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 and installation of camshafts and pushers of valves, check of a condition of components

Removal

 PERFORMANCE ORDER

  1. Remove a belt of a drive of GRM (see. Removal and installation of a belt of a drive of GRM). Before weakening of a gas-distributing belt deduce the engine from situation VMT by deployment of a cranked shaft on 60 ° counter-clockwise for the purpose of alignment of distribution of efforts developed by klapanny springs and the prevention of a provorachivaniye of camshafts fraught with damage of internal components of the mechanism as a result of input of pistons in contact to valves.
  1. Remove cogwheels of camshafts (see. Removal and installation of cogwheels cranked / camshafts and intermediate rollers).
  1. Begin with an inlet camshaft: moving on a spiral from edges inside (in sequence, return shown on an illustration 26.15), in stages, on a half of turn for an approach, evenly weaken bolts of fastening of covers of support of a shaft (the effort developed by klapanny springs at such approach also will be weakened evenly and gradually). As soon as action of springs will be neutralized, turn out bolts manually and remove covers — try not to allow losses of directing plugs of covers (if those are provided).

    And — the Order of a tightening of fixture of covers of support of a final camshaft (for an inlet shaft the same order)
    B — the Order of numbering of covers of basic bearings of camshafts
    C — Identification marking should be distinct is distinguishable both on covers, and on a head surface

A.

B.

C.

Covers of basic bearings are numbered as it should be from 1 to 5 (an inlet shaft) and from 6 to 10 (a final shaft) and at assembly should be established strictly on the former places. Be attentive, do not lose directing plugs of covers (where are established).


Non-compliance with care when weakening fixture of covers of basic bearings can lead to their mechanical damage that will result in need of replacement of a head of cylinders to weaken a cover carelessly, they can be broken. If it is broken though one cover, it is necessary to change all head of the block — when manufacturing a cover are processed together with a head and in an individual order on the market of spare parts are not delivered.

  1. Raise a camshaft and take it from the engine, carefully remove an epiploon.
  2. Operating in a similar manner, remove a final camshaft.
  1. Prepare 16 small transparent plastic bags or pure plastic glasses and mark them according to numbering of valves. By means of a rubber sucker take from a head pushers and spread out them on the corresponding glasses.

In order to avoid an oil effluence from hydrojacks stack pushers working end faces up.

Check

 PERFORMANCE ORDER

  1. Attentively study a condition of bearing necks and camshaft cams. In case of identification задиров or scratches replace a shaft. Check also a condition of working surfaces of bearings of sliding in support of the case of the gas-distributing mechanism, in case of detection of defects not subject to elimination it is necessary to replace a head of cylinders (see above Removal).
  2. Serially stacking camshafts in prisms, by means of a tsiferblatny measuring instrument of plunzherny type determine size of their radial palpation (by bearing necks). At an exit of results of measurements out of limits of an admissible range (see. Specifications) the camshaft is subject to replacement.
  3. Check a condition of pushers and their landing nests in a head. In case of identification of signs of excessive wear of working surfaces, cracks, задиров and other damages, replace pushers.

Pushers are subject to replacement also in case operation of the klapanny mechanism was lately accompanied by the raised noise background.

Installation

 PERFORMANCE ORDER

  1. Grease pushers with pure impellent oil and accurately place them on the nests landing in a head of cylinders.

    С3 — the Inlet shaft
    T3 — the Final shaft

  1. Having greased with molibdensoderzhashchy greasing, lay in the beds camshafts.

On engines of 1.8 l the inlet shaft is marked with marking С3, final — T3. Make sure that the cranked shaft is still developed under 60 ° before VMT and develop camshafts so that cams of the first cylinder appeared are developed by working ledges up. Temporarily plant on pins of shaft cogwheels and make sure of correctness of combination of adjusting labels of VMT with reciprocal labels on a head (see. Reduction of the piston of the first cylinder in the provision of the top dead point of a step of compression (VMT).

  1. Make sure of absoluteness of purity and dryness of interfaced surfaces of covers of basic bearings and heads of cylinders. Grease necks and cams of shaft with pure impellent oil.
  1. Put a hermetic layer on interfaced surfaces of extreme covers and a block head from both parties of nests under landing of epiploons.
  1. At the corresponding complete set make sure of presence on the places of directing plugs, then establish covers.

Covers are numbered on increasing in the direction from lobbies to back, besides, the corresponding numbering is put on the top plane of a head — marking should be read at a view of the engine in front.

  1. Tighten bolts of fastening of covers of an inlet shaft at first by hand, then, moving on a spiral from the center outside, in stages on a half of turn for an approach evenly (for the purpose of ensuring course and uniformity of an otzhimaniye of klapanny springs) hold on them before pressing of covers to a head. Further, in the same order fit fixture with demanded effort.

Non-compliance with an order of a tightening of fixture can lead to damage of covers and need of replacement of a head of cylinders (see above Removal).

  1. Operating in a similar manner, tighten fixture of covers of basic bearings of a final shaft.
  2. Establish new epiploons (see. Replacement of epiploons of camshafts).
  3. Establish cogwheels of camshafts (see. Removal and installation of cogwheels cranked / camshafts and intermediate rollers).
  4. Achieve the correct combination of adjusting labels of VMT cranked and camshafts, then establish into place a belt of a drive of GRM (see. Removal and installation of a belt of a drive of GRM).
  5. Establish a cover of the gas-distributing mechanism and a cover of a drive of GRM (see. Removal and installation of a cover of the gas-distributing mechanism and Removal and installation of a cover of a drive of GRM).