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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Sequence of dismantling of the engine

It is simplest to carry out engine dismantling, having established it on the portable assembly stand. The such adaptation always can be borrowed rather cheaply in a car-care center workshop. Before fixing the engine at the stand, it is necessary to remove from it a flywheel / a driving disk — the engine fastens at the stand by means of bolts rolled in the block.

If possibility to use the stand is absent, dismantling should be made, having placed the engine on a strong workbench, or having reliably arranged it on a firm floor of garage. At work without the stand watch that the engine casually did not overturn.

If it is planned to make replacement of the engine on restored, remove with old all hinged units and external components and transfer them on the replaceable block. In number such, subject to shift, components enter:

At removal from the old engine of external components try to remember characteristics of their installation. Fix in a notebook landing provisions of laying, epiploons, remote rings and plugs, pins, arms, washers, bolts and other fine details.

At a scheme choice with use of the reduced set of the block consisting of the block of cylinders with established in it by cranked shaft and shatunno-piston groups, remove from the old unit also a head of cylinders, the pallet of a case and the oil pump (possible alternatives of schemes of performance of major maintenance see. Alternative versions of schemes of regenerative repair of the engine).

At carrying out complete major maintenance of the old unit, make its dismantling and take all internal components. The optimum order of removal of knots and details below is given:

  • Inlet pipeline and final collector;
  • Cover of the gas-distributing mechanism;
  • Covers of a drive of GRM with bolts;
  • GRM drive (gas-distributing a belt / chain with gear wheels / asterisks, intermediate rollers and natyazhitel);
  • Camshafts with components of a drive of valves;
  • Head of cylinders;
  • Water pump;
  • Case pallet;
  • Maslozabornik with the mesh filter;
  • Forward cover / oil pump;
  • Shatunno-porshnevye assemblies;
  • Cranked shaft and radical bearings;

Before starting engine dismantling, prepare the following materials, tools and details (see also Removal and installation of a cover of a drive of GRM):

Standard set of the metalwork tool;

  • Set of cardboard or plastic containers / plastic bags for the organized storage of small components;
  • Scraper for cleaning of interfaced surfaces;
  • Vertical drill for removal of step wear in the top part of cylinders;
  • Stripper for dismantle of a damper of krutilny fluctuations;
  • Set of micrometers;
  • Telescopic nutromer;
  • Tsiferblatny measuring instrument of plunzherny type (DTI);
  • The tool for compression of klapanny springs;
  • Hon for processing of mirrors of cylinders;
  • The tool for pro-cleaning of flutes under installation of piston rings;
  • Electrodrill;
  • Set of taps and lerok;
  • Wire brushes;
  • Cylindrical brushes for pro-cleaning of oil galleries;
  • Solvent.