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 cover of the gas-distributing mechanism

Removal

Engines of 1.7 l of SOHC

 PERFORMANCE ORDER

  1. Remove the air purifier case assembled with air lines and a measuring instrument of a consumption of air (see. Head of the Power supply system and release).
  1. Weaken collars and disconnect hoses of system of ventilation of the case, brought to the forward and back parties of a cover — it is necessary to unscrew two bolts of fastening of conducting to a camshaft cover, having raised conducting for receiving access to a back hose of ventilation of a case.
  1. Remove a pulley of a cranked shaft. Turn out fixing bolts and, uncover the gas-distributing mechanism together with sealing laying.

Engines of 1.7 l of DOHC

 PERFORMANCE ORDER

  1. Remove an air purifier and inlet air lines assembled with a weight measuring instrument air (see. Head of the Power supply system and release).
  2. Remove from a cover of the gas-distributing mechanism the control unit the engine (ECM) (see. Head of the Power supply system and release).
  3. Disconnect electroconducting, give fixing screws / nut and remove an arm of fastening of ECM.
  4. Turn out a fixing bolt, disconnect electroconducting and remove an elevating eye of the engine from a back right part of a head of cylinders. Weaken a bolt of fastening of the left back elevating eye.
  1. Weaken shtutserny sockets of fastening of fuel tubes to TNVD.

Access to shtutserny connections is limited — originators of the real Management consider necessary to turn out a bolt of fastening of the case of a filter / maslookhladitel and to take spongy filling from space between TNVD and the filter case.

  1. Disconnect lines of supply of fuel from nozzles.
  2. Give fixing bolts and remove external consolidations of nozzles.
  3. Turn out a bolt of fastening of a route trench of electroconducting to a back part of a head of cylinders. Release two clamps and remove a trench.
  4. Give bolts of fastening of the top cover of a drive of GRM to a drive of the klapanny mechanism.
  5. Turn out fixing bolts and uncover the gas-distributing mechanism together with sealing laying.
  6. Check a condition of sealing laying, in case of need make its replacement.

Engines of 2.0 l

 PERFORMANCE ORDER

  1. Turn out fixing screws and remove from a cover of the gas-distributing mechanism the top plastic cover.
  2. Release fixing collars and disconnect a hose of system of ventilation of a case from a back part of a cover. On the Zafira models remove consolidation of an impellent compartment and a cover of the fairing established before a windscreen.
  1. On engines with a low-pressure head turbo-supercharging (X20DTL or to Y20DTL) weaken collars of fastening of a metal tube to assembly of a turbokompressor and a rubber sleeve to the pipeline, turn out two fixing bolts and remove from the engine air line assembly together with established between a tube and the compressor a sealing ring. On engines with a high-pressure head turbo-supercharging (Y20DTH) release clamps, turn out bolts of fastening of arms and remove the air sleeve laid between turbokompressory and interkulery.
  1. On all models liberate electroconducting of candles of an incandescence from clamps on the back party of a cover. Turn out a bolt of fastening of a route trench of electroconducting of the inlet pipeline to a cover. Disconnect brought to the right side of a cover a vacuum hose.
  1. Turn out bolts of fastening of a cover and remove them together with sealing washers. Having raised a cover, remove it together with sealing laying. Check a condition of sealing laying and the washers, the failed elements replace.

Installation

Engines of 1.7 l of SOHC

 PERFORMANCE ORDER

  1. Make sure that interfaced surfaces of a cover and the case are absolutely pure and dry. Accurately lay sealing laying on a cover.
  1. Press a cover to the case — track, that sealing laying did not move. Screw fixing bolts and tighten them with demanded effort.
  2. Attach hoses of system of ventilation of a case and fix them collars.
  3. Establish inlet air lines and the air purifier case.

Engines of 1.7 l of DOHC

 PERFORMANCE ORDER

  1. Make sure of absoluteness of purity and dryness of interfaced surfaces, lay in a cover flute sealing laying. Check a condition of a sealing ring in the lower part of a cover, in case of need make replacement.
  1. Grease interfaced surfaces with hermetic, having tracked, that it did not get to an oil opening in the right back part of a final camshaft. Consolidations of nozzles are marked by "UPPER" and «OUTSIDE» inscriptions.


  1. Accurately lay a cover on the regular place, having tracked, that sealing laying was not displaced. Establish the top section of a cover of a drive of GRM. Screw bolts of fastening of a cover of the gas-distributing mechanism and tighten them with demanded effort.
  1. Further installation is made as it should be the return to an order of removal of components — pay attention to the next moments:
    1. All bolts should be tightened strictly with demanded effort;
    2. External consolidations of nozzles are marked by "UPPER" inscriptions (top) and «OUTSIDE» (external) — establish consolidations, having tracked, that they appeared put on cones of nozzles;
    3. After engine start attentively examine it about identification of signs of development of leaks.

Engines of 2.0 l

 PERFORMANCE ORDER

  1. Make sure of absoluteness of purity and dryness of interfaced surfaces, lay in a cover flute sealing laying.
  1. Put on sealing washers bolts of fastening of a cover. Establish bolts on a cover, having tracked fixing by the bottom coat hanger of their heads of sealing washers.
  1. Grease with hermetic semicircular cut in the right part of an interfaced surface of a head of cylinders and from both parties of a cover of the left bearing.


  1. Accurately lay a cover into place, screw and by hand tighten all fixing bolts.
  2. Tighten all fixing bolts with demanded effort.
  3. Connect to the unions vacuum hoses, fix in clamps electroconducting. Connect to a back part of a cover PCV hose.
  4. On models with a low-pressure head turbo-supercharging establish an inlet air line and an air tube — do not forget to replace a sealing ring. Track reliability of a tightening of collars and clamps. On models with a high-pressure head turbo-supercharging establish into place a sleeve connecting a turbokompressor to an interkuler. Track reliability of a tightening of fixture.
  5. On all models establish a plastic cover and reliably tighten bolts of its fastening. On the Zafira models establish into place consolidation of an impellent compartment and the panel of a forward fairing.