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 installations of chains and asterisks of a drive of GRM, check of a condition of components (engines of 2.0 l)

Correctly to establish gazoraspredeleniye phases, special fixing Opel adaptations which can be made be required and is independent (see. Check and adjustment of phases of a gazoraspredeleniye (engines of 2.0 l). If any of these options is not available, charge performance of this operation to specialists of car-care center. If the problem has to be solved make-shifts, before removal of components mark their adjusting provision of chains on asterisks.


The scheme of laying of chains and positioning of asterisks of a drive of GRM on engines of 2.0 l

1 — the Asterisk of a cranked shaft
2 — the Asterisk of the bottom chain of TNVD

3 — the Asterisk of the top chain of TNVD
4 — a camshaft Asterisk

Removal

Top chain and asterisks

 PERFORMANCE ORDER

  1. Disconnect a negative wire from the battery and uncover the gas-distributing mechanism (see. Removal and installation of a cover of the gas-distributing mechanism).
  2. Establish the piston of the first cylinder in 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). Block a cranked shaft in this situation.
  3. For the purpose of providing a free access to a cover of an asterisk of TNVD 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). Also remove a belt of a drive of auxiliary units (see. Head Routine maintenance). Mark the provision 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 a support to an arm of a head of cylinders and three bolts of fastening to its mudguard. Prop up the right side of the engine a telezhechny jack, having lifted it as it is possible above, without loading thus excessively other support and lines of communication (hoses, cables, electroconducting plaits).
  4. The scheme of laying of chains of a drive of GRM on engines of 2.0 l — see an illustration the Scheme of laying of chains and positioning of asterisks of a drive of GRM on engines of 2.0 l.
  5. Remove both natyazhitel (see. Removal and installation of natyazhitel of chains of a drive of GRM (engines of 2.0 l)).
  6. Turn out the bottom bolt of fastening of a rack of a tension roller of an auxiliary driving belt and a bolt of an axis of its basis. Remove assembly of a natyazhitel from the engine.

For installation the new bolt of fastening of an asterisk of a camshaft and new bolts of fastening directing to the top chain is required.


Needlessly do not remove a rack from assembly of a natyazhitel, otherwise at installation it should be ground in.

  1. Turn out fixing bolts.
  1. Cнимите a cover of asterisks of TNVD from a cover of a gas-distributing chain of GRM.
  1. Special adaptations block TNVD and camshaft asterisks (see. Removal and installation of a belt of a drive of GRM). In the absence of near at hand special adaptations mark the adjusting provision of a chain on asterisks, and also the provision of asterisks concerning the landing flanges.
  1. Turn out fixing bolts.
  1. Cнимите an uspokoitel of the top chain from the top part of a head of cylinders.

Bolts of fastening of an uspokoitel of the top chain before removal should be heated up the thermal gun (the powerful hair dryer) for the purpose of a softening of hermetic fixing a carving and considerably will facilitate a task.

  1. Holding a camshaft a rozhkovy key for лыски, turn out a bolt of fastening of its asterisk. For the purpose of simplification of a problem of combination of labels at installation, tie up a chain to an asterisk.

If used fixing adaptations, remove them before weakening of a bolt of an asterisk, then establish again.

  1. If established, remove fixing TNVD a core, then turn out bolts of fastening of asterisks of TNVD to a flange. Remove TNVD asterisk for the top chain and a camshaft asterisk. Liberate an asterisk and remove the top chain.

Bottom chain of GRM and asterisk

 PERFORMANCE ORDER

  1. Remove the top chain of a drive of GRM and an asterisk (see above).
  2. Uncover chains of a drive of GRM (see. Removal and installation of a cover of a drive of GRM).
  3. Mark the provision of a chain on asterisks and asterisks on flanges.
  1. Separate TNVD asterisk from a flange and remove it together with an engine chain — try to remember the adjusting provision of components.
  1. Remove an asterisk from a pin of a cranked shaft.
  1. Take from a groove on a pin.

Check

 PERFORMANCE ORDER

  1. Survey teeths of asterisks on existence of traces of a vykrashivaniye, wear or other damages. In case of detection of defects at least to one of asterisks it is subject to replacement complete with a steam room to it on the corresponding chain. Together with asterisks it is replaced as well a chain.
  2. Check a condition of cheeks and rollers of chains. Degree of wear is defined by freedom of its stretching. The new chain practically should not be stretched. The worn-out chain is subject to replacement. The chain is subject to replacement also at performance of major maintenance of the engine, long use and emergence of an excessive noise background of functioning of a drive of GRM. Though in it also there is no emergency, ordinary the chain is replaced in a set with asterisks — attempt to save on small sometimes turns around the subsequent expensive repair. In case of absence of confidence of an assessment of a condition of components address for council to specialists of car-care center.
  3. Survey also uspokoitel of chains and boots of their natyazhitel. The damaged and worn-out components are subject to replacement.

Installation

Top chain and asterisks

 PERFORMANCE ORDER

  1. At installation of new components transfer on them adjusting labels from old details. Make sure that the cranked shaft is in the provision VMT of the end of a step of compression of the piston of the first cylinder and is blocked from a provorachivaniye.
  2. Plant a chain on an asterisk of a camshaft and establish assembly on the regular place.
  3. Establish an asterisk of TNVD and enter it into gearing with a chain.
  4. Achieve combination of the landing labels put in the course of dismantle and fix asterisks on camshaft and TNVD flanges — in case of need untie a camshaft asterisk from a chain.
  1. Achieve combination of a label of installation of phases of a gazoraspredeleniye of an asterisk of TNVD with an opening in a flange, then screw bolts of fastening of an asterisk, having tightened them in this stage only by hand.
  1. Screw the NEW bolt of fastening of an asterisk of a camshaft, having tightened while only by hand.
  1. Establish a natyazhitel of the bottom chain (see. Removal and installation of natyazhitel of chains of a drive of GRM (engines of 2.0 l).
  1. Establish into place an uspokoitel of the top chain (an adjusting ledge up). Screw NEW fixing bolts and tighten them with demanded effort.
  1. In the presence of special adaptations fix a camshaft, TNVD and a cranked shaft from a provorachivaniye, and also for confidence of correctness of provision of components. If adaptations are absent, track for combination of the labels put in the course of dismantle.
  2. At use of fixing adaptations make adjustment of the mechanism of a gazoraspredeleniye (see. Check and adjustment of phases of a gazoraspredeleniye (engines of 2.0 l), then take adaptations.
  3. If special adaptations were not used, achieve combination of the components of labels put in the course of dismantle, then tighten bolts of fastening of asterisks of TNVD with demanded effort. Tighten a bolt of fastening of an asterisk of a camshaft with effort for a stage 1, holding a camshaft from a provorachivaniye for лыски a rozhkovy key. Make sure that labels did not get off and hold on a bolt on corners, stages 2 and 3 — use a goniometric nozzle, or put with paint or a marker basic labels.
  4. Establish a natyazhitel of the top chain (see. Removal and installation of natyazhitel of chains of a drive of GRM (engines of 2.0 l).
  5. Make sure of absoluteness of purity and dryness of interfaced surfaces of a cover of asterisks of TNVD and a chain cover. If the cover was established with laying, do not forget to replace the last. Tighten fixing bolts with demanded effort. If laying was not, lay in a cover flute a hermetic pillow in thickness about 2 mm, then press a cover, screw fixing bolts and tighten them with demanded effort.
  6. Establish on the engine a natyazhitel of a belt of a drive of auxiliary units — track, that axial bolts and bolts of fastening of a rack were tightened with demanded effort. At rack replacement, or after the compelled dismantle old, grind in a rack back and forth motions, having seized a replaceable face head by a six-sided part of the basis. Having made sure of correctness of functioning of a rack, establish a driving belt (see. Head Routine maintenance).
  7. Establish the right support of a suspension bracket of the power unit on a head of cylinders, then lower the engine and clean a jack. Fix a support on a mudguard — track correctness of combination of the landing labels put in the course of dismantle and tighten fixing bolts with demanded effort.
  8. Establish a cover of the gas-distributing mechanism (see. Removal and installation of a cover of the gas-distributing mechanism).
  9. Establish a reception pipe of system of production of the fulfilled gases, the case of an air purifier and the sensor of provision of a cranked shaft (see. Head of the Power supply system and release). If adaptations for camshaft fixing were used, establish on a head of cylinders the vacuum pump (see. Head Brake system).

Bottom chain and asterisks

 PERFORMANCE ORDER

  1. If new components are established, transfer on them adjusting labels from old details.
  2. Establish a shponka of a cranked shaft, then plant on a pin an asterisk — track shponka hit in a shponochny groove.
  3. Make sure of correctness of installation of a flange of TNVD (cut in a flange should be combined with an opening in the pump case). The cranked shaft should be established in the provision VMT of the end of a step of compression of the piston of the first cylinder and is blocked.
  4. Achieving combination put in the course of dismantle of labels, enter a pump asterisk about gearing with a chain and establish assembly on the engine. Put on a chain an asterisk of a cranked shaft. Make sure that labels did not get off, and cut in a flange of the pump was combined with an opening in an asterisk.
  5. Establish a cover (see. Removal and installation of a cover of a drive of GRM). Establish the top chain of a drive of GRM, (see above).