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
   - Procedures of repair of petrol engines DOHC 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 of cogwheels cranked / camshafts and intermediate rollers
      Replacement of epiploons of camshafts
      Removal and installation of camshafts and pushers of valves, check of a condition of components
      Removal and installation of a head of cylinders
      Removal and pallet installation картера
      Removal and installation of the gauge of level of impellent oil
      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
      Removal, installation and adjustment of the balancing mechanism of a cranked shaft (engines 2.0)
   + 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
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Removal and installation of a head of cylinders

Start work performance only after full cooling of the engine!

Removal

All engines

 PERFORMANCE ORDER

  1. Dump pressure in the power supply system (see the Head of the Power supply system and release). 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).
  1. Remove a belt of drive ГРМ (Removal and installation of a belt of drive ГРМ see). Before easing газораспределительного a belt deduce the engine from position ВМТ by deployment of a cranked shaft on 60 ° counter-clockwise for the purpose of alignment of distribution developed клапанными springs of efforts and prevention проворачивания the camshafts, fraught with damage of internal components of the mechanism as a result of input of pistons in contact to valves.

Engines 1.4, 1.6 and 1.8 l

 PERFORMANCE ORDER

  1. 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 from a final collector a reception pipe of system of release of the fulfilled gases in gathering with basic кронштейномю
    2. Disconnect electroconducting from a ljambda-probe.
    3. Disconnect electroconducting from the gauge of position of a cranked shaft (CKP).
    4. Uncover газораспределительного the mechanism (Removal and cover installation газораспределительного the mechanism see).
  2. Remove cogwheels of camshafts (Removal and installation of cogwheels cranked / camshafts and intermediate rollers see).
  3. Turn out bolts of fastening of a back cover of drive ГРМ to the case газораспределительного the mechanism.
  4. If yet have not done it, disconnect electroconducting from the management block (ECU) on a left-hand side of a head of cylinders.
  5. Release fixing collars and disconnect hoses of system of cooling from the thermostat case.
  1. For the purpose of removal of a cooling liquid from the block of cylinders disconnect the hoses going from the heat exchanger of a heater to the inlet pipeline (see the Head of System of cooling, heating), — as soon as вытекание liquids will stop, restore initial connection of hoses. The spilt liquid collect paper towels. Turn out two bolts with heads of type TORX and separate a connecting flange of a hose from a back part of a head of cylinders.

    A — Removal of a flange of connection of a hose of system of cooling (the engine 1.8)
    B — Removal of a flange of connection of a hose of system of cooling (engines 1.4 and 1.6)

A.

B.
  1. On engines of 1.4 and 1.6 l liberate two hoses of ventilation картера from basic arm ECU at the left on a head.
  2. On engines of 1.8 l turn out a fixing bolt and take aside directing tube щупа measurements of level of impellent oil.
  3. 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, in regular intervals 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 a head of cylinders from the block, — in case of need обстучите it from sides a hammer with soft brisk.

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

Engines of 2.0 l

 PERFORMANCE ORDER

  1. 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.
  2. Uncover газораспределительного the mechanism (Removal and cover installation газораспределительного the mechanism see).
  3. Remove cogwheels of camshafts (Removal and installation of cogwheels cranked / camshafts and intermediate rollers see).
  4. Turn out bolts of fastening of a back cover of drive ГРМ to the case газораспределительного the mechanism.
  5. If the inlet pipeline is not dismantled, remove basic arms the generator / the pipeline and take away the generator back.
  6. Disconnect an accelerator cable (see the Head of the Power supply system and release).
  7. Disconnect from the inlet pipeline a vacuum hose of the servo-driver of the brake amplifier.
  8. Disconnect gasoline pipe lines from a fuel highway.
  9. Ослабьте fixing collars also disconnect hoses охладительного a path from the heat exchanger of a heater and the throttle case.
  10. If yet have not done it, disconnect electroconducting of injectors of injection of fuel and take her aside.
  11. Remove a final camshaft (Removal and installation of camshafts and pushers of valves, check of a condition of components see).
  12. 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 third of turn for the approach, by means of 12-faced key TORX Т55 (KM-2355) in regular intervals 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 a head of cylinders from the block, — in case of need обстучите it from sides a hammer with soft brisk.

At all do not hook a head the lever in order to avoid damage of interfaced surfaces! Mark position of two directing plugs, remove them from the block 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

Removal and installation of a head of cylinders see.

Installation

All engines

 PERFORMANCE ORDER

  1. Make sure that the cranked shaft is still developed under 60 ° before ВМТ.
  2. Pure rags dry wipe interfaced surfaces of the block and a head.
  3. 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.
  1. Put on NEW bolts of fastening of a head of cylinders of a washer, then accurately 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, 4th stages and 5th, — take advantage of a goniometric nozzle, or put a paint or a marker basic labels.

Engines 1.4, 1.6 and 1.8 l

 PERFORMANCE ORDER

  1. Restore initial connection of hoses охладительного a path, — do not forget to replace a sealing ring фланцевого connection with the back party of a head. Track reliability of a tightening of fixing bolts / of collars.
  2. Restore initial connection of electroconducting. Track correctness of packing of plaits and reliability of fixing all of them the provided clamps.
  3. Establish a back cover газораспределительного a belt, screw fixing bolts and tighten them with demanded effort.
  4. Establish cogwheels of camshafts (Removal and installation of cogwheels cranked / camshafts and intermediate rollers see).
  5. Result the engine in position ВМТ (Reduction of the piston of the first cylinder in position of the top dead point of a step of compression (ВМТ see)) and establish and газораспределительный a belt (Removal and installation of a belt of drive ГРМ see).
  6. Establish covers газораспределительного the mechanism and drive ГРМ (Removal and cover installation газораспределительного the mechanism and Removal and installation of a cover of drive ГРМ see).
  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 a wheel, lower the car on the earth and tighten wheel bolts with demanded effort.
  9. Check up correctness of a lining and connection of hoses охладительного a path.
  10. Make sure of correctness of a lining and reliability of connection of all hoses, then make refuelling of system of cooling (see the Head of System of cooling, heating).
  11. Establish into place the ignition module, a protective casing of the engine and assemblage of an air cleaner with air lines.
  12. Connect the storage battery.
  13. Start the engine and check up it on presence of signs of development of leaks of working liquids.

Engines of 2.0 l

 PERFORMANCE ORDER

  1. Establish a final camshaft (Removal and installation of camshafts and pushers of valves, check of a condition of components see).
  2. Restore initial connection of hoses охладительного a path.
  3. Establish a back cover газораспределительного a belt, screw fixing bolts and tighten them with demanded effort.
  4. Establish cogwheels of camshafts (Removal and installation of cogwheels cranked / camshafts and intermediate rollers see).
  5. Execute procedures, since the paragraph Engines 1.4, 1.6 and 1.8 l — item 5.