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, service and installation of the oil pump

Removal

Engines of 1.7 l of SOHC

 PERFORMANCE ORDER

  1. Remove a back cover of a belt of a drive of GRM (see. Removal and installation of a cover of a drive of GRM).
  2. Remove lityevy section of the pallet of a case (see. Removal and installation of the pallet of a case).
  3. Remove assembly of a natyazhitel and an intermediate roller (see. Removal and installation of natyazhitel of chains of a drive of GRM (engines of 2.0 l).
  4. On models from RKPP ask the assistant for the purpose of blocking of a cranked shaft from a provorachivaniye to include the highest transfer and against the stop to squeeze out a pedal of a foot brake. On models from AT turn out one of bolts of fastening of the hydrotransformer and draw the last to a transmission case by means of a steel level and suitable bolts with washers (see. Head Automatic transmission). If the engine is removed from the car, it is necessary to block a flywheel / a driving disk (see. Removal, check of a condition and flywheel installation / driving disk). Turn out a fixing bolt and remove a cogwheel.

  5. Disconnect an oil tube from the case of the oil filter and take tubes together with an arm aside.
  1. Disconnect electroconducting from the sensor of pressure of oil.
  1. Turn out six fixing bolts and remove the oil pump from directing plugs.
  1. Having hooked a screw-driver, take from the pump case an epiploon and will throw out it — at assembly the epiploon is subject to replacement without fail.

Engines of 1.7 l of DOHC

The Reduktsionny valve of pressure of oil will screw in the block of cylinders and it can not be removed without preliminary dismantle of TNVD.


 PERFORMANCE ORDER

  1. Remove a belt of a drive of GRM (see. Removal and installation of a belt of a drive of GRM).
  2. Remove cogwheels of the oil pump and a cranked shaft (see. Removal and installation of a natyazhitel of a belt and cogwheels of a drive of GRM (engines of 1.7 l).
  3. Remove cast section of the pallet of a case (see. Removal and installation of the pallet of a case). Turn out fixing bolts, shift a cover of the oil pump to a pin of a cranked shaft, having accepted precautionary measures not to drop directing plugs. Remove the sealing ring established round a case part of the oil pump and will throw out it — at assembly the ring is subject to replacement without fail.
  4. With marker mark the provision of an external rotor of the pump — at assembly components should be established strictly in similarly.
  1. Take internal and external rotors from the block of cylinders.


  1. In case of need remove TNVD (see. Head of the Power supply system and release) also turn out the reduktsionny valve from a back part of the block of cylinders. The valve is to the right of the bottom arm of fastening of TNVD. Remove a sealing ring.

Engines of 2.0 l

The oil pump is built in a cover of a drive of GRM, the description of procedures of its removal and installation see. Removal and installation of a cover of a drive of GRM.

The Reduktsionny valve of the oil pump can be removed, without dismantling a cover of a drive of GRM. For valve dismantle it is enough to remove the case pallet.

Check

Engines of 1.7 l of SOHC

 PERFORMANCE ORDER

  1. On the pump removed from the engine turn out screws with crosswise shlitsa and remove an internal cover of the pump.

  1. Check sizes of gaps between teeths of external and internal rotors, and also between an external rotor and the pump case (a radial gap of an external rotor).
  1. By means of a steel ruler and щупа lezviyny type measure size of an axial gap (люфта) rotors.
  1. If results of measurements fall outside the limits admissible ranges (see. Specifications), make replacement of the corresponding components. Pay attention that landing marking is put on a surface of an external rotor.
  1. The Reduktsionny valve can be turned out from the pump case, for pro-cleaning and check of a condition of components.

    And — the Piston reduktsionny the valve
    In — the Spring of assembly of the reduktsionny valve
    With — the Thermostatic valve
    D — the Cap

  1. The sensor of emergency pressure of oil will screw in a back part of the pump. The defective sensor is subject to replacement (see. Head engine Electric equipment).
  2. The thermostatic valve of an oil cooler / perepuskny the valve of the filter will screw in the case of the oil filter.

Engines of 1.7 l of DOHC

 PERFORMANCE ORDER

  1. Carefully clean all components and attentively study a condition of rotors, cases and pump covers. In case of identification of damages and signs of excessive wear replace defective components. If the pump case in the block of cylinders has marking, address for consultation to specialists of firm car repair shop of the Opel company.

  1. If the condition of components is found satisfactory, establish rotors in the case of pump assembly. With the help щупов lezviyny type measure size of gaps between an external rotor and the case of the pump and a gap between teeths of an internal and external rotor. Measure size axial люфта rotors and check the cover plane. If results of measurements fall outside the limits admissible ranges (see. Specifications), replace worn-out components.


  1. If removed the reduktsionny valve, check freedom of moving of the piston and smoothness of its return under the influence of effort developed by a spring. In case of need replace the valve assembled.

Engines of 2.0 l

 PERFORMANCE ORDER

  1. Turn out fixing bolts and uncover the pump from the interior of a chain cover.
  1. With marker mark adjusting provisions of both rotors.
  1. Take rotors from the pump case.


  1. Turn out a cap of the valve of adjustment of pressure of oil in the basis of the case of the pump.
  1. Take a spring, the plug and a plunzher — try to remember the adjusting provision of components. Remove from a valve cap a sealing ring.


  1. Turn out a cap of the reduktsionny valve from a back part of a cover of a chain — the valve is established over three bolts in a back part of a cover.
  1. Take from a cover a spring and a plunzher — try to remember the adjusting provision of components. Remove from a cap a sealing ring.
  1. Clear all components. Estimate degree of wear of rotors, cases of the pump and plunzher of valves. Replace defective components. If rotors of the pump are already marked, replace all pump assembled.
  1. If the condition of all components does not cause doubts, bring together them upside-down, paying attention to the next moments:

    1. Track for correctness of orientation of rotors and plunzher at their installation in pump assembly;
    2. Do not forget to replace sealing rings of caps, track, that caps were tightened with demanded effort;
    3. Track, that bolts of fastening of a cover of the pump also were tightened with demanded effort;
    4. In end fill the oil pump with pure impellent oil, manually turning an internal rotor.

Installation

Engines of 1.7 l of SOHC

 PERFORMANCE ORDER

  1. If removed, establish a new sealing ring of the reduktsionny valve and establish the valve assembled in the block of cylinders, having tightened it with demanded effort.
  1. By means of a cylindrical opravka (a replaceable face head of the corresponding size, or a piece of a pipe of suitable diameter) or heads plant in the case of the oil pump a new epiploon (sealing sponges inside) — track, that the opravka rested only against the rigid external region of an epiploon. Make sure that the epiploon is pressed aflush with a case surface.

Before installation grease sealing sponges of an epiploon with pure impellent oil.

  1. Grease pump rotors with pure impellent oil and plant them in the pump case. Track correctness of combination of the adjusting labels put in the course of dismantle. Marking should be turned in the engine.
  1. Put a layer of suitable hermetic on an internal interfaced surface of an internal cover of the case of the pump and establish it on the case.
  2. Screw screws of fastening of a cover and tighten them with demanded effort.
  3. Carefully wipe interfaced surfaces of the case of the pump and the block. Check existence on the places of directing plugs of the pump. Remove all traces of hermetic from a carving part of bolts of fastening of the pump.
  1. Replace laying and establish the pump on the block of cylinders, trying not to damage working edges of an epiploon about a cranked shaft. Achieve the correct gearing of cuts in an internal rotor with the corresponding ledges on a pin of a cranked shaft. Tighten fixing bolts with demanded effort.
  1. Further installation is made as it should be, the return to an order of dismantle of components. Pay attention to the next moments:

    1. Tighten all fixture with demanded effort;
    2. At installation of an oil tube of a maslookhladitel use do not forget to replace sealing elements;
    3. Check oil level in the engine, in case of need make the corresponding adjustment (see. Head Routine maintenance);
    4. Do not forget to replace a bolt of fastening of a cogwheel of a cranked shaft.

Engines of 1.7 l of DOHC

 PERFORMANCE ORDER

  1. If removed the reduktsionny valve, replace a sealing ring and establish the valve assembled in the block of cylinders, having tightened it with demanded effort.
  2. Grease pump rotors with pure impellent oil and establish them in the pump case, using previously the put marking.
  1. Before installation, accurately hooking a screw-driver, remove epiploons of the oil pump and a cranked shaft. Establish new epiploons sponges in the engine and press them aflush with the case by means of a suitable cylindrical opravka (see above Engines of 1.7 l of SOHC, item 2).
  1. Make sure of absoluteness of purity and dryness of interfaced surfaces of the oil pump and the block of cylinders. Check existence on the places of directing plugs. Remove all traces of hermetic from carving parts of bolts of fastening of the pump.
  1. Lay new consolidation in a flute round a case part of the pump in a cover and put a layer of suitable hermetic on an interfaced surface of a cover of the pump.
  1. Accurately establish a pump cover into place — try not to damage sponges of epiploons of a cranked shaft and a rotor shaft. Combine a cover with directing plugs and press it to the block, supervising the provision of epiploons.
  2. With special hermetic for fixing of carving connections grease carving parts of fixing bolts. Screw bolts and tighten them with demanded effort. Pay attention that the longest bolt should be rolled in the bottom left opening in a cover.
  3. Establish cogwheels 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).
  4. Establish the case pallet (see. Removal and installation of the pallet of a case).
  5. In end, fill in in the engine pure oil (see. Head Routine maintenance).

Engines of 2.0 l

See. Removal, service and installation of the oil pump.