Opel Astra, Zafira

Since 1998 of release

Repair and car operation



Opel Astra
+ Cars Opel Astra and Zafira
+ The operation manual
+ Routine maintenance
- The engine
   Specifications
   Check компрессионного pressure in cylinders
   Diagnostics of a condition of the engine with vacuum gauge application
   - Procedures of repair of petrol engines SOHC without their extraction from the car
      Reduction of the piston of the first cylinder in position of the top dead point of a step of compression (ВМТ)
      Removal and cover installation газораспределительного the mechanism
      Removal and installation of a pulley of a cranked shaft
      Removal and installation of a cover of drive ГРМ
      Removal and installation of a belt of drive ГРМ
      Removal and installation натяжителя газораспределительного a belt and cogwheels of drive ГРМ
      Replacement of an epiploon of a camshaft
      Removal, check of a condition and installation of a camshaft from the case газораспределительного the mechanism
      Removal, check of a condition and installation of components of a drive of valves
      Removal and installation of a head of cylinders
      Removal and pallet installation картера
      Removal, service and installation of the oil pump
      Removal, check of a condition and flywheel / installation приводного a disk
      Replacement of epiploons of a cranked shaft
      Check of a condition and replacement of support of a suspension bracket of the power unit
   + Procedures of repair of petrol engines DOHC 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
   + The general and engine major repairs
+ Systems of cooling, heating
+ The 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 and installation of a head of cylinders

Start work performance only after full cooling of the engine!

Removal

 PERFORMANCE ORDER

  1. Disconnect and remove the storage battery (the engine Electric equipment see the Head).
  2. Empty cooling system (see the Head of System of cooling, heating).
  3. Turn out spark plugs and remove a belt of a drive of auxiliary units (Routine maintenance see the Head).
  4. Remove a belt of drive ГРМ (Removal and installation of a belt of drive ГРМ see).
  5. Turn out fixing bolts and remove an arm of fastening of the engine on the right side of a head of cylinders.
  6. Remove the inlet pipeline and a final collector (see the Head of the Power supply system and release). If the head of cylinders is not subject to service, it can be removed in gathering with the pipeline and a collector:
    1. Disconnect electroconducting from a potentiometer of position throttle заслонки, a regulator of turns of idling (ISC), injectors of injection of fuel, the valve рециркуляции the fulfilled gases (EGR), the valve of a purge of a coal adsorber and a ljambda-probe.
    2. Dump pressure in the power supply system and disconnect fuel lines from a fuel highway. Disconnect also all vacuum hoses and hoses of system of cooling from the inlet pipeline / of the case of a throttle.
    3. Remove a basic arm from an inlet collector, also remove the top arm of fastening of the generator.
    4. Disconnect an accelerator cable.
    5. Disconnect from a final collector a reception pipe of system of release of the fulfilled gases in gathering with a basic arm.
    6. Disconnect electroconducting from a ljambda-probe.
  1. Uncover газораспределительного the mechanism (Removal and cover installation газораспределительного the mechanism see).
  2. Remove a camshaft cogwheel (Removal and installation натяжителя газораспределительного a belt and cogwheels of drive ГРМ see).
  3. Turn out bolts of fastening of a back cover of drive ГРМ to the case газораспределительного the mechanism.
  4. Disconnect electroconducting from the module of ignition, the gauge of temperature of a cooling liquid (ECT), detonation gauges (KS) and positions of a cranked shaft (CKP). Give a bolt of fastening of the tyre of grounding in a forward part of a head and remove from a head a protective casing of electroconducting.
  5. Release fixing collars and disconnect hoses of system of cooling from a thermostat casing.
  6. Make sure that all hoses, tubes, wires and other lines of communication are disconnected and do not disturb to dismantle of a head of cylinders.
  1. Operating in an order, the return shown, gradually, on a turn quarter for the approach, ослабьте bolts of fastening of a head of cylinders so that there was a possibility of their reversing manually. Remove bolts from a head in the complete set with the washers.
  1. Having lifted upwards, separate from a head the case газораспределительного the mechanism, — in case of need обстучите the case from sides a hammer with soft brisk.

At all do not hook the case the lever in order to avoid damage of interfaced surfaces! Mark position of two directing plugs, remove them from a head and clean in a reliable place.

  1. Separate a head of cylinders from the block, — try not to drop levers of a drive of valves and маслоотражательные caps. In case of need slightly обстучите a head from sides a hammer with soft brisk, — at all DO NOT HOOK its lever (the prevention above see)! Mark position of two directing plugs, remove them and clean in a reliable place.
  1. Remove a sealing lining, — yet do not throw out a lining for the purpose of identification on it new.

Preparation for installation

 PERFORMANCE ORDER

  1. Carefully smooth out and dry wipe interfaced surfaces of a head and the block of cylinders. Use a firm plastic or wooden scraper for removal of all traces of a material of an old lining and a deposit. Also clear the bottoms of pistons. Be extremely cautious, — surfaces are easy for damaging. Remember that the dirt should not get in маслотоки, water galleries channels and carving apertures — закупорьте their stoppers or stick with an adhesive tape. For prevention of hit of a deposit in backlashes between pistons and cylinders, fill the last of dense greasing which on termination of clearing procedure will be easy for removing a rigid brush. On termination of cleaning wipe all surfaces pure dry rags.
  2. Survey interfaced surfaces of a head and the block on presence of deep scratches, cracks and other damages. Small defects can be eliminated small шабером, in more serious cases the head should be pierced, or to replace.
  3. Make sure of cleanliness and dryness of carving apertures, — just in case blow their compressed air (it is possible to take advantage of the bicycle pump). Presence at deaf apertures of traces of greasing can lead to block destruction at a tightening of bolts as a result of increase of hydraulic pressure.
  4. Bolts of fastening of a head are subject to replacement without fail, without dependence from their current condition.
  5. By means of a steel ruler and щупа лезвийного type check up planeness of an interfaced surface of a head (the General see and engine major repairs).
  6. Replace bolts of fastening of a head of cylinders, — bolts are subject to replacement without fail without dependence from their current condition.

Installation

 PERFORMANCE ORDER

  1. Result the piston of the first cylinder in position ВМТ of the end of a step of compression.
  2. Pure rags dry wipe interfaced surfaces of the block and a head.
  1. Make sure of that both directing plugs are established in the nests.
  1. Lay on an interfaced surface of the block of cylinders a new sealing lining, — the lining keeps within marks «OBEN/TOP» upwards.
  1. Establish a head on the block of cylinders — track correctness of hit of directing plugs in reception nests.
  2. Dry wipe pure rags interfaced surfaces of a head and the case газораспределительного the mechanism. Make sure of correctness of installation of levers of a drive of valves, маслоотражательных caps and hydraulic jacks.
  1. Put a layer of suitable hermetic (consult on a car repair shop) on the top interfaced surface of a head of cylinders.
  1. Establish directing plugs and grease with pure impellent oil levers of a drive of valves.
  2. Accurately establish the case газораспределительного the mechanism (with the camshaft enclosed in it) on a head of cylinders, track correctness of hit of directing plugs in reception nests, — track correctness of hit of directing plugs in reception nests.
  1. Put on NEW bolts of fastening of the case газораспределительного the mechanism / of a head of cylinders of a washer, then screw bolts and tighten them by hand.
  1. Operating in strictly certain sequence, in stages in regular intervals, tighten bolts with effort of 1st stage.
  1. In a former order hold on bolts on corners at first 2nd, then — 3rd and 4th stages, — take advantage of a goniometric nozzle, or put a paint or a marker basic labels.
  2. Screw bolts of fastening of a back cover of drive ГРМ and tighten them with demanded effort.
  3. Make sure of correctness of installation of an arm of the right support of a suspension bracket of the power unit and tighten bolts of its fastening with demanded effort.
  4. Establish a camshaft cogwheel (Removal and installation натяжителя газораспределительного a belt and cogwheels of drive ГРМ see) and газораспределительный a belt (Removal and installation of a belt of drive ГРМ see).
  5. Restore initial connection of electroconducting, track correctness of a lining of plaits and reliability of their fastening in all provided intermediate clamps.
  6. Connect to the case of the thermostat hoses охладительного a path, — track reliability of a tightening of fixing collars.
  7. Establish to the place of the inlet pipeline and a final collector (see the Head of the Power supply system and release).
  8. Establish into place protection картера and the right forward wheel. Lower the car on the earth and tighten wheel bolts with demanded effort.
  9. Make sure of correctness and reliability of connection of all hoses, then make refuelling of system of cooling (see the Head of System of cooling, heating).
  10. Connect the storage battery.
  11. Start the engine and check up it on presence of signs of development of leaks of working liquids.