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 shatunno-piston assemblies and check of size of working gaps in shatunny bearings of a cranked shaft

At performance of major maintenance of the engine replacement of piston wheels and loose leaves of shatunny bearings is recommended to be made regardless of their condition.

Preparation

Before installation of shatunno-piston assemblies of a wall of cylinders should be carefully wiped, from their upper edges traces of step wear are completely removed and the facet is removed. It is meant that the cranked shaft is already established on the regular place in the block (see. Installation of a cranked shaft and check of working gaps of radical bearings).

 PERFORMANCE ORDER

  1. Uncover the bottom head of shatunny assembly of the first cylinder (make sure available the marking factory or put in the course of dismantle). Take from a head of a rod and its cover loose leaves of the old bearing and carefully wipe their beds pure неворсящейся rags.

Check of a working gap of the shatunny bearing


Scheme of the correct arrangement of locks of piston rings of petrol engines


Scheme of the correct arrangement of locks of piston rings of diesel engines of 1.7 l of DOHC and 2.0 l


Scheme of the correct arrangement of locks of piston rings of diesel engines of 1.7 l of SOHC



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 a back of the new top loose leaf and put it to bed the bearing in a rod head. Track, that the directing uvula of the loose leaf got to a reciprocal flute in a rod. At all застукивайте the loose leaf in a bed a hammer. Grease with nothing the bearing at this stage.
  2. Wipe a back of the second loose leaf and lay it in a cover of the bottom head of a rod. Again track, that the uvula got to a reciprocal groove. Do not apply some any greasing — extremely important that interfaced surfaces of the bearing and a rod remained absolutely pure and dry.
  3. Arrange piston rings locks, as shown (see illustrations the Scheme of the correct arrangement of locks of piston rings of petrol engines, the Scheme of the correct arrangement of locks of piston rings of diesel engines of 1.7 l of DOHC and 2.0 l or the Scheme of the correct arrangement of locks of piston rings of diesel engines of 1.7 l of SOHC).
  4. Pull on bolts of fastening of a cover of the bearing pieces of a rubber hose suitable on diameter.
  5. Grease the piston and piston rings with pure impellent oil. Put on the piston a tool opravka for a staving of rings. Leave a skirt of the piston acting of a tool opravka approximately on 6.4 mm for free filling it in the cylinder. Rings should be pressed out aflush with a forming surface of the piston.
  6. Turn a cranked shaft so that the neck of the first crank appeared in situation NMT. Grease with impellent oil a mirror of the first cylinder.
  7. Having developed assembly by labels in the necessary party (see. Removal of shatunno-piston assemblies), accurately fill a rod in the first cylinder of the block. Get in the cylinder a piston skirt, having densely pressed to a block surface bottom edge of an opravka of the tool for a staving of rings.
  8. To Obstuchita the upper edge of an opravka for a guarantee of density of its pressing to the block on all perimeter of bottom edge.
  1. Accurately tapping on the piston bottom with the wooden handle of a hammer, enter the piston in the cylinder, at the same time directing the bottom head of a rod on a neck of the corresponding crank of a cranked shaft. Piston rings can unexpectedly jump out from under a tool opravka therefore constantly watch pressing density to its block. Do not hurry up, at emergence of the slightest resistance immediately stop a piston zastukivaniye. Find out the reason of jamming and eliminate it.

At all do not undertake attempts to push the piston in the cylinder force — it can lead to its mechanical damage or destruction of piston rings!

  1. After introduction of shatunno-piston assembly in the engine, before final installation of a cover of the bottom head of a rod, it is necessary to check a working gap of the shatunny bearing of a cranked shaft.
  1. Cut off a piece of the calibrated plastic wire from a measuring set of Plastigage, in the length width of the loose leaf of the shatunny bearing are slightly shorter, and lay it along the first shatunny neck of a cranked shaft, parallel to an axis of the last.
  1. Wipe a bearing surface in a cover of the bottom head of a rod and establish a cover on a rod. Track, that the label on a cover appeared is turned in the same party, as a label on a rod.
  2. Slightly grease the bottom end faces of fixing nuts with pure impellent oil, screw them and in three stages tighten with demanded effort.

In case of need in order to avoid key jamming, use a thin-walled face head. At emergence of signs of jamming of a key between a nut and a rod, slightly raise a head and continue a tightening. Do not allow a provorachivaniye of a cranked shaft in the course of performance of all procedure.

  1. Give nuts and carefully uncover a rod. Try not to damage the flattened-out piece of the calibrated wire.
  1. Till width of the flattened-out wire measured on a scale, printed on packing to Plastigage set, define size of a working gap in the bearing. Compare result of measurement to requirements (see. Specifications).
  1. If the size of a gap falls outside the limits an admissible range before looking for loose leaves of other standard size, check, whether got under backs enclosed in a bed in a rod and a cover of loose leaves dirt / oil. Once again measure diameter of a neck of a shaft. Rasplyushchivaniye of a wire since one end more than from another speaks about existence of a konusnost of a neck.

Final installation of shatunno-piston assembly

 PERFORMANCE ORDER

  1. Carefully scratch out a nail or edge of an old credit card all traces of the calibrated wire from a neck and/or bearing surface.
  2. Make sure of absoluteness of purity of both bearing surfaces, then evenly grease them with a thin layer of molibdensoderzhashchy or assembly impellent greasing. For ensuring access to a surface of the top loose leaf it is necessary to push a little the piston in the cylinder — do not forget to put on bolts of a cover of a rod protective hoses in order to avoid damage of a surface of a neck of a shaft. Try not to allow vyskakivaniye from the cylinder of piston rings.
  3. Return a rod into place, having carefully put on it the bottom head a neck of the crank, remove from bolts protective hoses, establish a cover, and in three stages tighten fixing bolts / nuts with demanded effort (see. Specifications).

Track correctness of combination of labels on a cover of a rod and its bottom head.

  1. Repeat all procedure for the remained shatunno-piston assemblies.
  2. Do not lose sight of the following important points:
    1. Watch that on backs of loose leaves and their bed in rods and covers dirt did not get;
    2. Watch, that each assembly was established in the cylinder (even in case of installation of new components as gaps of piston rings were adjusted to concrete cylinders);
    3. Pistons should settle down in marking in the demanded direction (see. Removal of shatunno-piston assemblies);
    4. Do not forget to grease before installation of assemblies by impellent oil of a mirror of cylinders;
    5. Do not forget to grease bearings (after check of working gaps in the last) before final installation of covers.
  3. Having finished installation of shatunno-piston assemblies, check freedom of rotation of a cranked shaft, having turned it several times manually.
  4. In summary it is necessary to check once again axial люфт a cranked shaft (see. Removal of a cranked shaft).
  5. Compare results of measurement axial люфта to requirements (see. Specifications). If люфт was in norm before dismantling of the engine and the old shatunno-piston assemblies are used, no surprises should be. In case of a size exit люфта out of admissible limits after replacement of rods, the last are necessary for removing from the engine and to give to a car-care center workshop for the corresponding machining.