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 a head of cylinders

Start work performance only after complete cooling of the engine!

Removal

All engines

 PERFORMANCE ORDER

  1. Dump pressure in a power supply system (see. Head of the Power supply system and release). Disconnect and remove the storage battery (see. Head engine Electric equipment).
  2. Empty cooling system (see. Head of System of cooling, heating).
  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.

L engines 1.4, 1.6 and 1.8

 PERFORMANCE ORDER

  1. 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 from a final collector a reception pipe of system of production of the fulfilled gases assembled with basic кронштейномю
    2. Disconnect electroconducting from a lambda probe.
    3. Disconnect electroconducting from the sensor of provision of a cranked shaft (CKP).
    4. Uncover the gas-distributing mechanism (see. Removal and installation of a cover of the gas-distributing mechanism).
  2. Remove cogwheels of camshafts (see. Removal and installation of cogwheels cranked / camshafts and intermediate rollers).
  3. Turn out bolts of fastening of a back cover of a drive of GRM to the case of the gas-distributing mechanism.
  4. If yet did not do it, disconnect electroconducting from the control unit (ECU) on the left side of a head of cylinders.
  5. Release fixing collars and disconnect hoses of system of cooling from the thermostat case.
  1. For the purpose of removal of cooling liquid from the block of cylinders disconnect the hoses going from the heat exchanger of a heater to the inlet pipeline (see. The head of System of cooling, heating) — as soon as an effluence of liquid will stop, restore initial connection of hoses. The spilled liquid collect paper towels. Turn out two bolts with heads of the TORX type and separate a connecting flange of a hose from a back part of a head of cylinders.

    A — Removal of a flange of connection of a hose of system of cooling (the engine of 1.8 l)
    B — Removal of a flange of connection of a hose of system of cooling (l engines 1.4 and 1.6)

A.

B.
  1. On engines 1.4 and 1.6 of l liberate two hoses of ventilation of a case from a basic arm of ECU at the left on a head.
  2. On engines of 1.8 l turn out a fixing bolt and take aside directing tube щупа measurements of level of impellent oil.
  3. 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, evenly 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 a head of cylinders from the block — in case of need обстучите it from sides a hammer with soft brisk.

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

  1. Remove sealing laying — yet do not throw out laying for the purpose of identification on it new.

Engines of 2.0 l

 PERFORMANCE ORDER

  1. 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.
  2. Uncover the gas-distributing mechanism (see. Removal and installation of a cover of the gas-distributing mechanism).
  3. Remove cogwheels of camshafts (see. Removal and installation of cogwheels cranked / camshafts and intermediate rollers).
  4. Turn out bolts of fastening of a back cover of a drive of GRM to the case of the gas-distributing mechanism.
  5. If the inlet pipeline is not dismantled, remove basic arms the generator / pipeline and take away the generator back.
  6. Disconnect an accelerator cable (see. Head of the Power supply system and release).
  7. Disconnect from the inlet pipeline a vacuum hose of the servo-driver of the brake amplifier.
  8. Disconnect gasoline pipe lines from the fuel highway.
  9. Weaken fixing collars and disconnect hoses of an okhladitelny path from the heat exchanger of a heater and the throttle case.
  10. If yet did not do it, disconnect electroconducting of injectors of injection of fuel and take her aside.
  11. Remove a final camshaft (see. Removal and installation of camshafts and pushers of valves, check of a condition of components).
  12. 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 third for an approach, by means of a 12-faced key of TORX T55 (KM-2355) evenly 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 a head of cylinders from the block — in case of need обстучите it from sides a hammer with soft brisk.

At all do not hook a head the lever in order to avoid damage of interfaced surfaces! Mark position of two directing plugs, remove them from the block 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

See. Removal and installation of a head of cylinders.

Installation

All engines

 PERFORMANCE ORDER

  1. Make sure that the cranked shaft is still developed under 60 ° before VMT.
  2. Pure rags dry wipe interfaced surfaces of the block and a head.
  3. 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.
  1. Put on NEW bolts of fastening of a head of cylinders of a washer, then accurately 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, 4th stages and the 5th — use a goniometric nozzle, or put with paint or a marker basic labels.

L engines 1.4, 1.6 and 1.8

 PERFORMANCE ORDER

  1. Restore initial connection of hoses of an okhladitelny path — do not forget to replace a sealing ring of flange connection from the back party of a head. Track reliability of a tightening of fixing bolts / collars.
  2. Restore initial connection of electroconducting. Track correctness of laying of plaits and reliability of fixing by their all provided clamps.
  3. Establish a back cover of a gas-distributing belt, screw fixing bolts and tighten them with demanded effort.
  4. Establish cogwheels of camshafts (see. Removal and installation of cogwheels cranked / camshafts and intermediate rollers).
  5. Bring the engine into situation VMT (see. Reduction of the piston of the first cylinder in the provision of the top dead point of a step of compression (VMT)) also establish also a gas-distributing belt (see. Removal and installation of a belt of a drive of GRM).
  6. Establish covers of the gas-distributing mechanism and GRM drive (see. Removal and installation of a cover of the gas-distributing mechanism and Removal and installation of a cover of a drive of GRM).
  7. Establish to the place of the inlet pipeline and a final collector (see. Head of the Power supply system and release).
  8. Establish a wheel, lower the car on the earth and tighten wheel bolts with demanded effort.
  9. Check correctness of laying and connection of hoses of an okhladitelny path.
  10. Make sure of correctness of laying and reliability of connection of all hoses, then make filling of system of cooling (see. Head of System of cooling, heating).
  11. Establish into place the ignition module, a protective casing of the engine and air purifier assembly with air lines.
  12. Connect the storage battery.
  13. Start the engine and check it on existence of signs of development of leakages of working liquids.

Engines of 2.0 l

 PERFORMANCE ORDER

  1. Establish a final camshaft (see. Removal and installation of camshafts and pushers of valves, check of a condition of components).
  2. Restore initial connection of hoses of an okhladitelny path.
  3. Establish a back cover of a gas-distributing belt, screw fixing bolts and tighten them with demanded effort.
  4. Establish cogwheels of camshafts (see. Removal and installation of cogwheels cranked / camshafts and intermediate rollers).
  5. Execute procedures, since the paragraph l Engines 1.4, 1.6 and 1.8 — item 5.