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

http://flashlottos24.ru/


Removal, separation and engine installation

Removal

It is worth to remember that fuel is inflammable liquid in the highest measure! At work with components of a power supply system observe all taken measures of fire safety. Do not smoke, do not come nearer to a venue of works with open fire or unprotected by the lamp shade carrying. Do not make system service in the room equipped with working at natural gas and heating devices equipped with a control torch (such as водогреи and dryers for clothes). Do not forget that fuel is among the cancerogenic substances promoting development of a cancer. Try not to allow fuel hits on open sites of a body — use protective rubber gloves, at casual unforeseen contact carefully wash out hands warm water with soap. Immediately collect the spilled fuel and do not put the rags impregnated with a fuels and lubricants near sources of open fire. Remember that the power supply system equipped with injection of fuel of models constantly is under pressure. Before starting a detachment of fuel lines, dump residual pressure in system (for more details see. Head of the Power supply system and release). At service of components of a power supply system put on goggles. Constantly hold near at hand the class B fire extinguisher!


The path of central air of air also constantly is under pressure, and therefore before a rassoyedineniye of refrigerator lines it is necessary to make a system discharge in the conditions of a specialized workshop.


The standard complete set of all modern cars includes the SRS system which main components are safety cushions. Before starting performance of any works near an arrangement of sensors of the directed overloads of SRS, around a steering column or the dashboard, without fail disconnect system in order to avoid the casual operation of safety cushions fraught with receiving serious traumas.


Originators of the real Management recommend to make engine removal assembled with transmission. Assembly of the unit falls down and is taken from under the car in view of what it is necessary to take care of ways of reliable fixing of a vehicle in the lifted situation.


 PERFORMANCE ORDER

  1. Tire out the car on an equal horizontal platform with rather firm covering. Remove a cowl (see. Head Body). Bring forward wheels into rectilinear situation, take a key from the lock of ignition and block a steering column.
  2. On diesel models of 1.7 l remove the control unit a heater on the left side of the basic pallet of the storage battery. Remove the battery with the pallet (see. Head engine Electric equipment).
  3. Prop up back wheels protivootkatny boots, strongly cock the parking brake. Weaken bolts of fastening of forward wheels. To Poddomkratta a car front also establish it on props. Remove forward wheels. At the corresponding complete set remove protection of a case.
  4. If the engine acts in film for the purpose of performance of major maintenance, merge from it oil and remove the oil filter (see. Head Routine maintenance).
  1. Execute the following procedures (see. Head of the Power supply system and release):

    1. Remove an air purifier assembled with air lines;
    2. Remove a reception pipe and an average part of system of production of the fulfilled gases;
    3. Disconnect power supply system lines;
    1. On diesel models of 1.7 l of DOHC disconnect fuel lines from TNVD — on other diesel models disconnect lines of giving and fuel return from the fuel filter;
    1. Disconnect and take aside cables of gas and (at the corresponding complete set) a cable темпостата, - try to remember routes of laying of cables;
    2. Disconnect a vacuum hose of the servo-driver of the brake amplifier — try to remember a route of laying of a cable;
    3. On diesel models release fixing collars, disconnect and take aside the air sleeves connecting a turbokompressor to an interkuler and an interkuler with the inlet pipeline;
    4. Disconnect a hose from the vacuum pump and the EGR valve — take a hose aside;
    5. On petrol models disconnect a hose of the valve of ventilation of a fuel tank from the throttle case.
  1. On petrol models remove a front bumper (see. Head Body).
  2. On diesel models of 1.7 l of SOHC release fixing and disconnect from branch pipes hoses of the maslookhladitel laid between the block of cylinders and a radiator.
  1. Operating in compliance with the instructions provided in the Head of System of cooling, heating execute the following actions:

    1. Empty cooling system;
    2. Weaken collars and remove the top and bottom hoses of system of cooling from a radiator. Disconnect from the engine all hoses of an okhladitelny path;
    3. On a back partition of an impellent compartment disconnect hoses of an okhladitelny path from the heater heat exchanger: having compressed a collar, shift forward a ring and liberate a hose from the shtutserny socket — pay attention that in the top shlangovy connections black rings are used.
    1. On equipped with air central air models disconnect from the engine and take aside lines of a refrigerator path;
    1. Having passed suitable bolts or cores in openings of basic arms, fix on the place the К/В system radiator / condenser.
  1. Make an electroconducting detachment:

Petrol engines

  1. Turn a lock ring and disunite the big multicontact socket of conducting of the engine in a forward part of the assembly block of the relay in an impellent compartment.

 

    1. Sockets of all other brought to the main plait of electroconducting of plaits of an impellent compartment.

 

Diesel engines

  1. Turn a lock ring and disunite the big multicontact socket of conducting of the engine in a forward part of the assembly block of the relay in an impellent compartment.

 

    1. Turn out bolts and disconnect a loop from a terminal tip of a plusovy wire of the battery and two loops from a tip of a negative wire.

 

    1. Open a cover of the impellent compartment of the assembly block located in the left back corner and take the relay of green color and a safety lock with the blocks.

 

    1. On engines of 1.7 l of DOHC lift the lever and disconnect from the control unit established over the inlet pipeline the engine (ECM) the extreme back socket.
    2. Liberate electroconducting plaits from all intermediate clamps and place them from above over the engine.
    3. On engines of 1.7 l of SOHC disconnect electroconducting from the following components:

      • EGR valve;
      • The sensor of temperature of cooling liquid (ECT);
      • The electronic module of management (ECM) — take out a locking element;
      • Glow plugs;
      • Sensor of provision of a cranked shaft (CKP);
      • Sensor of temperature of oil;
      • Sensor switch of fires of a backing.

 

    1. At last, turn out three bolts of fastening of electroconducting to a back part of a cover of the gas-distributing mechanism and take away conducting from the engine, also liberate conducting from clamps on a forward part of the block of cylinders — take all plaits aside from the engine.

 

  1. Merge transmission oil/ATF.
  1. On models from RKPP press a clamp at once behind the shtutserny socket a hydraulic hose of a drive of a path of coupling (see. Head Coupling and power shafts). Accurately a screw-driver having hooked a lock bracket of the socket, disconnect a hose from a coupling dome.
  1. Disconnect from transmission of draft of switching selector transfers / cable (see. Head Manual transmission or Automatic transmission).
  1. On models from AT disconnect from transmission electroconducting and hoses of a path of cooling of ATF.
  1. Attach a rigging to elevating eyes and hang out the power unit.
  1. Remove both power shafts (see. Head Coupling and power shafts).
  2. Remove a forward stretcher (see. Head Suspension bracket and steering).
  3. Once again make sure that and nothing stirs all lines of communication to extraction of the power unit from an impellent compartment.
  1. Mark adjusting provisions of components of support of a suspension bracket of the power unit and an adapterny plate of transmission. Turn out three bolts of fastening of the right support of the engine to an arm on the block of cylinders, also give three bolts of fastening of a support to a body element. Turn out three bolts of fastening of the left support to an adapterny plate of transmission. On the models equipped with central air of air, disconnect electroconducting, give fixture, remove and tie up the To/in compressor to the front panel. In case of need liberate hoses of a refrigerator path from clamps behind the right support of a suspension bracket of the power unit.

At all do not open a refrigerator path!

  1. Get under the engine a telezhechny jack. Lower the power unit, watching that not передавить hoses or electroconducting and not to damage the radiator / fan. In case of need address to the help of the assistant — it is possible, the unit should be inclined slightly, for its conclusion from an aperture of an impellent compartment. Fix the unit on a jack.
  2. Disconnect an elevating rigging and roll out from under the car a jack with the power unit fixed on it.

Separation of the engine from transmission

Models with RKPP

 PERFORMANCE ORDER

  1. Having removed the power unit, lay it on wooden whetstones on a workbench or on a clean floor in garage.
  2. On models with stamped steel pallets, turn out fixing bolts and remove from a transmission case a flywheel cover.
  3. Remove a starter (see. Head engine Electric equipment).
  4. Make sure of that the weight of the power unit is evenly distributed on props. Turn out bolts of fastening of transmission to the engine — try to remember an order of installation of all bolts and arms fixed by them.
  5. Accurately separate transmission from the engine, without allowing a box povisaniye primary shaft on coupling.
  6. Remove freely planted directing plugs and clean them in a reliable place.

Models with AT

 PERFORMANCE ORDER

  1. Having removed the power unit, lay it on wooden whetstones on a workbench or on a clean floor in garage.
  2. Remove a starter (see. Head engine Electric equipment).
  3. For the purpose of ensuring access to bolts of fastening of the hydrotransformer liberate from a pallet flange a rubber cover (covers). Turn out a bolt to which there is an access, then, turning for a pulley bolt a cranked shaft, serially unscrew all other bolts of fastening of the hydrotransformer to a driving disk (on engines 1.4, 1.6 and 1.8 of l three fixing bolts are used, on engines of 2.0 l — six).

At assembly bolts are subject to replacement without fail.

  1. That the hydrotransformer did not drop out at transmission office, push it on a shaft deep into a case.
  2. Further act in an order stated above (see. Models with RKPP).

Connection of the engine with transmission

All models

Act as it should be, the return to an order of separation of the power unit.

Installation

 PERFORMANCE ORDER

  1. Сориентировав correctly, get the power unit under an impellent compartment of the car. Connect a rigging to elevating eyes of the engine. Get the block in an impellent compartment and arrange it so that there was a possibility of installation of support of a suspension bracket of the power unit. Establish support and while slightly tighten fixture.
  2. For a usadka on support, move the unit in different directions.
  3. Lower the unit and tighten fixture of support of its suspension bracket with demanded effort. Disconnect an elevating rigging and deduce from under the car a telezhechny jack.
  4. Further installation is carried out as it should be, the return to a dismantle order. Pay attention to the next moments:
    1. All fixture tighten with demanded effort (see. Specifications to the corresponding Heads of the Management);
    2. Track correctness of laying of plaits of electroconducting and reliability of fastening of their contact sockets. Make sure that conducting is laid on sufficient removal from heat sources;
    3. Restore initial connection of all hoses and tubes — track reliability of a tightening of fixing collars;
    4. On models from RKPP, check adjustment of a drive of gear shifting, in case of need make the corresponding adjustment (see. Head Manual transmission);
    5. Fill cooling system (see. Head of System of cooling, heating);
    6. Fill in in transmission fresh oil (RKPP) or ATF (AT) / make correction of level of working liquid (see. Head Routine maintenance);
    7. Make adjustment of cables of gas (see. Head of the Power supply system and release) and (at the corresponding complete set) темпостата;
    8. After the first start of the engine attentively examine all surface of the power unit and a partition of an impellent compartment on existence of signs of development of leakages of working liquids.

If major maintenance of the engine was carried out before to make its start — see. Trial start and an engine running in after major maintenance.