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 the pallet of a case

Removal

All engines

 PERFORMANCE ORDER

  1. Disconnect a negative wire from the battery. Cock the parking brake, then поддомкратьте a front of the car and establish it on props. At the corresponding complete set remove protection of a case.
  2. Merge impellent oil (see. Head Routine maintenance), then establish a new sealing washer and screw a drain stopper on a place and tighten it with demanded effort.

Engines of 1.7 l

On models of 1.7 l of SOHC dismantle of the pallet of a case is interfaced to removal of the bridge of covers of radical bearings of a cranked shaft. At crossing point installation bolts of its fastening are subject to replacement without fail.


 PERFORMANCE ORDER

  1. Turn out bolts of fastening of the bottom section of the pallet to the main casting. Separate the bottom section of the pallet and remove it from the engine.
  2. On engines of 1.7 l of SOHC for removal of the main cast section of the pallet, disconnect electroconducting from the sensor of temperature of oil established in its forward part, on engines of 1.7 l of DOHC — remove a reception pipe of system of production of the fulfilled gases (see. Head of the Power supply system and release).
  1. Turn out a bolt (ы) fastenings of a directing tube measuring щупа to the block of cylinders / to lityevy section of the pallet.
  1. On engines of 1.7 l of SOHC take directing tube from the main lityevy section of the pallet.
  1. Then turn out a connecting bolt and disconnect a maslovozvratny tube of a turbokompressor from lityevy section of the pallet. Remove sealing washers.
  1. Turn out two bolts of fastening of a maslozabornik to molding of the pallet and lift the receiver — pay attention that the maslozabornik is equipped with two sealing rings.
  2. Gradually releasing, turn out bolts and the nuts, fixing cast section of the pallet to the block to a cylinders / cover or the case of the oil pump, a transmission case. If the pallet "became attached" to laying, обстучите its hammer with soft the brisk.

On models of 1.7 l of SOHC the released pallet should be shifted towards a forward stretcher.

  1. On models of 1.7 l of SOHC turn out bolts of fastening of the bridge of covers of radical bearings and remove the last together with pallet molding.
  1. On engines of 1.7 l of DOHC remove attached to the block of cylinders from below a maslootrazhatelny plate.

Engines of 2.0 l

 PERFORMANCE ORDER

  1. Disconnect electroconducting from the sensor of temperature of oil and (at the corresponding complete set) the sensor of level of oil.
  1. Turn out bolts of fastening of a flange of the pallet to RKPP case.
  1. Gradually releasing, turn out bolts of fastening of the pallet to the basis of the block of cylinders / to the oil pump. In case of need slightly обстучав the pallet a hammer with soft brisk, separate it from the engine and take from under the car.

All engines

 PERFORMANCE ORDER

  1. Check a condition of the mesh filter of a maslozabornik — in case of need remove it together with a sealing ring and wash out in solvent.


Installation

Engines of 1.7 l of SOHC

 PERFORMANCE ORDER

  1. Carefully smooth out interfaced surfaces of the bottom and main sections of the pallet of a case. Impose a pillow of suitable hermetic on an interfaced surface around a joint it with a cover of the oil pump and a cover of the back radical bearing.
  1. Lay new sealing laying on an interfaced surface of the main cast section of the pallet and place the last on a forward stretcher.
  1. Establish into place the bridge of covers of radical bearings, screw NEW fixing bolts and tighten them with demanded effort.
  1. Press cast section of the pallet to the engine, screw and by hand tighten all bolts of its fastening.
  2. Tighten fixing bolts with demanded effort.

If the cast section of the pallet is established on the engine removed from the car and separated from transmission, it is necessary to make sure that the section flange from a flywheel was combined with the corresponding flange of the block of cylinders.

  1. Tighten with demanded effort bolts of fastening of casting of the pallet to a transmission case.
  2. Connect to the pallet a maslovozvratny tube of a turbokompressor, using new consolidations. Tighten a bolt of fastening of a tube with demanded effort.
  3. Fill directing tube measuring щупа in cast section of the pallet, having replaced sealing rings, connect a tube to the block. Tighten a bolt of a basic arm of a tube on the block with demanded effort.
  4. Connect electroconducting to sensors of provision of a cranked shaft and oil temperatures. Fix conducting in a basic arm.
  1. Establish sealing rings for the tube end маслозаборникаи connect a tube to cast section of the pallet. Tighten NEW bolts of fastening of a tube with demanded effort.
  1. Carefully smooth out interfaced surfaces of the main and bottom sections of the pallet, having completely released them from oil traces, and dirt.
  2. Using new laying, establish the bottom section of the pallet on molding of the main section. Screw and tighten with demanded effort fixing bolts.
  3. Establish protection of a case, lower the car on the earth and fill the engine with fresh impellent oil (see. Head Routine maintenance).

Engines of 1.7 l of DOHC

 PERFORMANCE ORDER

  1. Remove all traces of dirt, oil and hermetic of interfaced surfaces of both sections of the pallet, and — if acted in film — from a maslozabornik.
  1. In case of need, replace a sealing ring of a maslozabornik and establish the last in the basis of the block of cylinders. Screw a bolt of fastening of a maslozabornik and tighten it with demanded effort. Establish a maslootrazhatelny plate.
  1. Make sure of absoluteness of purity and dryness of interfaced surfaces of the block of cylinders and the main cast section of the pallet of a case. Grease with suitable hermetic the top interfaced surface on top the main section of the pallet.
  1. Establish on pallet molding new rubber sealing laying of a directing tube measuring щупа.
  1. Establish cast section of the pallet and acquire bolts and nuts of its fastening. Pay attention that four long bolts are rolled in openings in a back part of molding of the pallet. If dismantle of the pallet was made on the engine removed and separated from transmission, track, that back surfaces of the block of cylinders and molding of the pallet appeared are deduced in one plane. Moving from the center to edges, in a diagonal order, evenly tighten bolts of fastening of molding of the pallet with demanded effort.
  1. Screw bolts of fastening of molding of the pallet to a case of transmission and tighten them with demanded effort.
  2. Make sure of correctness of installation of a directing tube measuring щупа it is established, wrap bolts of its fastening and tighten them with demanded effort.
  3. Establish a reception pipe of system of production of the fulfilled gases (see. Head of the Power supply system and release).
  4. Make sure of absoluteness of purity and dryness of interfaced surfaces of the main and bottom sections of the pallet. Put a layer of suitable hermetic on an interfaced surface of the bottom section. Press the bottom section of the pallet to top, screw and tighten with demanded effort fixing bolts.
  5. At the corresponding complete set establish into place protection of a case. Lower the car on the earth and fill in fresh impellent oil (see. Head Routine maintenance).

Engines of 2.0 l

 PERFORMANCE ORDER

  1. Carefully smooth out interfaced surfaces of the block of cylinders / pallet of a case and if removed — a maslozabornik.
  2. In case of need, having replaced a sealing ring, establish on the pallet a maslozabornik, having tightened bolts of his fastening with demanded effort.
  1. Put a layer of suitable hermetic on an interfaced surface of the block of cylinders in joint places with the case of the oil pump and a cover of a back support of a cranked shaft.
  1. Having replaced sealing laying, press the pallet to the block of cylinders, screw and by hand tighten fixing bolts.
  1. Moving from the center to edges, in a diagonal order, evenly tighten bolts of fastening of the pallet to the block of cylinders / to the oil pump with demanded effort.
  2. With demanded effort tighten bolts of fastening of a flange of the pallet to a transmission case.
  3. Connect electroconducting to the sensor of temperature of oil and (if it is established) the sensor of level of oil.
  4. At the corresponding complete set establish into place protection of a case of the engine. Lower the car on the earth and fill in in the engine fresh impellent oil (see. Head Routine maintenance).