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

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Installation of a cranked shaft and check of working gaps of radical bearings

It is recommended to replace loose leaves of radical bearings regardless of their condition.


 PERFORMANCE ORDER

  1. Installation of a cranked shaft is the first step of procedure actually engine assemblies. It is meant that at this stage the cranked shaft and the engine block already are properly cleaned, checked and subjected to necessary regenerative repair.
  2. Overturn the engine upside down.
  3. Give fixing bolts, remove covers of radical bearings and spread out them on a workbench as installation on the engine.
  4. If yet did not do it, take from the beds in the block and covers old loose leaves of radical bearings. Wipe beds pure неворсящейся rags — they should be irreproachably pure.

Check of working gaps of radical bearings

Try not to touch surfaces of new loose leaves barehanded in order to avoid undesirable contact of bearings to traces of oil always present on fingers and chemically aggressive substances.


 PERFORMANCE ORDER

  1. Wipe backs of new loose leaves of radical bearings and enclose the halves equipped with an oil flute in the beds in the block (if old loose leaves are used, track that they kept within strictly on the former places). The remained halves of loose leaves enclose in the corresponding covers of bearings. Track, that uvulas of loose leaves entered into reciprocal landing grooves in beds of the block and covers. Oil openings in the block should appear correctly combined with openings in loose leaves.

By no means make attempts to begin to knock the loose leaf resistant to installation in the bed a hammer. Grease with nothing bearings at this stage!

  1. Remember that the combined loose leaf equipped with persistent half rings keeps within the top bed of the third radical bearing on all engines, except a diesel engine of 1.7 l of DOHC where the second bearing is persistent, and in the latter case half rings are delivered as separate components and should keep within special cuts in bearing beds maslosgonny flutes outside.
  1. Wipe surfaces of bearings in the block and radical necks of a cranked shaft pure неворсящейся rags.
  2. Check passableness of oil openings of a shaft, in case of need clean them. Any containing in маслотоках extraneous particles, eventually, inevitably get to bearings.
  3. Carefully wiped cranked shaft accurately lay in radical bearings of the block (do not use any greasing).
  4. Before establishing a shaft finally, it is necessary to check sizes of working gaps in its radical bearings.
  1. Cut the calibrated plastic wire from a measuring set of Plastigage pieces, in the length width of loose leaves are slightly shorter, and lay on one slice of a wire along each of radical necks of a shaft, parallel to their axis.
  1. Wipe surfaces of loose leaves in covers and establish the last on the regular places (track correctness of orientation of marking). Try not to shift laid along shaft necks pieces of the calibrated wire. Slightly oil a carving of fixing bolts and screw them, having fixed covers.
  2. Moving on a spiral from the center outside, in three stages tighten bolts of fastening of covers with demanded effort (see. The specification) — do not allow a shaft provorachivaniye in the course of a fixture tightening!
  3. Turn out bolts and carefully remove covers of radical bearings. Combine the removed covers as an arrangement them on the engine. Try not to damage the flattened-out calibrated wire and do not turn a shaft. If any of covers does not give in to removal, for release it is accurate обстучите its hammer with soft the brisk.
  1. Till the width of the flattened-out threads measured on a scale, put on packing of a set of Plastigage, define size of working gaps of bearings. Compare results of measurements to requirements (see. Specifications).
  1. If the size of a gap leaves out of admissible limits, probably, loose leaves not that standard size (were established see. Check of a condition of radical and shatunny bearings of a cranked shaft). Before looking for new loose leaves, make sure that under enclosed at this stage extraneous particles did not get. If the calibrated wire is flattened out since one end more than from another, it testifies to existence of a konusnost of a neck (see. Check of a condition of a cranked shaft).
  2. Carefully remove the flattened-out calibrated wire from necks, having scratched out all its traces any not too strong tool (for example, edge of an old credit card). As a last resort, it is possible to use own nail — the main thing that on a surface of necks / loose leaves did not remain scratches and задиров.

Final installation of a cranked shaft

 PERFORMANCE ORDER

  1. Carefully take a cranked shaft from the engine.
  2. Wipe surfaces of bearings in the block and evenly grease them with a thin layer of molibdensoderzhashchy or assembly impellent greasing. Do not forget to grease also persistent surfaces also.

Try not to allow greasing hits on backs of loose leaves!

  1. Make sure of absoluteness of purity of necks of a cranked shaft, then grease (the same greasing or pure impellent oil) surfaces of pins contacting to epiploons. Lay a shaft on the regular place. Wipe and grease loose leaves in covers of bearings. Track, that persistent loose leaves were laid in a bed of the corresponding bearings in the block (see above Check of working gaps of radical bearings, item 2).
  1. Establish covers of bearings on the engine. On all engines, except a diesel engine of 1.7 l of DOHC, covers of the 1st and 4th bearings at first are established (the first the bearing closest to a drive of GRM) is — track that the marking put on covers was read at a view of the engine behind. In a cover of the 5th (back) bearing before installation it is necessary to fill lateral flutes with type No. 90485251 hermetic. On diesel engines of 1.7 l of DOHC (without the fifth cover), however, interfaced surfaces of the first cover before installation it is necessary to grease the same order slightly the hermetic, the shooters beaten out on covers should specify towards GRM drive.
  1. Slightly grease a carving part and the bottom surfaces of heads of fixing bolts with pure impellent oil, then screw and by hand tighten bolts.
  1. Moving on a diagonal from the center to edges, evenly tighten all bolts with effort of the first stage, then, in the same order hold on them on corners of stages 2 and 3 (see. Specifications) — use a goniometric nozzle, or put with paint or a marker basic labels. Having held on bolts, fill a little more hermetic in flutes of a back cover while it will not begin to be squeezed out of them — surpluses wipe pure rags.
  1. Knock on end faces of pins of a shaft with a hammer through a brass or lead drift for the purpose of alignment of persistent surfaces and a shaft usadka before a final tightening of fixture.
  2. Several times turn a cranked shaft manually, checking freedom of its rotation.
  3. In summary with the help щупа lezviyny type or a tsiferblatny measuring instrument define size axial люфта in bulk (see. Removal of a cranked shaft). If persistent surfaces of a shaft are not worn-out and are not damaged, and bearings are replaced new, the size люфта should not fall outside the limits an admissible range.
  4. Establish shatunno-piston assemblies (see. Installation of shatunno-piston assemblies and check of size of working gaps in shatunny bearings of a cranked shaft).
  5. At the corresponding complete set plant in a back pin of a cranked shaft the new directing plug of primary shaft of a transmission.
  6. On diesel engines of 1.7 l of DOHC make replacement of a forward epiploon, make sure of absoluteness of purity and dryness of interfaced surfaces of its case and the block of cylinders. Grease interfaced surfaces with hermetic, check existence on the places of directing plugs and press the epiploon case to the block. Having greased with hermetic a carving part of fixing bolts, screw them in the openings and tighten with demanded effort. Establish a back epiploon.
  7. On other engines installation of new epiploons of a cranked shaft is made according to the instructions stated in appropriate sections (see. Procedures of repair of petrol SOHC engines without their extraction from the car, Procedure of repair of petrol DOHC engines without their extraction from the car or Procedure of repair of diesel engines of 1.7 l and 2.0 l without their extraction from the car).
  8. At the corresponding complete set establish on covers of radical bearings a cast bridge sheaf, screw and tighten with demanded effort bolts of its fastening.
  9. Further assembly of the engine is made in compliance by the instructions provided in appropriate sections (see. Procedures of repair of petrol SOHC engines without their extraction from the car, Procedure of repair of petrol DOHC engines without their extraction from the car or Procedure of repair of diesel engines of 1.7 l and 2.0 l without their extraction from the car).