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
      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 cogwheels cranked / camshafts and intermediate rollers
      Replacement of epiploons of camshafts
      Removal and installation of camshafts and pushers of valves, check of a condition of components
      Removal and installation of a head of cylinders
      Removal and installation of the pallet of a case
      Removal and installation of the sensor of level of impellent oil
      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
      Removal, installation and adjustment of the balancing mechanism of a cranked shaft (engines of 2.0 l)
   + 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




Removal, installation and adjustment of the balancing mechanism of a cranked shaft (engines of 2.0 l)

Removal

Some engines of 2.0 l of DOHC are equipped with the balancing block (2) established between the block of cylinders and the main section of the pallet of a case. The block consists of two balancing shaft rotating in opposite directions with a drive from a cranked shaft.


 PERFORMANCE ORDER

  1. Remove pallet assembly with a maslozabornik (see. Removal and installation of the pallet of a case).
  1. In stages on one having weakened fixing bolts, turn out them and remove the balancing mechanism from the block of cylinders assembled with the adjusting laying (1) established between balancing assembly and the block of cylinders.

Installation

If works on service of a cranked shaft were performed, or replacement of the balancing mechanism of the engine was made, before installation of the last it will be necessary to adjust люфт gearings of teeths of driving gear wheels.

At installation of the former mechanism provided that with cranked shaft no works were performed, need for this adjustment disappears.

Competent adjustment of gearing of gear wheels outside the conditions of firm car repair shop Opel can be made only with use of the special KM-949 adaptation.

 PERFORMANCE ORDER

  1. Prepare the special adaptation. Bring the engine into the provision VMT of the end of a step of compression of the piston of the first cylinder (see. Reduction of the piston of the first cylinder in the provision of the top dead point of a step of compression (VMT).
  1. Develop gear wheels of balancing shaft so that pins of the last settled down лысками down and strictly horizontally.
  1. Establish adjusting laying on the top interfaced surface of balancing assembly. Press assembly to the block of cylinders. Make sure that the gear wheel of a shaft of the mechanism entered into gearing with a gear wheel of a cranked shaft, then screw fixing bolts and tighten them with demanded effort.
  1. Fix the KM-949 adaptation. Screw a long bolt with a nakatka in an end face of a pin of a balancing shaft from the inlet pipeline. Establish the measuring lever in situation «9 hours» if to look at the engine behind. By hand tighten a bolt.
  2. Screw a short bolt with a nakatka in an end face of the second balancing shaft. Tighten a bolt by hand.
  3. Establish on balancing assembly or the block of cylinders a tsiferblatny measuring instrument so that its plunzher rested against the measuring lever between dredging on its smooth surface of the lever.
  1. For a bolt with a nakatka turn the left balancing shaft clockwise against the stop and null a measuring instrument.
  2. Turn a shaft against the stop counter-clockwise, consider instrument readings and write down result.
  3. Having received results of all four measurements, turn a cranked shaft for a bolt of its cogwheel clockwise so that the measuring lever on "inlet" balancing to a shaft appeared in situation «at 6 o'clock». Weaken a bolt with a nakatka and move the lever to situation «at 9 o'clock». Repeat measurement and read two more instruments, every time turning a balancing shaft.
  4. If the result though one of measurements falls outside the limits an admissible range (see. Specifications), therefore, люфт gearings of gear wheels needs adjustment. Adjustment is reached by selection of the remote laying established between the block of cylinders and balancing assembly. Laying is marked according to thickness (see. Specifications) — the code is beaten out directly on a laying surface.
  5. Having defined size of a gap and, knowing thickness of old laying, it is possible to calculate thickness of demanded replaceable laying. Laying is issued with a step of thickness of 0.02 mm. Let, for example, the gap size at the established laying «70» made 0.08 mm. If laying to replace with No. 67, the size of a gap will be reduced to 0.06 mm.

Installation several laying is not allowed at once!

  1. Having picked up laying and having established assembled with it the balancing block, make a series of control measurements. In case of need repeat procedure of selection of laying.
  2. Remove a measuring instrument and turn out bolts from end faces of balancing shaft.
  3. Establish the case pallet (see. Removal and installation of the pallet of a case).