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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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Removal and installation of a natyazhitel of a belt and cogwheels of a drive of GRM (engines of 1.7 l)

Camshaft cogwheel

Removal

SOHC engines

 PERFORMANCE ORDER

  1. Remove a belt of a drive of GRM (see. Removal and installation of a belt of a drive of GRM).
  2. Uncover the gas-distributing mechanism (see. Removal and installation of a cover of the gas-distributing mechanism).
  3. Fix a camshaft from a provorachivaniye, holding it a rozhkovy key for six-sided section. Turn out a fixing bolt and remove a camshaft cogwheel.

DOHC engines

 PERFORMANCE ORDER

  1. Remove a belt of a drive of GRM, (see. Removal and installation of a belt of a drive of GRM). Before an otdavaniye of a bolt of fastening of a cogwheel, turn a cranked shaft on 60 ° back from situation VMT for the purpose of prevention of input of valves in contact to pistons.
  2. For the purpose of prevention turning a camshaft completely screw a bolt fixing a cogwheel.
  1. Turn out fixing bolt and remove a cogwheel from a camshaft pin — try to remember the adjusting provision of components. If the core blocking cogwheels has free landing, remove it from a camshaft and clean in a reliable place.

Installation

SOHC engines

The new bolt of fastening of a cogwheel of a camshaft is required!


 PERFORMANCE ORDER

  1. Establish a cogwheel, screw the NEW fixing bolt and tighten it, while only by hand.
  2. Establish a belt of a drive of GRM (see. Removal and installation of a belt of a drive of GRM).

DOHC engines

 PERFORMANCE ORDER

  1. Make sure of that the blocking core is on the regular place, then establish a cogwheel on a camshaft — track hit of a fixing core in a reciprocal opening.
  2. Screw a bolt of fastening of a cogwheel, then achieve combination of adjusting openings in a wheel and a head and screw bolt М6. Tighten a bolt of fastening of a cogwheel with demanded effort. Turn a cranked shaft on 60 ° clockwise before reduction risks on a cogwheel of a cranked shaft in situation «at 12 o'clock» and its combination with a cast label on a cover of the oil pump.
  3. Establish a belt of a drive of GRM (see. Removal and installation of a belt of a drive of GRM).

TNVD cogwheel

Removal

SOHC engines

 PERFORMANCE ORDER

  1. Remove a belt of a drive of GRM (see. Removal and installation of a belt of a drive of GRM).
  1. Insert the KM-6011 adaptation into an opening for flange fixing for the purpose of prevention of a provorachivaniye of a cogwheel of TNVD. In the absence of near at hand special adaptation use a core in diameter of 9.5 mm and length of 75 mm.
  1. Turn out three fixing bolts and remove a cogwheel.

DOHC engines

 PERFORMANCE ORDER

  1. Remove a belt of a drive of GRM (see. Removal and installation of a belt of a drive of GRM).

  2. For the purpose of prevention of a provorachivaniye of a shaft of TNVD against the stop screw bolt М8 fixing a cogwheel.

In case of need the cogwheel can be blocked by a different way: by means of the adaptation in the form of a fork with screwed on the ends equipped with fixing nuts bolts.

  1. Release and turn out a nut of fastening of a cogwheel.
  1. Remove a cogwheel from TNVD shaft — try to remember the adjusting provision of components. If the shponka has weak landing in a pin of a shaft of TNVD, remove it and clean in a reliable place.

The cogwheel has konusny landing on a pin of a shaft and in certain cases for its removal the stripper can be demanded.

Installation

SOHC engines

 PERFORMANCE ORDER

  1. Plant a cogwheel on a pump shaft — track cut combination on an asterisk with cut on a flange and an opening for input of blocking core KM-6011.
  2. Screw bolts of fastening of a cogwheel and tighten them, while only by hand.
  3. Establish a belt of a drive of GRM (see. Removal and installation of a belt of a drive of GRM).

DOHC engines

 PERFORMANCE ORDER

  1. Make sure of correctness of landing of a shponka in a shaft pin, then establish a cogwheel — track shponka hit in a shponochny groove.
  2. Screw a fixing nut and tighten it with demanded effort, having blocked a cogwheel from a provorachivaniye by a vvorachivaniye of fixing bolt М8.
  3. If for fixing of an asterisk the bifurcate adaptation was used, achieve combination of adjusting openings and screw bolt М8.
  4. Establish a belt of a drive of GRM (see. Removal and installation of a belt of a drive of GRM).

Cogwheel of a cranked shaft

Removal

SOHC and DOHC engines

 PERFORMANCE ORDER

  1. Remove a pulley of a cranked shaft (see. Removal and installation of a pulley of a cranked shaft).
  2. 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). Weaken a bolt of fastening of a cogwheel.
  3. Remove a belt of a drive of GRM (see. Removal and installation of a belt of a drive of GRM).
  4. Turn out a fixing bolt with a washer and remove a cogwheel — if the wheel does not give in, use a suitable stripper. At free landing of a shponka in a shaft pin, take it and clean in a reliable place.
  5. On DOHC engines remove from a pin of a cranked shaft a flange pro-rate, - try to remember the adjusting provision of components.

Installation

SOHC and DOHC engines

 PERFORMANCE ORDER

  1. Installation is made as it should be, the return to an order of dismantle of components — track correctness of landing of a shponka in a pin of a shaft and correctness of combination with it shponochny groove of a nave of a cogwheel.

On DOHC engines the flange pro-rate is established by acting party outside.

Cogwheel of the oil pump (DOHC engines)

Removal

 PERFORMANCE ORDER

  1. Remove a belt of a drive of GRM (see. Removal and installation of a belt of a drive of GRM).
  1. Having blocked a cogwheel of the oil pump from a provorachivaniye by means of a replaceable face head with the extension piece, put on on one of bolts of fastening of a cover of the oil pump, turn out the central bolt of fastening of a cogwheel.
  1. Remove a cogwheel from a shaft of the oil pump, try to remember the adjusting provision of components.

Installation

 PERFORMANCE ORDER

  1. Establish a cogwheel — track correctness of combination of a shponochny groove with a shponka. Tighten a nut with demanded effort, blocking a cogwheel from a provorachivaniye an asterisk in the way used at removal.
  2. Establish a belt of a drive of GRM (see. Removal and installation of a belt of a drive of GRM).

Natyazhitel assembled

Removal

SOHC engines

 PERFORMANCE ORDER

  1. Remove a belt of a drive of GRM (see. Removal and installation of a belt of a drive of GRM).
  2. Turn out a fixing bolt and remove assembly a natyazhitel from the engine.

DOHC engines

 PERFORMANCE ORDER

  1. Remove a belt of a drive of GRM (see. Removal and installation of a belt of a drive of GRM).

  1. Carefully release a tension spring, then turn out fixing bolts and remove assembly of a natyazhitel.

Installation

SOHC and DOHC engines

 PERFORMANCE ORDER

  1. Installation is made as it should be, the return to an order of dismantle of components. On SOHC engines track combination of the directing lever (1) with reciprocal cuts in a cover of the oil pump (2).

On SOHC engines the final tightening of a fixing bolt of a natyazhitel is made after installation of a gas-distributing belt.

Intermediate roller

Removal

SOHC and DOHC engines

 PERFORMANCE ORDER

  1. Remove a GRM belt (see. Removal and installation of a belt of a drive of GRM).
  1. Turn out a bolt of fastening and remove a roller from the engine.



On SOHC engines the intermediate roller acts in film together with a pro-rate.

Installation

SOHC and DOHC engines

Installation is made as it should be, the return to an order of dismantle of components. Track, that the fixture was tightened with demanded effort.