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




Removal of shatunno-piston assemblies

Before starting extraction from the engine of shatunno-piston assemblies, it is necessary to remove a head of cylinders, the pallet of a case and a maslozaborny tube, the bridge of covers of radical bearings / a maslootrazhatelny plate / balancing assembly (depending on a complete set) (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).


 PERFORMANCE ORDER

  1. By means of a special vertical drill completely remove traces of step wear from the top part of cylinders — act according to the instructions of the manufacturer enclosed to a vertical drill. The step is formed on piston stroke border, approximately in 6.4 mm under the top cut of the cylinder at the expense of mechanical production of metal and a nagaroobrazovaniye, to define its existence it is possible to the touch a finger nail. Attempts of extraction of shatunno-piston assemblies without removal of step development are fraught with damage of pistons.
  1. Having finished preparation of cylinders, overturn the engine upside down so that the cranked shaft appeared from above.
  1. Before removing rods from a cranked shaft, estimate size axial люфта their landings on the corresponding necks of the last. Densely enter an edge (I) measuring щупа into a gap between a lateral wall of the bottom head of a rod and a crank cheek, having completely chosen люфт a rod on a shaft neck. The total thickness of the picked-up edges щупа also will equal to size axial люфта a rod. Compare result of the carried-out measurement to requirements (see. Specifications). If the size axial люфта exceeds limiting admissible value, this rod is subject to replacement. Axial люфт a new rod, or old on new to a shaft, it can appear less than the bottom admissible limit, in this case the rod can be pierced — consult with specialists of car-care center. Serially check all remained rods.
  1. Make sure available on the bottom heads of rods and their covers of identification labels of belonging to the cylinder, in case of need put labels independently by means of a small center punch or a marker.
  1. Turn a cranked shaft so that pistons of the 1st and 4th cylinders appeared in provisions NMT.
  2. In stages (on 1/2 turns for an approach) weaken nuts / bolts of fastening of a cover of the bottom head of a rod of the first cylinder so that there was a possibility of their otvorachivaniye manually. Uncover a rod together with the loose leaf of the bearing placed in it — try not to drop the last.

On some engines the cut of the bottom head of rods is formed by a preparation razlamyvaniye with preservation of a form of a break by special processing for the best quality of a joint. At dismantle of covers from rods of this kind observe extreme care, - do not damage interfaced surfaces.

  1. For protection of a neck of a shaft and a mirror of the cylinder pull on hairpins of fastening of the bottom head of a rod pair of pieces of a hose suitable on the size.
  2. Take from a rod head the bearing loose leaf, then, having rested the wooden handle of a hammer against a bearing bed in the bottom head, вытолкните shatunno-piston assembly from the block at the top the cylinder. At resistance emergence immediately stop extraction of assembly and make sure of completeness of removal of step wear in the top part of the cylinder.
  3. Operating in a similar manner, take from the engine shatunno-piston assembly of the 4th cylinder, then turn the engine on 180 ° clockwise and take assemblies of the 2nd and 3rd cylinders.

Extraction start only after the rod will be strictly located parallel to a cylinder axis!

  1. In order to avoid casual mechanical damage of bearings and loss of components, establish into place loose leaves and fix covers of bearings on the bottom heads of the rods, having by hand tightened fixing bolts / nuts.
  2. Do not remove pistons from rods (for more details see. Check of a condition of components of shatunno-piston group).