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
   - General and major maintenance of the engine
      Removal of the power unit from the car - methods and precautionary measures
      Removal, separation and engine installation
      Alternative versions of schemes of regenerative repair of the engine
      Sequence of dismantling of the engine
      Dismantling of a head of cylinders
      Cleaning and check of a condition of a head of cylinders
      Assembly of a head of cylinders
      Removal of shatunno-piston assemblies
      Removal of a cranked shaft
      Cleaning and check of a condition of the block of cylinders
      Honingovaniye of mirrors of cylinders
      Check of a condition of components of shatunno-piston group
      Check of a condition of a cranked shaft
      Check of a condition of radical and shatunny bearings of a cranked shaft
      Engine assembly order
      Installation of piston rings
      Installation of a cranked shaft and check of working gaps of radical bearings
      Installation of shatunno-piston assemblies and check of size of working gaps in shatunny bearings of a cranked shaft
      Trial start and engine running in after major maintenance
+ 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




Check of a condition of components of shatunno-piston group

All engines

Previously shatunno-piston assemblies should be carefully cleared. Rings are necessary for removing from pistons.

Piston rings are subject to replacement without fail.


 PERFORMANCE ORDER

  1. By means of the special adaptation, or several щупов lezviyny type remove rings from pistons — try not to damage walls of the last casually.

Remember that rings are made of fragile metal and can break at a strong razzhimaniye, - be not wounded!

  1. Scratch out from the bottoms of pistons traces of coal deposits. After removal of the main layer of deposits smooth out a surface manually a wire brush or a piece of a fine-grained emery paper.

At all do not use for cleaning made of a soft material and pistons easily subject to an erosion wire nozzles to an electrodrill! After cleaning put on the bottoms of pistons marking should differ clearly.

  1. By means of the special adaptation clean flutes under installation of rings on pistons.

It is alternatively possible to use for this purpose a fragment of an old piston ring, however be careful — do not scratch a bottom and walls of a flute and do not cut fingers.

  1. Having removed the main deposits, wash out shatunny assemblies by solvent and carefully dry them, whenever possible with application of the compressed air. Check passableness of maslovozvratny openings in back walls of flutes under installation of piston rings, and also oil openings in the bottom heads of rods.

When using the compressed air do not forget to put on goggles!

  1. If walls of pistons and a mirror of cylinders are not damaged and excessively are not worn-out, and the block of the engine was not pierced and not replaced, need for replacement of pistons also disappears. Normal wear of pistons is shown in the form of vertical traces of development on a persistent surface and a small weak point of landing of the top kompressionny ring in the flute. Do not forget that replacement of piston rings is made without fail, regardless of their condition.
  2. Attentively examine each of pistons on existence of cracks in a skirt, round ledges under installation of piston fingers and around an arrangement of rings.
  3. Check persistent surfaces of a skirt of the piston on existence of scratches, the bottom — on existence of through openings and прогаров on edge. Presence of scratches on a skirt can be regarded as a sign of long overheats of the engine, or too early ignition of an air and fuel mix — check serviceability of functioning of system of cooling. Progara along the edges of the bottom are the detonation certificate. In any case, the reason of the revealed violation should be eliminated in order to avoid recurrence. As the possible reasons of formation of the listed defects leakages of soaked-up air, the wrong configuration of an air and fuel mix, violation of installation of a corner of an advancing of ignition, the wrong functioning of systems of ignition and EGR can act also.
  4. Dot corrosion of pistons in the form of cavities speaks about hit in chambers of combustion and/or a case of the engine of cooling liquid. Besides, take care, that the reason of internal leaks was eliminated.
  1. Estimate size of a lateral gap of landing of piston rings in the flutes for what enclose a new ring outside in the flute on the piston and shchupy lezviyny type measure a remaining gap. Repeat measurement in two-three points on flute perimeter. Watch to mixing kompressionny rings — top differs from the second. If the size of a gap exceeds admissible value (see. Specifications), pistons are subject to replacement.
  1. Define size of a landing gap of pistons in the cylinders for what measure diameters of the last (see. Cleaning and check of a condition of the block of cylinders) also subtract from them diameters of the corresponding pistons. Measurement of diameter of the piston is made on a persistent surface of a skirt at an angle 90 ° to an axis of a piston finger and on the set removal from the bottom. If the landing gap of the piston in the cylinder exceeds admissible value (see.), the block it is necessary to give specifications to a pro-point with a selection of new pistons and piston rings of repair diameter.
  1. Estimate correctness of landing of pistons on rods, having tried повращать components in opposite directions. Existence a little appreciable люфта speaks about excessive wear of a joint. For situation correction it is necessary to deliver shatunno-piston assemblies in a car-care center workshop where necessary regenerative repair and replacement of fingers will be made.

Petrol engines

On all petrol engines piston fingers are planted in the top heads of rods with a tightness and have floating landing in lugs of pistons in view of what performance of procedure of removal of pistons from rods (in case of such need) also should be entrusted to specialists of car-care center. In parallel, rods can be checked on existence of signs of a bend, twisting and other deformations with use of the special diagnostic equipment.

Needlessly it is not necessary to remove pistons from rods.

Diesel engines

 PERFORMANCE ORDER

  1. On diesel engines fingers have floating landing as well in rods and are fixed on pistons by means of lock rings. In case of need, having hooked a suitable screw-driver, remove lock rings and manually squeeze out a finger of assembly. Mark the removed finger by means of an adhesive tape on accessory to the shatunno-piston assembly and clean in a reliable place. Lock rings at assembly are subject to replacement without fail.
  1. Survey the top head of a rod and a piston finger on existence of signs of wear, and задиров other mechanical damages. By a micrometer measure diameter of a finger, compare result of measurement to requirements (see. Specifications), in case of need make replacement. If the finger or a rod is worn-out, both details, except engines of 1.7 l of DOHC where it is possible to replace the plug pressed in the top head in an individual order are subject to replacement — consult at firm car repair shop Opel.
  1. Rods (in the absence of mechanical damages) do not need replacement — visually estimate their existence of signs of obvious deformations, in the presence of suspicions on bend / twisting, address for the help to specialists of car-care center, or make replacement of defective components.

  2. Having estimated a condition of all components, prepare replaceable details. Replaceable pistons arrive on the market of spare parts complete with fingers and lock rings.

Lock rings can be got separately.

  1. On engines of 1.7 l of SOHC make assembly of pistons with rods so that the ledge on a rod from the bearing appeared from a flywheel, the arrow should indicate the bottom of the piston in the direction of a GRM belt of the engine.
  1. On engines of 1.7 l of DOHC the dot label on the bottom of the piston should appear from the same party, as a ledge on a rod.
  1. On engines of 2.0 l pistons with rods gather so that the arrow indicated the bottom of the piston aside, opposite to those from which the cast label on the bottom head of a rod settles down.

    1 — the Lock ring
    2 — the Piston finger
    3 — the Label in the form of an arrow
    4 — the Piston
    5 — the Rod
    6 — the Acting label on the bottom head

  1. Slightly grease piston fingers with pure impellent oil, and fix them pistons on the top heads of rods. Make sure of freedom of a povorachivaniye of the piston concerning a rod on a finger axis. Establish new lock rings (locks up) and make sure of reliability of their landing in reception flutes.

All engines

 PERFORMANCE ORDER

  1. Check rods on existence of cracks and other mechanical damages. Temporarily remove covers of the bottom heads, take loose leaves of old bearings, wipe beds in covers and heads and check them on existence of agnails, задиров and roughnesses. Having finished check, enclose loose leaves into place, establish covers on the bottom heads of rods, and by hand tighten fixing bolts.

If the engine is under repair for the purpose of elimination of knock of fingers, replace shatunny assemblies.