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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Check and adjustment of phases of a gazoraspredeleniye (engines of 2.0 l)


The blocking adaptations necessary for performance of check and adjustment of phases of a gazoraspredeleniye

And — the Core of fixing of a cranked shaft (an equivalent of the special KM-929 tool)
In — the Core of fixing of a flange of TNVD (an equivalent of the special KM-927 tool)

With — the Adaptation for camshaft blocking (an equivalent of the special KM-932 tool)


Dimensional characteristics of the adaptation for blocking of a cranked shaft (mm)


Dimensional characteristics of the adaptation for blocking of a flange of TNVD (mm)

For carrying out these checks the following special Opel tools (or their equivalents) be required:

  1. the adaptation for blocking of a camshaft (KM-932)
  2. the adaptation for blocking of a flange of TNVD (KM-927)
  3. the adaptation for blocking of a cranked shaft (KM-929)
  4. lever of an asterisk of a camshaft (KM-933).

In case of need the suitable tool can be made by own strengths of the amateur mechanic according to the presented dimensional characteristics.

By means of the adaptation for camshaft blocking the groove in a pin of a camshaft is fixed parallel to an interfaced surface of a head of cylinders.


 PERFORMANCE ORDER

  1. Disconnect a negative wire from the battery. Remove a belt of a drive of auxiliary units (see. Head Routine maintenance). Turn out the bottom bolt of fastening of a rack of a tension roller and an axial bolt of the basis of a natyazhitel. Remove assembly of a natyazhitel from the engine.

Do not remove a rack from assembly of a natyazhitel, otherwise there will be a need for polishing of working surfaces.

  1. Remove the vacuum pump of the servo-driver of the brake amplifier of brakes (see. Head Brake system).
  2. For the purpose of simplification of access to a cover of an asterisk of TNVD and to the pump execute the following preparatory operations:
    1. 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).
    2. Mark the provision of an arm 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 the right support of the engine to an arm of a head and three bolts of fastening of a support of the engine to a mudguard. Prop up the right side of the engine a telezhechny jack. Lift the engine as far as possible above, without overloading, however, the remained support and lines of communication (tubes, hoses, electroconducting plaits).
  3. Uncover the gas-distributing mechanism (see. Removal and installation of a cover of the gas-distributing mechanism) also bring the piston of the first 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).
  4. Remove the sensor of provision of a cranked shaft (CKP) (see. Head of the Power supply system and release).
  5. Turn out fixing bolts and uncover TNVD asterisks a cover of a chain of a drive of GRM.
  1. Make sure that risk on a pulley of a cranked shaft it was combined with an adjusting label on a cover of a gas-distributing chain and pass in an opening under CKP sensor installation fixing core, having entered it into gearing with cut in a shaft body.


  1. Having blocked a cranked shaft, pass fixing core through an opening in a flange of TNVD and push its end in an opening in the pump.
  1. Then fill the adaptation for camshaft blocking in a groove in a pin of the last.
  1. If all fixing adaptations freely on the regular places, therefore, phases of a gazoraspredeleniye become correctly established and adjustment is not required — pass to performance of procedures (cm lower than subitem 22 — 27) . If at least one tool it is not possible to establish properly, make the corresponding adjustment (see further) — pay attention to need of replacement of a bolt of an asterisk of a cranked shaft and a sealing ring of a bolt of a natyazhitel.
  2. Take the adaptations blocking a camshaft and a flange of TNVD, turn out bolts of fastening of an arm of the right support to a head of cylinders.
  3. Take away a cap of a natyazhitel of the top chain of GRM from a back part of a head of cylinders and remove a plunzher — try to remember his adjusting situation. Remove a sealing ring and will throw out it — at installation the ring is subject to replacement without fail.
  4. Holding a camshaft for лыски a rozhkovy key, release and turn out a bolt of fastening of an asterisk. Screw a new bolt and tighten it while only by hand.
  5. Weaken bolts of fastening of an asterisk of TNVD to a pump flange.
  1. Having blocked a cranked shaft from a provorachivaniye, make sure that VMT label on an asterisk of the top chain of GRM is combined with an opening for control of phases of a gazoraspredeleniye in TNVD flange. Pass fixing core and tighten bolts of fastening of an asterisk with demanded effort.
  1. Push the end of a core of blocking of a camshaft a groove at an end face of a pin of the last, having combined directing pin with an opening.
  2. Having established fixing adaptations on the regular places, establish the lever of an asterisk of a camshaft — in the absence of the lever, use two bolts, having passed them in asterisk openings. Then, operating as with the lever a big screw-driver, block an asterisk from a provorachivaniye. Ask the assistant to hold the gas-distributing chain tense the top party — it is necessary to make small effort an asterisk, having left that all weak point of a chain on the party of a natyazhitel.
  3. Having pulled the top chain, make sure that fixing TNVD the core moves in the opening with insignificant resistance. At a zakusyvaniye of a core ask the assistant to weaken pressure upon an asterisk — if the core moves excessively freely, the effort should be increased a little.
  1. Having pulled demanded image the top chain, fix a camshaft a rozhkovy key and tighten a bolt of fastening of its asterisk with effort of the 1st stage. Check freedom of a course of fixing TNVD of a core, then hold on a bolt of fastening of an asterisk on a corner, at first the 2nd, then the 3rd stages of a tightening — use a goniometric prefix to a vorotka, or put with a marker basic labels.
  1. Remove all blocking adaptations and establish a new sealing ring on a cap of a natyazhitel of the top chain of a drive of GRM. Fill a plunzher in a head of cylinders (the deaf end to a chain), establish a cap and tighten it with demanded effort.

At installation of a new natyazhitel weaken it, completely, before click having drowned the central core of a cap — now the core of a natyazhitel should freely утапливаться and smoothly come back to a starting position.

  1. Turn a cranked shaft on two full two turns (720 °) in the normal direction (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), for the purpose of reduction of the piston of the first cylinder in VMT of the end of a step of compression — make sure of possibility of free installation of all fixing adaptations.
  1. Make sure of absoluteness of purity and dryness of interfaced surfaces of covers of an asterisk of TNVD and GRM drive. If the cover was initially established on laying, replace the last. Tighten bolts of fastening of a cover with demanded effort. If laying was not provided, impose on an interfaced surface of a cover a hermetic pillow in thickness about 2 mm, establish a cover and tighten with demanded effort bolts of its fastening.
  1. Establish on the engine a natyazhitel of a belt of a drive of auxiliary units, having tightened both bolts with demanded effort. If strut acted in film from assembly of a natyazhitel, grind in it several consecutive back and forth motions, having established a head on a six-sided part of the basis. If the rack functions regularly, establish a belt of a drive of auxiliary units (see. Head Routine maintenance).
  2. If removed, establish on a head of cylinders an arm of the right support of a suspension bracket of the power unit and clean propping-up engine a jack. Establish the right support on a mudguard and combine it with the labels put in the course of dismantle on an arm of a head of cylinders. Screw fixing bolts and tighten them with demanded effort. Establish a cover of the gas-distributing mechanism (see. Removal and installation of a cover of the gas-distributing mechanism).
  3. Establish into place a reception pipe of system of production of the fulfilled gases and the air purifier case (see. Head of the Power supply system and release).
  4. Establish on a head of cylinders the vacuum pump of the servo-driver of the brake amplifier (see. Head Brake system).
  5. Establish on the block of cylinders the CKP sensor (see. Head of the Power supply system and release) also connect a negative wire to the battery.