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
      Reduction of the piston of the first cylinder in the provision of the top dead point of the end of a step of compression (VMT)
      Check and adjustment of phases of a gazoraspredeleniye (engines of 2.0 l)
      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 natyazhitel of chains of a drive of GRM (engines of 2.0 l)
      Removal and installation of a belt of a drive of GRM
      Removal and installation of a natyazhitel of a belt and cogwheels of a drive of GRM (engines of 1.7 l)
      Removal and installations of chains and asterisks of a drive of GRM, check of a condition of components (engines of 2.0 l)
      Replacement of an epiploon of a camshaft (engines of 1.7 l)
      Check and adjustment of gaps of valves (engines of 1.7 l of DOHC)
      Removal and camshaft installation (ов) and components of a drive of valves
      Removal and installation of the case of the gas-distributing mechanism (engines of 1.7 l of DOHC)
      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
      Replacement of an epiploon of the oil pump (engines of 1.7 l)
      Removal and installation of a maslookhladitel
      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
   + 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 camshaft installation (ов) and components of a drive of valves

Removal

Engines of 1.7 l of SOHC

Application at removal of a camshaft from the engine of 1.7 l of SOHC of the special KM-890 adaptation allows not to disturb laying of a head of cylinders with guarantee. In the absence of near at hand adaptation it is necessary to remove a head of cylinders (see. Removal and installation of a head of cylinders).


 PERFORMANCE ORDER

  1. Remove the storage battery.
  2. Remove a camshaft cogwheel (see. Removal and installation of a natyazhitel of a belt and cogwheels of a drive of GRM (engines of 1.7 l). For the purpose of prevention of an entrance of pistons in contact to valves turn a cranked shaft on 90 ° counter-clockwise.
  3. Release collars and remove an air line connecting a turbokompressor to an interkuler. Also remove a sleeve, going from an interkuler to the inlet pipeline.

Both sleeves are fixed also in intermediate clamps (see. Head of the Power supply system and release).

  1. Disconnect from the vacuum pump (4) a tube of the servo-driver of the brake amplifier and a vacuum tube (2 — 3).
  1. Turn out fixing bolts and remove the pump together with an arm of an air line of system of a turbo-supercharging.
  1. Turn out two screws with heads under a prutkovy key (Allen) and remove a persistent plate of a camshaft.
  1. In the presence of near at hand KM-890 adaptation, use of. The adaptation consists of a set of plates with adjustable legs. Plates are drawn to the case of the gas-distributing mechanism, wringing out the legs levers of a drive of valves then the camshaft can be taken freely from the case of the driving mechanism. If possibility of use of the adaptation is absent, it is necessary to remove the case of the gas-distributing mechanism. As case bolts at the same time fix as well a head of cylinders, it is necessary to remove as well it (see. Removal and installation of a head of cylinders).

Bolts and laying are not subject to a reuse and at assembly should be replaced new regardless of their condition.

  1. Having removed a camshaft, prepare 8 transparent polyethylene bags or small plastic glasses and mark them according to numbering of valves. Remove levers of a drive of the valves, figured washers fixing them and hydraulic racks of jacks. Spread out the removed components on bags / glasses according to the put marking.

Engines of 1.7 l of DOHC

 PERFORMANCE ORDER

  1. Uncover the gas-distributing mechanism (see. Removal and installation of a cover of the gas-distributing mechanism).
  2. Remove fuel nozzles (see. Head of the Power supply system and release).
  3. Remove a camshaft cogwheel (see. Removal and installation of a natyazhitel of a belt and cogwheels of a drive of GRM (engines of 1.7 l)).
  4. Turn out fixing nuts and uncover the 5th support of camshafts with left (from transmission) the parties.
  1. The gear wheel of a drive of a final camshaft is equipped with the additional gear section serving for compensation axial люфта. The compensatory section should be blocked with the main gear wheel of a shaft by means of a suitable bolt or a core. Pass a bolt / core in an opening on inside of the main gear wheel and push it through compensatory section. Such blocking will allow to unload a compensatory spring at removal of any of camshafts.
  1. Moving on a spiral from edges to the middle, gradually, on one turn for an approach, weaken nuts of fastening of covers of the remained support to remove stress from springs of valves gradually and evenly. After all klapanny springs will appear are unloaded, nuts can be turned on by hand.

Otvorachivaniye of nuts in any order it is fraught with destruction of covers of basic bearings of a camshaft, thus it is necessary to change all head of cylinders as it is cast and processed together with covers of support, and covers in an individual order on the market are not delivered.

  1. Remove covers of support — try to remember the adjusting provision of components.

Serial numbers are put on covers of support (with 1 on 5). Marking in the form of an arrow at installation of covers should indicate towards a GRM belt.

  1. Remove camshafts from a head of cylinders.
  1. Prepare 16 small transparent plastic bags or pure plastic glasses and mark them according to numbering of valves. Take from a head pushers with washers and spread out them on the corresponding glasses.

Engines of 2.0 l

At installation the new bolt of fastening of an asterisk of a camshaft and new bolts of fastening of an uspokoitel of the top chain is required.


 PERFORMANCE ORDER

  1. Disconnect a negative wire from the battery and uncover the gas-distributing mechanism (see. Removal and installation of a cover of the gas-distributing mechanism).
  2. Remove the vacuum pump of the servo-driver of the brake amplifier (see. Head Brake system).
  3. Bring the piston of the 1st cylinder into the provision VMT of the end of a step of compression (see. Reduction of the piston of the first cylinder in the provision of the top dead point of the end of a step of compression (VMT)) also block a cranked shaft in this situation.
  4. For the purpose of providing a free access to a cover of an asterisk of TNVD remove the case of an air purifier and a reception pipe of system of production of the fulfilled gases (see. Head of the Power supply system and release). Also remove a belt of a drive of auxiliary units (see. Head Routine maintenance). Mark the provision of the right support of a suspension bracket of the power unit in relation to an arm of a head of cylinders. Turn out three bolts of fastening of a support to an arm of a head of cylinders and three bolts of fastening to its mudguard. Prop up the right side of the engine a telezhechny jack, having lifted it as it is possible above, without loading thus excessively other support and lines of communication (hoses, cables, electroconducting plaits).
  5. Remove a natyazhitel of the top chain (see. Removal and installation of natyazhitel of chains of a drive of GRM (engines of 2.0 l)).
  6. Turn out the bottom bolt of fastening of a rack of a tension roller of a belt of a drive of auxiliary units, give a bolt of an axis of the basis of a natyazhitel and remove assembly of the last from the engine.

It is not necessary to remove without special need a rack from assembly of a natyazhitel, - at installation it should be ground in.

  1. Turn out fixing bolts and uncover TNVD asterisks a cover of a drive of GRM.
  2. Mark situation on the asterisks of the top chain. Also mark situation to a camshaft asterisk on a pin of the last.
  1. Turn out fixing bolts and take from a head of cylinders an uspokoitel of the top chain.

Before an otdavaniye of bolts they should be warmed up the thermal gun (the powerful hair dryer) for the purpose of a softening of the hermetic put on a carving.

  1. Holding a camshaft a rozhkovy key, turn out a bolt of fastening of an asterisk — before an otdavaniye of a bolt take the adaptation fixing a camshaft — do not forget to establish the adaptation into place after the bolt will be turned out.
  1. Liberate a camshaft asterisk from a chain and remove it from the engine.
  1. Fix a chain a screw-driver for the purpose of prevention of falling it in a head — lay a screw-driver on an interfaced surface of a head.
  1. Pay attention to marking of covers of support of a camshaft. Covers are numbered as it should be with 1 on 5, and the cover No. 1 — settles down from a chain of a drive of GRM. If marking is badly distinguishable, put new independently to avoid confusion at assembly.
  1. Moving on a spiral from edges to the middle, gradually, on one turn for an approach, weaken bolts of fastening of covers — after all klapanny springs will appear are unloaded, bolts can be turned out manually. Combine the removed bolts together with the covers — try not to lose directing plugs established in the 5th support. Take a camshaft from a head of cylinders.

Otvorachivaniye of nuts in any order it is fraught with destruction of covers of basic bearings of a camshaft, thus it is necessary to change all head of cylinders as it is cast and processed together with covers of support, and covers in an individual order on the market are not delivered.

  1. Prepare eight transparent polyethylene bags or small plastic glasses and mark them according to numbering of valves. Remove levers of a drive of valves and spread out them on bags / glasses according to the put marking.
  1. In case of need removals of hydropushers, dismantle transitional tubes of nozzles (see. Head of the Power supply system and release). Extraction of pushers is best of all for making by means of the magnetized core or rubber capture. The removed components spread out on bags / glasses according to marking.

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. On engines of 1.7 l of SOHC the damaged and worn-out support can be replaced. On engines of 1.7 l of DOHC and 2.0 l are subject to replacement all assembly of a head of cylinders as it is cast and processed together with covers of support, and covers in an individual order on the market are not delivered.
  2. Having laid a camshaft (ы) in prisms, determine size of its radial palpation (by bearing necks) by means of a tsiferblatny measuring instrument of plunzherny type. At an exit of results of measurements out of limits of an admissible range (see. Specifications) the camshaft is subject to replacement.
  3. On engines of 1.7 l the camshaft epiploon (is subject to obligatory replacement also see. Replacement of an epiploon of a camshaft (engines of 1.7 l)).
  4. On engines of 1.7 l of SOHC and 2.0 l estimate degree of wear and the general condition contacting to cams of a camshaft of working surfaces of levers of a drive of valves. In case of identification of cracks, cavities, furrows and задиров it is necessary to replace levers.
  5. On models of 1.7 l of SOHC check a condition of a persistent plate of a camshaft, in case of need make replacement.

At increased axial люфте a shaft the plate also is subject to replacement.

  1. Check a condition of pushers / hydrojacks 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

Engines of 1.7 l of SOHC

 PERFORMANCE ORDER

  1. Grease all hydropushers fixing washers and levers of a drive of valves with pure impellent oil and establish them strictly on the former places. Grease rubbing surfaces of levers with molibdensoderzhashchy greasing of type «Molikot And».
  1. Establish the KM-890 adaptation, accurately fill a camshaft in the case of the gas-distributing mechanism, having passed its pin through a new epiploon and fix it a persistent plate. Tighten bolts of fastening of a persistent plate with demanded effort.
  1. Make sure of that levers of a drive of valves and their fixing washers are established on the places and are not warped, then carefully remove the KM-890 adaptation.
  2. Establish a camshaft cogwheel while only having by hand tightened a bolt of its fastening.
  3. Turn a camshaft in a way that the cam of a drive of the final valve of the 1st cylinder (near to a gas-distributing belt) was developed by a working ledge up. Turn a cranked shaft on 90 °, having brought it into situation VMT, and establish a belt of a drive of GRM (see. Removal and installation of a belt of a drive of GRM).
  1. Fill a shaft of the vacuum pump in an opening in the left end face of the case of the gas-distributing mechanism and fix an arm of a tube of a turbokompressor the top bolt of fastening of the pump. Make sure that the shaft of a drive of the vacuum pump properly entered into gearing with a camshaft pin. Tighten bolts of fastening of the pump with demanded effort.
  1. Connect to the vacuum pump a vacuum hose of the servo-driver of the brake amplifier.
  2. Establish into place a sleeve, a connecting interkuler with the inlet pipeline, and also laid between the compressor and an interkuler an air line. Establish fixing clamps and reliably tighten bolts of fastening of arms.
  3. Establish and connect the storage battery.

Engines of 1.7 l of DOHC

 PERFORMANCE ORDER

  1. Grease pushers with pure impellent oil and establish strictly on former in the places — track correctness of installation of all washers.
  1. For the purpose of prevention of risk of an entrance of valves in contact to the bottoms of pistons turn a cranked shaft approximately on 60 ° counter-clockwise. Grease washers of pushers and a support of camshafts with pure impellent oil and lay shaft on support. Make sure that the compensatory section of a gear wheel of a final camshaft is blocked with the main gear wheel. Make sure that the label on an external surface of a gear wheel of a final camshaft is located between two labels on an external surface of a gear wheel of an inlet camshaft and approximately on one line with a cut of the case of the gas-distributing mechanism.

If the final camshaft was replaced, it is necessary to get the Vauxhall KM-6092 adaptation for compression of a spring of a compensatory gear wheel before installation.

  1. Make sure of absoluteness of purity and dryness of interfaced surfaces of support and covers of camshafts. Grease interfaced surfaces, and also cams of camshafts with pure impellent oil.
  1. Interfaced surfaces of the first support and its cover grease with suitable hermetic (consult at car repair shop).
  1. Establish on the places of a cover of support from No. 1 on No. 4 — covers are marked and should be established by shooters in the direction of a belt of a drive of GRM.
  1. Screw nuts of fastening of covers, having tightened them while only by hand.
  2. Remove fixing sections of a gear wheel of a final camshaft a bolt / core, then establish a cover of the 5th support.
  1. Operating in strictly certain sequence, gradually, on one turn for an approach, tighten nuts of fastening of covers, smoothly loading klapanny springs. Continue a tightening in former sequence until covers will not nestle on support, then hold on all fixture with demanded effort.

The tightening of nuts in any order is fraught with destruction of covers of basic bearings of a camshaft, thus it is necessary to change all head of cylinders as it is cast and processed together with covers of support, and covers in an individual order on the market are not delivered.

  1. Establish a new epiploon of a camshaft (see. Replacement of an epiploon of a camshaft (engines of 1.7 l)).
  2. Establish a cogwheel of a camshaft and a belt of a drive of GRM (see. Removal and installation of a natyazhitel of a belt and cogwheels of a drive of GRM (engines of 1.7 l) both Removal and installation of a belt of a drive of GRM).
  3. Check gaps in valves, in case of need make their adjustment (see. Check and adjustment of gaps of valves (engines of 1.7 l of DOHC)), then establish a cover of the gas-distributing mechanism (see. Removal and installation of a cover of the gas-distributing mechanism).
  4. Establish to the place of a nozzle (see. Head of the Power supply system and release).

Engines of 2.0 l

 PERFORMANCE ORDER

  1. If removed, grease with pure impellent oil pushers and establish them on the former places in a head of cylinders. Establish transitional tubes of nozzles (see. Head of the Power supply system and release).
  1. Establish on the places levers of a drive of valves (labels on their top surface to transitional tubes of nozzles).
  1. Grease cams and bearing necks of a camshaft with pure impellent oil and lay a shaft on the regular place. Make sure that the cranked shaft on the former is blocked in situation VMT and develop a camshaft working ledges of cams of a drive of valves of the first cylinder up so that the groove in an end face of a pin of a camshaft appeared is parallel to the top cut of a head, and an opening of control of phases of a gazoraspredeleniye — in situation «at 12 o'clock».


  1. Make sure of absoluteness of purity and dryness of interfaced surfaces of bearing support of a camshaft and their covers. Grease cams and camshaft necks with pure impellent oil.
  1. Grease with hermetic interfaced surfaces of the 5th (extreme left) shaft support, then establish in a head of cylinders directing plugs.
  1. Establish on the places of a cover of support of a camshaft. Covers are numbered as it should be with 1 on 5 and at a look from the forward party of the engine of figure should be read correctly.
  1. By hand tighten bolts of fastening of covers, then, moving on a spiral from the middle to edges, gradually, on one turn for an approach, tighten bolts of all covers, smoothly loading klapanny springs. Continue to tighten fixture until covers will not nestle on support, and in summary tighten bolts with demanded effort.

The tightening of nuts in any order is fraught with destruction of covers of basic bearings of a camshaft, thus it is necessary to change all head of cylinders as it is cast and processed together with covers of support, and covers in an individual order on the market are not delivered.

  1. Watching correctness of combination of the labels put in the course of dismantle, put on a chain for TNVD and camshaft asterisks. Plant a camshaft asterisk on a pin of the last (also track correctness of combination of labels). Screw and tighten the NEW fixing bolt.
  1. Fill into place an uspokoitel of the top chain (an adjusting ledge up), screw NEW fixing bolts and tighten from with demanded effort.
  2. In the presence of near at hand special fixing adaptations, make adjustment of phases of a gazoraspredeleniye (see. Check and adjustment of phases of a gazoraspredeleniye (engines of 2.0 l)). Having finished adjustment, remove adaptations.
  1. If possibility of use of special adaptations is absent, achieve combination of the landing labels of an asterisk put in the course of dismantle and a camshaft. Holding a camshaft a rozhkovy key for лыски, tighten a bolt of fastening of an asterisk with effort of the 1st stage. Make sure of correctness of combination of labels, hold on a bolt consistently corners of stages of 2 and 3 tightenings — use a goniometric nozzle, or put with paint or a marker basic labels.
  1. Establish a natyazhitel of the top chain (see. Removal and installation of natyazhitel of chains of a drive of GRM (engines of 2.0 l)).
  2. Make sure of absoluteness of purity and dryness of interfaced surfaces of covers of asterisks of TNVD and GRM drive. If covers it was planted on laying, do not forget to replace the last. Screw fixing bolts and tighten them with demanded effort. If laying was not provided, fill a cover flute with a hermetic pillow in thickness about 2 mm, then press a cover, screw fixing bolts and tighten them with demanded effort.
  3. Establish a natyazhitel of a belt of a drive of auxiliary units, having tightened fixing and axial bolts with demanded effort. At replacement of a natyazhitel, or after his dismantling it is necessary to make rack grinding in — use a face head, having put on it a six-sided part of the basis. If the rack functions normally, establish a belt of a drive of auxiliary units (see. Head Routine maintenance).
  4. Establish on a head of cylinders assembly of the right support of a suspension bracket of the power unit. Lower the unit, then fix a support on a mudguard, having tracked correctness of combination of the landing labels put in the course of dismantle. Tighten fixing bolts with demanded effort.
  5. Establish a cover of the gas-distributing mechanism (see. Removal and installation of a cover of the gas-distributing mechanism).
  6. Establish a reception pipe of system of production of the fulfilled gases, the case of an air purifier and the sensor of provision of a cranked shaft (see. Head of the Power supply system and release).
  7. Establish assembly of the vacuum pump (see. Head Brake system).