filter
5 — Reduktsionny the valve

6 — the Main maslotok
7 — the Radical neck of a cranked shaft
8 — Shatunnaya a neck of a cranked shaft
9 — Maslotok of vertical supply of oil
10 — a camshaft Neck

The model range of Opel Astra/Zafira differs in extreme width of a range of consumers of engines brought to attention. The complete list of considered models of engines applied to a complete set is provided in Specifications at the beginning of the present Chapter. In view of limitation of a place, in the real Management some, most typical representatives of each class of applied engines are offered attention of readers only, namely: petrol 8-клапанный the SOHC engine in volume of 1.6 l (a code of the producer of X16SZR), a number of petrol 16-klapanny DOHC engines in volume from 1.4 to 2.0 l (codes of the producer of X14XE, X16XEL, X18XE1 and X20XEV which later updating was the X20XER engine used for a complete set of the Astra-ORS models); and also 8-клапанные diesel engines in volume of 1.7 l of SOHC and DOHC (the X17DTL and Y17DT codes respectively) and two representatives of turbirovanny 16-klapanny diesel engines of SOHC in volume of 2.0 l (the X20DTL/Y20DTL codes with a low-pressure head turbo-supercharging and Y20DTH with pressurization of a high pressure). At the beginning of Head Specifications with a statement of detailed technical characteristics of the listed engines are provided.

Petrol engines of 1.6 l of SOHC

Ryadny 4-cylinder 8-клапанный the engine, with one camshaft of the top arrangement (SOHC). It is established cross-section in a forward part of the car. Transmission assembly is located to the left of the engine and transfers a torque developed by the last to forward wheels of the car.

The block of cylinders is made of an aluminum alloy and equipped with sleeves of dry type.

Observe the ordered efforts of a tightening of carving connections as aluminum molding belongs to category of soft materials and the tightening of fixture of components with excessive effort can lead to damage of carving openings!

The cranked shaft rotates in five slidings equipped by bearings radical support. Regulating axial люфт a shaft persistent half rings are established on the central (third) support of a shaft.

Rods are planted on working necks of a cranked shaft by the equipped bearings of sliding and horizontally cut bottom heads. To pistons rods fasten by means of planted внатяг in their top heads of piston fingers — in pistons fingers have floating landing. The pistons cast from aluminum are equipped with three piston rings — two kompressionny and one (bottom) maslosjemny.

The camshaft rotates in a bed strengthened from above of a head of cylinders, and is brought into rotation from a cranked shaft by means of a rubber gear belt (the same belt is used for a drive of the water pump). Ekstsentrikovye cams of a camshaft influence levers of a drive of the valves which working ends rest against end faces passed in directing plugs and the cores of podpruzhinenny valves equipped with maslootrazhatelny caps. The opposite ends of levers lean in the hydraulic jacks, carrying out automatic sample of klapanny gaps.

The system of greasing of the engine works from the shesterenchaty oil pump given in rotation from a pin of a cranked shaft. Oil gets through equipped with the mesh filter a maslozabornik from the pallet of a case of the engine and is filtered by the polnopotochny replaceable oil filter. Oil moves on provided in block molding маслотокам and is distributed on two main directions: to bearings of cranked and distributive shaft. In bearings oil moves under pressure through special drillings in bodies of shaft. Greasing of cams of a camshaft and klapanny components, no less than other internal components of the engine is carried out by a razbryzgivaniye method.

The typical scheme of functioning of system of greasing — see an illustration the General scheme of functioning of system of greasing of the engines used for a complete set of Opel Astra/Zafira cars.

The conclusion from the block of the engine of karterny gases is carried out by means of system of ventilation of half-closed type. Gases are removed through a cover of the gas-distributing mechanism and on a special hose arrive in the inlet pipeline.

Petrol engines 1.4 — 2.0 l of DOHC

The engine 4-cylinder ryadny, 16-klapanny, is equipped with two camshafts of the top arrangement (DOHC), established cross-section in a forward part of the car. The drive is carried out on forward wheels by means of the transmission assembly fixed at the left on the engine.
Some of engines 2.0 are equipped the balancing assembly consisting of two additional shaft providing decrease in intensity of vibrations, connected with functioning of a cranked shaft. Assembly is established between the block of cylinders and the case pallet (for more details see. Removal, installation and adjustment of the balancing mechanism of a cranked shaft (engines of 2.0 l).

The design of the block of cylinders and shatunno-piston groups is similar described above for SOHC engines.

Both camshafts rotate in a head of the block and are brought from a cranked shaft by the rubber gear belt which is at the same time serving also for a drive of the water pump. The drive of inlet and final valves is carried out directly from ekstsentrikovy cams of the corresponding camshafts through equipped with hydraulic jacks of klapanny gaps pushers.
Functioning of systems of greasing and ventilation of a case occurs also similarly described above for SOHC engines.

Diesel engines of 1.7 l of SOHC

The engine 4-cylinder ryadny, 8-клапанный, with one distributive shaft of the top arrangement (SOHC), is established cross-section in a forward part of the car. Transmission assembly fastens to the engine at the left and carries out torque transfer on forward wheels.

The block of cylinders is made by a method of pig-iron molding with the cylinders formed directly in his body (the block with dry sleeves).

The cranked shaft rotates in five slidings equipped by bearings radical support. Regulating axial люфт a shaft persistent half rings are planted in the top half of the central (third) support. Distinctive feature of this engine is application of a cast coupler of support of a cranked shaft.

Rods are planted on a shaft by the bottom horizontally cut heads equipped with bearings of sliding. Cast aluminum pistons are connected to rods means of the piston fingers freely floating in the top heads of rods and fixed in lugs of pistons by lock rings. Each piston is equipped with three piston rings — two kompressionny and one (bottom) maslosjemny.

Inlet and final valves подпружинены also move in pressed in a head of cylinders directing plugs. The camshaft is given from a cranked shaft by means of a gear belt and rotates directly in a block head. The drive of valves is carried out from a camshaft by means of the driving levers established directly under cams. Sample of klapanny gaps is made automatically at the expense of equipment of basic racks of driving levers by hydraulic jacks.

The system of greasing is organized similarly described above for petrol engines, with that only a difference that for the purpose of increase of intensity of cooling of the bottoms of pistons in the basis of each of cylinders of the block is established on an oil spray. For maintenance of normal temperature of oil at the raised loadings the engine is in addition equipped with a maslookhladitel.

Diesel engines of 1.7 l of DOHC

The engine 4-cylinder ryadny, 16-klapanny, is equipped with two camshafts of the top arrangement (DOHC), established cross-section in a forward part of the car. The drive is carried out on forward wheels by means of the transmission assembly fixed at the left on the engine.

Design of the block of cylinders and shatunno-piston groups of 1.7 l of SOHC similarly described above for engines, excepting a coupler of radical support of a cranked shaft.

The inlet camshaft rotates in the case of the gas-distributing mechanism and is brought by zubchatoremenny transfer directly from a cranked shaft. The drive of a final camshaft is carried out by means of shesterenchaty transfer from an inlet shaft.

Cams of shaft influence cores of the valves placed in directing plugs through the pushers equipped with adjusting washers. Installation of klapanny gaps is carried out manually by selection of washers of the demanded thickness.

The system of greasing is organized similarly described above for petrol engines. For the purpose of maintenance of normal temperature of oil at the raised loadings the engine is in addition equipped with a maslookhladitel.

Diesel engines of 2.0 l of SOHCы

Two-liter (1994 cm 3) the engine is among the newest development of the Opel company and represents a 4-cylinder ryadny, 16-klapanny design with one camshaft of the top arrangement (SOHC). The engine is established cross-section in a forward part of the car, at the left transmission assembly by means of which the torque is transferred to leading forward wheels is connected to it.

The cranked shaft rotates in five radical bearing support. The basic half rings regulating size of axial люфта of a shaft, are established in the third support.

Rods are planted on necks of a cranked shaft by horizontally cut and equipped loose leaves of bearings of sliding by the bottom heads. Piston fingers have floating landing in the top heads of rods and are fixed by lock rings in lugs on walls of pistons. The pistons cast from aluminum are supplied with three piston rings: two kompressionny and one (bottom) maslosjemny.

The block of cylinders is cast from gray cast iron. Cylinders make a whole (dry sleeves) with the block.

Inlet and final valves подпружинены also move in pressed in a head of cylinders directing plugs.

The camshaft is given from a cranked shaft by means of a dvukhryadny chain drive: the bottom chain carries out a drive of the fuel pump of a high pressure (TNVD) directly from a cranked shaft, by means of the top chain the camshaft drive from the top chain is organized provides camshaft rotation from TNVD.

The unique camshaft rotates directly in a head of cylinders and carries out a drive of sixteen by means of driving levers and the pushers equipped with hydraulic jacks. Levers of a drive of valves are established directly under cams and serve everyone for a drive of two valves. Sample of klapanny gaps is made automatically.

The system of greasing is organized 1.7 l similarly described above for the engine.

All engines

The list of repair work carried out without engine extraction from the car

The following repair work listed below can be made without removal of the engine from the car:

  1. Compression check;
  2. Removal and installation of a cover of the gas-distributing mechanism;
  3. Removal and installation of a cover of a drive of GRM;
  4. Removal and installation of components of a drive of GRM (belt / chain, gear wheels / asterisks);
  5. Removal and installation of a natyazhitel gas-distributing belt / chain and uspokoitely chain diesel engines (engines of 2.0 l);
  6. Removal and camshaft installation (ов) and levers of a drive of valves / pushers);
  7. Adjustment of klapanny gaps (diesel engines of 1.7 l of DOHC);
  8. Removal and installation of a head of cylinders;
  9. Removal and installation of pistons with rods *;
  10. Removal and installation of the pallet of a case;
  11. Removal, regenerative repair and installation of the oil pump;
  12. Removal and installation of a maslookhladitel (at the corresponding complete set);
  13. Replacement of epiploons of a cranked shaft;
  14. Check of a condition and replacement of support of a suspension bracket of the power unit;
  15. Removal, check of a condition and flywheel installation / driving disk

* Though after removal of a head of the block and the pallet (without removing the engine) there is a possibility of dismantle of shatunno-piston assemblies, it is not necessary to abuse such possibility in view of the difficulties connected with need of observance of purity and carrying out a number of preparatory procedures. In view of told, the description of this procedure see. General and major maintenance of the engine.

Before the beginning of works make careful cleaning of an impellent compartment and external surfaces of the power unit with application of one of a wide range of special solvents. Such processing will allow to avoid dirt hit in the engine.

In case of need, the forthcoming work defined by character, it is possible to remove a cowl for the purpose of ensuring freedom of access to components subject to service (see. Head the Body) — in order to avoid casual damage of a paint and varnish covering cover car wings with special covers, or simply old blankets.