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




Removal and installation of a head of cylinders

Removal

Do not allow dirt hit in a power supply system and TNVD!


Dismantle of a head should be made from completely cooled down engine. In advance prepare new sealing laying of a head of cylinders.

Engines of 1.7 l of SOHC

 PERFORMANCE ORDER

  1. Disconnect and remove the storage battery (see. Head engine Electric equipment).
  2. Empty cooling system. Turn out fixing bolts and remove an air purifier assembled with air lines and a measuring instrument of weight of air (see. Head of System of cooling, heating).

  1. Disconnect the generator from an adjusting level and the top back basic arm. Weaken the bottom bolt of fastening of the generator, remove a belt of a drive of the generator and develop the generator back.

    1 — Bolts of fastening of the top arm
    2 — the Adjusting bolt
    3 — the Nut of an adjusting bolt
    4 — the Adjusting level

  1. Uncover the gas-distributing mechanism (see. Removal and installation of a cover of the gas-distributing mechanism).
  2. Liberate from clamps and the air sleeves laid between turbokompressory and interkulery and interkulery and the inlet pipeline (see. Head of the Power supply system and release).
  1. Disconnect from the vacuum pump (4) on the left side of the case of the gas-distributing mechanism a tube of the servo-driver of the brake amplifier and the vacuum line (2) and (3).
  1. Disconnect electroconducting from the sensor of temperature of cooling liquid, the sensor of pressure of pressurization and the electromagnetic EGR valve.
  2. Disconnect electroconducting from the case of the gas-distributing mechanism and take her aside.
  3. Weaken fixing collars and disconnect the top radiatorny hose from branch pipes on a flange and a radiator.
  1. Disconnect lines of giving and fuel return from the case of the gas-distributing mechanism.
  1. Release collars and disconnect a hose of a broad tank from the top forward branch pipe of the case of the thermostat and the case of the gas-distributing mechanism. Take a hose aside.
  2. Remove fastening elements among themselves fuel lines — try to remember the adjusting provision of components.
  3. Absolutely wipe shtutserny sockets of nozzles and TNVD exit (4 pieces), then weaken their cap nuts. Weakening nuts of shtutserny connections of TNVD, hold unions from a provorachivaniye the second key. Having released nuts, serially remove fuel tubes from the engine. Pure rags collect traces of the spilled fuel. In order to avoid hit in a dirt power supply system закупорьте nozzles, unions and tips of tubes pure plastic jams. Disconnect from the first nozzle the line of return of fuel.
  4. Give two nuts and disconnect electroconducting from candles of an incandescence of the 2nd and 3rd cylinders.
  5. Release the shtutserny socket and disconnect a maslopodayushchy tube of a turbokompressor from the block of cylinders (see. Head of the Power supply system and release).
  6. Disconnect a maslopodayushchy tube from a turbokompressor (see. Head of the Power supply system and release).
  7. Turn out a fixing bolt and disconnect a returnable oil tube of a turbokompressor from the top part of the pallet of a case. Remove sealing washers.
  8. Disconnect a basic arm of a final collector from the block of cylinders and a final collector. Turn out fixing nuts and disconnect a reception pipe of system of production of the fulfilled gases from a final collector.
  9. Turn out a fixing bolt and disconnect a basic arm of electroconducting and a tube of return of fuel from the left back part of a head of cylinders.
  10. Turn out two fixing bolts and remove the thermostat case from the right back part of a head of cylinders. Separate a casing from a metal tube of cooling in a back part of the block of cylinders — pay attention to two sealing rings, and take him aside together with a heater hose.
  1. Operating in sequence, return specified, gradually, on a half of turn for an approach, evenly weaken ten bolts of fastening of a head before emergence of possibility of an otdavaniye them manually.
  1. Remove bolts of fastening of a head together with washers.
  2. Remove the case of the gas-distributing mechanism from a head, prepare eight pure polyethylene bags or plastic glasses and mark them according to numbering of valves. Remove levers of a drive of the valves, figured washers fixing them and hydrojacks — spread out components on bags / glasses according to the put marking.
  3. Having resorted to the help of the assistant remove rather heavy head of cylinders from the block. Remove sealing laying — try not to lose two directing plugs, established in the block of cylinders. If plugs are planted freely and are easily taken out, take them and clean in a reliable place. Do not throw out old laying — it can be used as an example at acquisition of the new.

The description of procedure of dismantling of a head of cylinders in case of need carrying out its regenerative repair, see. General and major maintenance of the engine.

Engines of 1.7 l of DOHC

 PERFORMANCE ORDER

  1. Empty cooling system. Turn out fixing bolts and remove an air purifier assembled with air lines and a measuring instrument of weight of air (see. Head of System of cooling, heating).
  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).
  3. Turn out also bolts of fastening of a back cover of gas-distributing GRM to the case of the gas-distributing mechanism and a block head.
  4. Remove the case of the gas-distributing mechanism (see. Removal and installation of the case of the gas-distributing mechanism (engines of 1.7 l of DOHC), remove camshafts. Prepare 16 pure polyethylene bags or plastic glasses and mark them according to numbering of valves. Take from the landing nests in a head of cylinders pushers and combine them together with adjusting washers in as appropriate marked bags / glasses.
  5. Turn out three fixing bolts and remove from a final collector the thermofilter.
  6. Turn out bolts and nuts of fastening of a final collector to a head of cylinders. Remove washers. By means of a head of the TORX type turn out two hairpins of fastening of a collector and, having pulled, remove a collector from the engine. The alternative way of dismantle of a final collector is stated in Head of the Power supply system and release.
  1. Turn out fixing bolts and remove the EGR valve.
  1. Disconnect from nozzles fuel tubes (see. Head of the Power supply system and release).Начисто wipe the TNVD target shtutserny sockets (4 pieces), then weaken their cap nuts. Weakening nuts of shtutserny connections of TNVD, hold unions from a provorachivaniye the second key. Having released nuts, serially remove fuel tubes from the engine. Pure rags collect traces of the spilled fuel. In order to avoid hit in a dirt power supply system закупорьте nozzles, unions and tips of tubes pure plastic jams. Disconnect from the first nozzle the line of return of fuel.
  1. Disconnect a vacuum hose and the electroconducting socket from the electromagnetic EGR valve.
  1. Disconnect from TNVD a hose of return of fuel.
  1. Disconnect electroconducting from the sensor of pressure of the pressurization established behind the EGR valve on an inlet collector.
  1. Disconnect electroconducting from incandescence candles (see. Head engine Electric equipment).
  1. Release a collar and disconnect a hose of system of cooling from the left back part of a head of cylinders.
  1. Disconnect electroconducting from the sensor of temperature of cooling liquid. Turn out fixing bolts and remove the thermostat case from the left back part of a head of cylinders.
  1. Operating with sequence, return specified, gradually, on a half of turn for an approach, evenly weaken ten bolts of fastening of a head before emergence of possibility of an otdavaniye them manually.
  1. Remove bolts of fastening of a head together with washers.
  1. Having resorted to the help of the assistant remove rather heavy head of cylinders from the block. Remove sealing laying — try not to lose two directing plugs, established in the block of cylinders. If plugs are planted freely and are easily taken out, take them and clean in a reliable place. Do not throw out old laying — it can be used as an example at acquisition of the new.

The description of procedure of dismantling of a head of cylinders in case of need carrying out its regenerative repair, see. General and major maintenance of the engine.

Engines of 2.0 l

 PERFORMANCE ORDER

  1. Empty cooling system (see. Head of System of cooling, heating).
  2. Execute the operations described above (see. Removal and camshaft installation (ов) and components of a drive of valves — Removal, Engines of 2.0 l — of subitem 1-13) — pay attention that lifting of the engine will need a telezhechny jack — for the purpose of distribution of loading lay between a head of a jack and the case pallet wooden whetstone.
  1. Wipe absolutely places of connection of fuel hoses, turn out shtutserny bolts and remove sealing washers. Disconnect from the pump a hose of return of fuel, liberate hoses from intermediate clamps and take them aside from a head.


  1. Remove the inlet pipeline and a final collector (see. Head of the Power supply system and release). If the head is not subject to repair, it can be removed assembled with the pipeline and a collector:

    1. On models with a high-pressure head turbo-supercharging remove inlet air lines and a metal tube from a turbokompressor.
    2. Turn out bolts of fastening of a route trench of electroconducting to the top part of the inlet pipeline and take him aside from the engine. Disconnect the pipeline electroconducting of the sensor of provision of a cranked shaft (CKP);
    3. Remove the fuel tubes going from TNVD to nozzles. Disconnect vacuum hoses from the valve of switching of the inlet pipeline and the EGR valve;
    4. Disconnect electroconducting from candles of an incandescence and remove the turbokompressor thermofilter;
    5. Disconnect oil tubes of a turbokompressor from the block of cylinders. Disconnect a vacuum hose of a diaphragm;
    6. Remove the starter thermofilter. Turn out fixing bolts and remove directing electroconductings and a basic arm of a final collector from a back part of the block of cylinders.
  1. Release collars and disconnect hoses of system of cooling from forward and back parts of the left wall of a head of cylinders.


  1. Turn out the top fixing bolt and take away the generator from a head of cylinders.
  1. Turn out three bolts of fastening of the right side of a head of cylinders to the top part of a cover of a gas-distributing chain and the unique bolt of fastening of a head to the block.
  1. Operating in sequence, return specified, gradually, on a half of turn for an approach, weaken ten main bolts of fastening of a head so that there was a possibility of their reversing by hand.
  1. Remove bolts complete with washers.
  2. By means of the assistant lift a head and remove it from the engine. Remove sealing laying. Pay attention to two directing plugs established in the top part of a head of cylinders — if plugs have free landing, remove them and clean in a reliable place. Old laying will need to be kept for the purpose of identification on it new.

Do not put a head on the bottom interfaced surface, enclose under a head wooden whetstones so that they did not concern candles of an incandescence or sprays of nozzles which act from the plane of a head and can be damaged, if a head to put directly on a workbench.

The description of procedures of regenerative repair of a head of cylinders see. General and major maintenance of the engine.

Preparation for installation

All engines

 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 easy to damage. 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).
  1. On these engines the gap size between a head and pistons is regulated by thickness of laying. In the left forward corner of laying prosechka by which quantity it is possible to determine its thickness are provided.

    A — Identification of thickness of sealing laying of a head of cylinders of the engine of 1.7 l of SOHC (one prosechka)
    B — Identification of thickness of sealing laying of a head of cylinders of the engine of 1.7 l of DOHC (one prosechka)
    C — Identification of thickness of sealing laying of a head of cylinders of the engine of 2.0 l (two prosechka)

A.

B.

C.
    Quantity просечек Thickness of laying, mm
    Engines of 1.7 l of SOHC Engines of 1.7 l of DOHC Engines of 2.0 l

    Without просечек

    1.30

    1.45

    1.20

    One prosechka

    1.40

    1.50

    1.30

    Two prosechka

    1.50

    1.55

    1.40


  1. The demanded thickness of laying can be calculated also on size of a vystupaniye of the piston over a block surface (see further).
  1. Bring the engine into the provision VMT of the end of a step of compression of the piston of the first cylinder. Establish on the block a tsiferblatny measuring instrument of plunzherny type, press a plunzher of a measuring instrument to an interfaced surface of the block and null the device. Now move a plunzher on a surface of the bottom of the piston of the first cylinder and measure size of its vystupaniye (on engines of 1.7 l of SOHC — in three points of the bottom of each piston). Further, operating in a similar manner, define size of a vystupaniye of the piston of the fourth cylinder.

    A — Measurement of size of a vystupaniye of pistons on engines of 1.7 l of SOHC
    B — Measurement of size of a vystupaniye of pistons on engines of 1.7 l of DOHC
    C — Measurement of size of a vystupaniye of pistons on engines of 2.0 l

A.

B.

C.
  1. Turn a cranked shaft on a half of turn for the purpose of reduction in positions VMT of pistons of the 3rd and 2nd cylinders and repeat measurements. In summary return the engine to position VMT of the piston of the first cylinder.
  2. On engines of 1.7 l of SOHC combine all 12 received results (on three on each piston) and divide result on 12; on engines of 1.7 l of DOHC and 2.0 l laying steals up on the maximum size of a vystupaniye. By means of given below the table calculate necessary thickness of new laying.
Size of a vystupaniye of the piston, mm Demanded laying
Engines of 1.7 l of SOHC Engines of 1.7 l of DOHC Engines of 2.0 l

less than 0.80

0.63 — 0.696

0.40 — 0.50

without просечек

0.80 — 0.90

0.697 — 0.763

0.51 — 0.60

one prosechka

0.90 and more

0.764 — 0.830

0.61 — 0.70

two prosechka

On engines of 1.7 l of SOHC if any of pistons acts more strongly other more than on 0.05 mm, establish laying of bigger thickness. For example, if the average size of a vystupaniye makes 0.79 mm, and one of measurements makes 0.85 mm (a difference in 0.06 mm), use laying with one prosechka.

Installation

Replacement of bolts of fastening of a head of cylinders is made without fail, regardless of their current state!

Engines of 1.7 l of SOHC

  •  PERFORMANCE ORDER

    1. Pure rags dry wipe interfaced surfaces of the block and a head.
    1. Make sure of that two directing plugs are established in the nests. Lay on an interfaced surface of the block of cylinders new sealing laying — laying keeps within marking by "OBEN/TOP" mark up and forward on the engine.
    1. For the purpose of prevention of contact of pistons and valves turn a cranked shaft counter-clockwise on 90 °.
    2. By means of the assistant accurately establish a head on the block of cylinders — track correctness of hit of directing plugs in reciprocal nests.
    1. Grease the hydrojacks fixing washers and levers of a drive of valves with pure impellent oil and establish components on the regular places. Grease rubbing surfaces of levers of a drive of valves with molibdensoderzhashchy greasing of type «Molikot And».
    1. Put a layer of suitable hermetic (consult at car repair shop) on the top interfaced surface of a head of cylinders.
    1. Accurately establish the case of the gas-distributing mechanism (with the camshaft enclosed in it) on a head of cylinders.
    2. Grease with a thin butter layer a carving part and the bottom party of heads of bolts pure impellent oil, then screw bolts and tighten them by hand.
    1. Operating in strictly certain sequence, in stages evenly, tighten head 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.
    1. Establish the thermostat case on the right side of a head of cylinders, using new sealing rings on the ends of a tube of an okhladitelny path in a back part of the block of cylinders, and also between the case of the thermostat and a head of cylinders. Make sure that the metal tube in a back part of the block of cylinders was combined with the case. Tighten fixing bolts with demanded effort.
    1. Establish a maslopodayushchy tube on the block of cylinders and a turbokompressor, having tightened with demanded effort shtutserny bolts.
    2. Establish a basic arm on the generator and a turbokompressor — track, that the fixture was tightened with demanded effort.
    3. Put hermetic on an interfaced surface of a reception pipe of system of production of the fulfilled gases and laying and establish them on a final collector. Tighten nuts with demanded effort.
    4. Attach a basic arm to a final collector and the block and tighten bolts of its fastening with demanded effort.
    5. Attach a returnable oil tube of a turbokompressor to the top part of the pallet of a case — do not forget to replace sealing washers.
    6. Establish a back cover of a belt of a drive of GRM, an arm of a support of a suspension bracket of the power unit, an intermediate roller, a cogwheel of a camshaft and a gas-distributing belt (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).
    7. Establish the right support of a suspension bracket of the power unit both the bottom and top sections of a cover of the GRM gas-distributing belt (see. Removal and installation of a cover of a drive of GRM).
    8. Establish a pulley of a cranked shaft (see. Removal and installation of a pulley of a cranked shaft). Establish a forward wheel and lower the car on the earth.
    9. Connect electroconducting to glow plugs. Reliably tighten nuts.
    10. Establish hoses of an okhladitelny path on a target branch pipe and fix the last on a cover of the case of the gas-distributing mechanism.
    11. Connect the TNVD fuel lines to the case of the gas-distributing mechanism.
    12. Connect a hose of an okhladitelny path to the case of the thermostat and the top branch pipe of a radiator. Reliably tighten fixing collars.
    13. Connect to the thermostat case electroconducting.
    14. Connect electroconducting sockets to the temperature sensor, the sensor of pressure of pressurization and the electromagnetic EGR valve.
    15. Connect hoses of ventilation of a case to a cover of the case of the gas-distributing mechanism, reliably tighten fixing collars.
    16. Connect to the vacuum pump a vacuum hose and a tube of the servo-driver of the brake amplifier.
    17. Connection the air sleeve connecting a turbokompressor to an interkuler, - track reliability of fixing of a branch pipe fixing collars.
    18. Establish the generator on an adjusting level and tighten with demanded effort the bottom bolt of fastening of the generator.
    19. Establish belts of a drive of auxiliary units (see. Head Routine maintenance).
    20. Establish the air purifier case with air lines and the MAF sensor (see. Head of the Power supply system and release).
    21. Fill cooling system (see. Head of System of cooling, heating).
    22. Check oil level in the engine, in case of need make the corresponding adjustment.
    23. Tighten with demanded effort bolts of fastening of a wheel.
    24. Establish and connect the storage battery.
    25. Start the engine and check it on existence of signs of development of leaks. Having warmed up the engine to normal working temperature, hold on bolts of fastening of a head of cylinders on a corner of the 5th stage of a tightening (see. Specifications).

    Engines of 1.7 l of DOHC

  •  PERFORMANCE ORDER

    1. Pure rags dry wipe interfaced surfaces of the block and a head.
    1. Make sure of that directing plugs are established on the places.
    1. For the purpose of prevention of contact of valves with pistons turn a cranked shaft counter-clockwise on 60 ° from VMT.
    2. By means of the assistant establish a head on the block — track hit of directing plugs in reciprocal nests.
    3. Grease with a thin butter layer a carving part and the bottom party of heads of bolts pure impellent oil, then screw bolts and tighten them by hand.
    1. Moving from the middle to edges, in stages evenly, tighten head 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 and 5th stages — use a goniometric nozzle, or put with paint or a marker basic labels.
    2. Further installation is made as it should be, the return to an order of dismantle of components. Pay attention to the next moments:

      1. Before installation of a gas-distributing belt turn a cranked shaft in the normal direction (clockwise) before combination of labels of VMT;
      2. After installation of nozzles and fuel tubes check a power supply system on existence of signs of development of leaks (see. Head of the Power supply system and release);
      3. Make sure of correctness of laying of electroconducting;
      4. Check installation of klapanny gaps, in case of need make the corresponding adjustment (see. Check and adjustment of gaps of valves (engines of 1.7 l of DOHC));
      5. In end, fill cooling system (see. Head of System of cooling, heating).

    Engines of 2.0 l

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


     PERFORMANCE ORDER

    1. Pure rags dry wipe interfaced surfaces of the block and a head.
    1. Make sure of that directing plugs are established on the places. Lay on an interfaced surface of the block new sealing laying.
    1. Make sure of that the cranked shaft is in VMT and it is blocked, cams of a drive of valves of the first cylinder are developed by working ledges up, and and a groove in a face surface of a pin of a shaft will develop parallel to a head cut (a control opening above).
    2. By means of the assistant establish a head on the block of cylinders — track hit of directing plugs in reciprocal nests. Establishing a head, pass in it a gas-distributing chain and fix it on a head surface by means of a screw-driver or a suitable core.
    3. Grease with a thin butter layer a carving part and the bottom party of heads of bolts pure impellent oil, then screw bolts and tighten them by hand.
    1. Operating in strictly certain sequence, in stages evenly, tighten head 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, 5th and 6th stages — use a goniometric nozzle, or put with paint or a marker basic labels.
    2. Screw bolts of fastening of a head to a cover of a gas-distributing chain and the block of cylinders and tighten them with demanded effort.
    3. Develop the generator in regular situation and tighten the top bolt of its fastening with demanded effort (see. Head engine Electric equipment).
    4. Attach hoses of system of cooling to a head of cylinders and fix them collars.
    5. Establish the inlet pipeline, a final collector and accompanying components (see. Head of the Power supply system and release).
    6. Establish a camshaft asterisk (see. Removal and installations of chains and asterisks of a drive of GRM, check of a condition of components (engines of 2.0 l).
    7. Establish new sealing washers on shtutserny sockets топливопроводов to TNVD. Tighten sockets with demanded effort (see. Head of the Power supply system and release).
    8. In end, fill cooling system (see. Head of System of cooling, heating).