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
      Reduction of the piston of the first cylinder in the provision of the top dead point of a step of compression (VMT)
      Removal and installation of a cover of the gas-distributing mechanism
      Removal and installation of a pulley of a cranked shaft
      Removal and installation of a cover of a drive of GRM
      Removal and installation of a belt of a drive of GRM
      Removal and installation of a natyazhitel of a gas-distributing belt and cogwheels of a drive of GRM
      Replacement of an epiploon of a camshaft
      Removal, check of a condition and camshaft installation with the case of the gas-distributing mechanism
      Removal, check of a condition and installation of components of a drive of valves
      Removal and installation of a head of cylinders
      Removal and installation of the pallet of a case
      Removal, service and installation of the oil pump
      Removal, check of a condition and flywheel installation / driving disk
      Replacement of epiploons of a cranked shaft
      Check of a condition and replacement of support of a suspension bracket of the power unit
   + 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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Removal and installation of a head of cylinders

Start work performance only after complete cooling of the engine!

Removal

 PERFORMANCE ORDER

  1. Disconnect and remove the storage battery (see. Head engine Electric equipment).
  2. Empty cooling system (see. Head of System of cooling, heating).
  3. Turn out spark plugs and remove a belt of a drive of auxiliary units (see. Head Routine maintenance).
  4. Remove a belt of a drive of GRM (see. Removal and installation of a belt of a drive of GRM).
  5. Turn out fixing bolts and remove an arm of fastening of the engine on the right side of a head of cylinders.
  6. Remove the inlet pipeline and a final collector (see. Head of the Power supply system and release). If the head of cylinders is not subject to service, it can be removed assembled with the pipeline and a collector:
    1. Disconnect electroconducting from a potentiometer of provision of a butterfly valve, a regulator of turns of idling (ISC), injectors of injection of fuel, the valve of a retsirkulyatsiya of the fulfilled gases (EGR), the valve of a purge of a coal adsorber and a lambda probe.
    2. Dump pressure in a power supply system and disconnect fuel lines from the fuel highway. Disconnect also all vacuum hoses and hoses of system of cooling from the inlet pipeline / case of a throttle.
    3. Remove a basic arm from an inlet collector, also remove the top arm of fastening of the generator.
    4. Disconnect an accelerator cable.
    5. Disconnect from a final collector a reception pipe of system of production of the fulfilled gases assembled with a basic arm.
    6. Disconnect electroconducting from a lambda probe.
  1. Uncover the gas-distributing mechanism (see. Removal and installation of a cover of the gas-distributing mechanism).
  2. Remove a camshaft cogwheel (see. Removal and installation of a natyazhitel of a gas-distributing belt and cogwheels of a drive of GRM).
  3. Turn out bolts of fastening of a back cover of a drive of GRM to the case of the gas-distributing mechanism.
  4. Disconnect electroconducting from the module of ignition, the sensor of temperature of cooling liquid (ECT), sensors of a detonation (KS) and the provision of a cranked shaft (CKP). Give a bolt of fastening of the tire of grounding in a forward part of a head and remove from a head a protective casing of electroconducting.
  5. Release fixing collars and disconnect hoses of system of cooling from a thermostat casing.
  6. Make sure that all hoses, tubes, wires and other lines of communication are disconnected and do not disturb dismantle of a head of cylinders.
  1. Operating as it should be, the return shown, gradually, on a turn quarter for an approach, weaken bolts of fastening of a head of cylinders so that there was a possibility of their reversing manually. Remove bolts from a head in a set with the washers.
  1. Having lifted up, separate from a head the case of the gas-distributing mechanism — in case of need обстучите the case from sides a hammer with soft brisk.

At all do not hook the case the lever in order to avoid damage of interfaced surfaces! Mark position of two directing plugs, remove them from a head and clean in a reliable place.

  1. Separate a head of cylinders from the block — try not to drop levers of a drive of valves and maslootrazhatelny caps. In case of need slightly обстучите a head from sides a hammer with soft brisk — at all DO NOT HOOK it the lever (see the prevention above)! Mark position of two directing plugs, remove them and clean in a reliable place.
  1. Remove sealing laying — yet do not throw out laying for the purpose of identification on it new.

Preparation for installation

 PERFORMANCE ORDER

  1. Carefully smooth out and dry wipe interfaced surfaces of a head and the block of cylinders. Use a firm plastic or wooden scraper for removal of all traces of a material of old laying and a deposit. Also clear the bottoms of pistons. Be extremely careful — surfaces are easy for damaging. Remember that dirt should not get in маслотоки, water galleries channels and carving openings — закупорьте their jams or stick with an adhesive tape. For prevention of hit of a deposit in gaps between pistons and cylinders, fill the last of dense greasing which on termination of procedure of cleaning it will be easy to remove with a rigid brush. On termination of cleaning wipe all surfaces pure dry rags.
  2. Survey interfaced surfaces of a head and the block on existence of deep scratches, cracks and other damages. It is possible to eliminate small defects with a small shaber, in more serious cases the head should be pierced, or to replace.
  3. Make sure of purity and dryness of carving openings — just in case blow them the compressed air (it is possible to use the bicycle pump). Presence at deaf openings of traces of greasing can lead to block destruction at a tightening of bolts as a result of increase of hydraulic pressure.
  4. Bolts of fastening of a head are subject to replacement without fail, regardless of their current state.
  5. By means of a steel ruler and щупа lezviyny type check planeness of an interfaced surface of a head (see. General and major maintenance of the engine).
  6. Replace bolts of fastening of a head of cylinders — bolts are subject to replacement without fail regardless of their current state.

Installation

 PERFORMANCE ORDER

  1. Bring the piston of the first cylinder into the provision VMT of the end of a step of compression.
  2. Pure rags dry wipe interfaced surfaces of the block and a head.
  1. Make sure of that both directing plugs are established in the nests.
  1. Lay on an interfaced surface of the block of cylinders new sealing laying — laying keeps within «OBEN/TOP» marking up.
  1. Establish a head on the block of cylinders — track correctness of hit of directing plugs in reception nests.
  2. Dry wipe pure rags interfaced surfaces of a head and the case of the gas-distributing mechanism. Make sure of correctness of installation of levers of a drive of valves, maslootrazhatelny caps and hydraulic jacks.
  1. Put a layer of suitable hermetic (consult at car repair shop) on the top interfaced surface of a head of cylinders.
  1. Establish directing plugs and grease with pure impellent oil levers of a drive of valves.
  2. Accurately establish the case of the gas-distributing mechanism (with the camshaft enclosed in it) on a head of cylinders, track correctness of hit of directing plugs in reception nests — track correctness of hit of directing plugs in reception nests.
  1. Put on NEW bolts of fastening of the case gas-distributing mechanisms / heads of cylinders of a washer, then screw bolts and tighten them by hand.
  1. Operating in strictly certain sequence, in stages evenly, tighten bolts with effort of the 1st stage.
  1. In a former order hold on bolts on corners at first the 2nd, then — the 3rd and 4th stages — use a goniometric nozzle, or put with paint or a marker basic labels.
  2. Screw bolts of fastening of a back cover of a drive of GRM and tighten them with demanded effort.
  3. Make sure of correctness of installation of an arm of the right support of a suspension bracket of the power unit and tighten bolts of its fastening with demanded effort.
  4. Establish a camshaft cogwheel (see. Removal and installation of a natyazhitel of a gas-distributing belt and cogwheels of a drive of GRM) and a gas-distributing belt (see. Removal and installation of a belt of a drive of GRM).
  5. Restore initial connection of electroconducting, track correctness of laying of plaits and reliability of their fastening in all provided intermediate clamps.
  6. Connect to the thermostat case hoses of an okhladitelny path — track reliability of a tightening of fixing collars.
  7. Establish to the place of the inlet pipeline and a final collector (see. Head of the Power supply system and release).
  8. Establish into place protection of a case and the right forward wheel. Lower the car on the earth and tighten wheel bolts with demanded effort.
  9. Make sure of correctness and reliability of connection of all hoses, then make filling of system of cooling (see. Head of System of cooling, heating).
  10. Connect the storage battery.
  11. Start the engine and check it on existence of signs of development of leakages of working liquids.