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
   - Procedures of repair of diesel engines of 1.7 l and 2.0 l without their extraction from the car
      Reduction of the piston of the first cylinder in position of the top dead point of the end of a step of compression (ВМТ)
      Check and adjustment of phases газораспределения (engines 2.0)
      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 натяжителей chains of drive ГРМ (engines 2.0)
      Removal and installation of a belt of drive ГРМ
      Removal and installation натяжителя a belt and cogwheels of drive ГРМ (engines 1.7)
      Removal and installations of chains and asterisks of drive ГРМ, check of a condition of components (engines 2.0)
      Replacement of an epiploon of a camshaft (engines 1.7)
      Check and adjustment of backlashes of valves (engines of 1.7 l DOHC)
      Removal and camshaft installation (ов) and components of a drive of valves
      Removal and case installation газораспределительного the mechanism (engines of 1.7 l DOHC)
      Removal and installation of a head of cylinders
      Removal and pallet installation картера
      Removal, service and installation of the oil pump
      Replacement of an epiploon of the oil pump (engines 1.7)
      Removal and installation маслоохладителя
      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
   + 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 camshaft installation (ов) and components of a drive of valves

Removal

Engines of 1.7 l SOHC

Application at removal of a camshaft from the engine of special adaptation KM-890 of 1.7 l SOHC allows гарантированно not to disturb a lining of a head of cylinders. At absence near at hand adaptations it is necessary to remove a head of cylinders (Removal and installation of a head of cylinders see).


 PERFORMANCE ORDER

  1. Remove the storage battery.
  2. Remove a camshaft cogwheel (Removal and installation натяжителя a belt and cogwheels of drive ГРМ (engines 1.7 see. For the purpose of prevention of an input of pistons in contact to valves turn a cranked shaft on 90 ° counter-clockwise.
  3. Release collars and remove an air line connecting турбокомпрессор with интеркулером. Also remove a sleeve, going from интеркулера to the inlet pipeline.

Both sleeves are fixed also in intermediate clamps (see the Head of the Power supply system and release).

  1. Disconnect from the vacuum pump (4) tube of the servo-driver of the brake amplifier and a vacuum tube (2—3).
  1. Turn out fixing bolts and remove the pump together with an arm of an air line of system of a turbo-supercharging.
  1. Turn out two screws with heads under прутковый a key (Allen) and remove a persistent plate of a camshaft.
  1. At presence near at hand adaptations KM-890, take advantage of it. The Adaptation consists of a set of plates with adjustable legs. Plates are drawn to the case газораспределительного the mechanism, wringing out the legs levers of a drive of valves then the camshaft can be taken freely from the case приводного the mechanism. If possibility of application of the adaptation is absent, it is necessary to remove the case газораспределительного the mechanism. As case bolts simultaneously крепят as well a head of cylinders, it is necessary to remove as well it (Removal and installation of a head of cylinders see).

Bolts and lining are not subject to a reuse and at assemblage should be replaced new without dependence from their condition.

  1. Having removed a camshaft, prepare 8 transparent polyethylene bags or small plastic glasses and mark them according to numbering of valves. Remove levers of a drive of the valves, figured washers fixing them and hydraulic racks of jacks. Spread out the removed components on bags / to glasses according to the put marks.

Engines of 1.7 l DOHC

 PERFORMANCE ORDER

  1. Uncover газораспределительного the mechanism (Removal and cover installation газораспределительного the mechanism see).
  2. Remove fuel atomizers (see the Head of the Power supply system and release).
  3. Remove a camshaft cogwheel (Removal and installation натяжителя a belt and cogwheels of drive ГРМ (engines 1.7 see).
  4. Turn out fixing nuts and uncover 5th support of camshafts with left (from outside transmissions) the parties.
  1. The gear wheel of a drive of a final camshaft is equipped by the additional gear section serving for indemnification axial люфта. The compensatory section should be blocked with the basic gear wheel of a shaft by means of a suitable bolt or a core. Pass a bolt / a core in an aperture on an inside of the basic gear wheel and push it through compensatory section. Such blocking will allow to unload a compensatory spring at removal of any of camshafts.
  1. Moving on a spiral from edges to the middle, gradually, on one turn for the approach, ослабьте nuts of fastening of covers of the remained support to remove stress from springs of valves gradually and in regular intervals. After all клапанные springs will appear are unloaded, nuts it will be possible to turn on by hand.

Отворачивание nuts in any order it is fraught with destruction of covers of basic bearings of a camshaft, thus it is necessary to change all head of cylinders as it is cast and processed together with covers of support, and covers in an individual order on the market are not delivered.

  1. Remove covers of support, — try to remember adjusting position of components.

Serial numbers are put on covers of support (with 1 on 5). Marks in the form of an arrow at installation of covers should specify towards belt ГРМ.

  1. Remove camshafts from a head of cylinders.
  1. Prepare 16 small transparent polyethylene packages or pure plastic glasses and mark them according to numbering of valves. Take from a head pushers with washers and spread out them on corresponding glasses.

Engines of 2.0 l

At installation the new bolt of fastening of an asterisk of a camshaft and new bolts of fastening успокоителя is required to the top chain.


 PERFORMANCE ORDER

  1. Disconnect a negative wire from the battery and uncover газораспределительного the mechanism (Removal and cover installation газораспределительного the mechanism see).
  2. Remove the vacuum pump of the servo-driver of the brake amplifier (the Brake system see the Head).
  3. Result the piston of 1st cylinder in position ВМТ of the end of a step of compression (Reduction of the piston of the first cylinder in position of the top dead point of the end of a step of compression (ВМТ see)) and block a cranked shaft in this position.
  4. For the purpose of maintenance of an easy approach to a cover of asterisk ТНВД remove the case of an air cleaner and a reception pipe of system of release of the fulfilled gases (see the Head of the Power supply system and release). Also remove a belt of a drive of auxiliary units (Routine maintenance see the Head). Mark position of the right support of a suspension bracket of the power unit in relation to an arm of a head of cylinders. Turn out three bolts of fastening of a support to an arm of a head of cylinders and three bolts of fastening to its mudguard. Prop up the right party of the engine тележечным a jack, having lifted it as it is possible above, without loading thus excessively other support and lines of communication (hoses, cables, electroconducting plaits).
  5. Remove натяжитель the top chain (Removal and installation натяжителей chains of drive ГРМ (engines 2.0 see).
  6. Turn out the bottom bolt of fastening of a rack of a tension roller of a belt of a drive of auxiliary units, give a bolt of an axis of the basis натяжителя and remove assemblage of the last from the engine.

It is not necessary to remove without special need a rack from assemblage натяжителя, - at installation it should be ground in.

  1. Turn out fixing bolts and uncover asterisks ТНВД a cover of drive ГРМ.
  2. Mark position on the asterisks of the top chain. Also mark position to a camshaft asterisk on a pin of the last.
  1. Turn out fixing bolts and take from a head of cylinders успокоитель the top chain.

Before отдаванием their bolts it is necessary to warm up a thermal pistol (the powerful hair dryer) for the purpose of a softening of the hermetic put on a carving.

  1. Keeping a camshaft рожковым a key, turn out a bolt of fastening of an asterisk, — before отдаванием a bolt take the adaptation fixing a camshaft, — do not forget to establish the adaptation into place after the bolt will be turned out.
  1. Liberate an asterisk of a camshaft from a chain and remove it from the engine.
  1. Fix a chain a screw-driver for the purpose of prevention of its falling in a head, — lay a screw-driver on an interfaced surface of a head.
  1. Pay attention to marks of covers of support of a camshaft. Covers are numbered as it should be with 1 on 5, and the cover №1 — settles down from outside chains of drive ГРМ. If marks are badly distinguishable, put new independently to avoid mess at assemblage.
  1. Moving on a spiral from edges to the middle, gradually, on one turn for the approach, ослабьте bolts of fastening of covers, — after all клапанные springs will appear are unloaded, bolts can be turned out manually. Combine the removed bolts together with the covers, — try not to lose directing plugs established in 5th support. Take a camshaft from a head of cylinders.

Отворачивание nuts in any order it is fraught with destruction of covers of basic bearings of a camshaft, thus it is necessary to change all head of cylinders as it is cast and processed together with covers of support, and covers in an individual order on the market are not delivered.

  1. Prepare eight transparent polyethylene bags or small plastic glasses and mark them according to numbering of valves. Remove levers of a drive of valves and spread out them on bags / to glasses according to the put marks.
  1. In case of need removals of hydropushers, dismantle transitive tubes of atomizers (see the Head of the Power supply system and release). Extraction of pushers is better to make by means of a magnetised core or rubber capture. The removed components spread out on bags / to glasses according to marks.

Check

 PERFORMANCE ORDER

  1. Attentively study a condition подшипниковых necks and camshaft cams. In case of revealing задиров or scratches replace a shaft. Check up also a condition of working surfaces of bearings of sliding in case support газораспределительного the mechanism. On engines of 1.7 l SOHC the damaged and worn out support can be replaced. On engines of 1.7 l DOHC and 2.0 l all assemblage of a head of cylinders as it is cast and processed together with covers of support is subject to replacement, and covers in an individual order on the market are not delivered.
  2. Having laid a camshaft () in prisms, define size of its radial palpation (on подшипниковым to necks) with the help циферблатного a measuring instrument плунжерного type. At an exit of results of measurements for limits of an admissible range (Specifications see) the camshaft is subject to replacement.
  3. On engines of 1.7 l the camshaft epiploon (Replacement of an epiploon of a camshaft (engines 1.7 see) is subject to obligatory replacement also.
  4. On engines of 1.7 l SOHC and 2.0 l estimate degree of deterioration and the general condition contacting to cams of a camshaft of working surfaces of levers of a drive of valves. In case of revealing of cracks, cavities, furrows and задиров it is necessary to replace levers.
  5. On models 1.7 of l SOHC check up a condition of a persistent plate of a camshaft, in case of need make replacement.

At increased axial люфте a shaft the plate also is subject to replacement.

  1. Check up a condition of pushers / of hydrojacks and their landing nests in a head. In case of revealing of signs of excessive deterioration of working surfaces, cracks, задиров and other damages, replace pushers.

Pushers are subject to replacement also in the event that work клапанного the mechanism was lately accompanied by the raised noise background.

Installation

Engines of 1.7 l SOHC

 PERFORMANCE ORDER

  1. Grease all hydropushers fixing washers and levers of a drive of valves with pure impellent oil and establish them strictly on the former places. Grease rubbing surfaces of levers молибденсодержащей with type greasing «Molikot And».
  1. Establish adaptation KM-890, accurately fill a camshaft in the case газораспределительного the mechanism, having passed its pin through a new epiploon and fix its persistent plate. Tighten bolts of fastening of a persistent plate with demanded effort.
  1. Make sure of that levers of a drive of valves and their fixing washers are established on the places and are not warped, then cautiously remove adaptation KM-890.
  2. Establish a camshaft cogwheel while only by hand having tightened a bolt of its fastening.
  3. Turn a camshaft таки in the image that the cam of a drive of the final valve of 1st cylinder (near to газораспределительному to a belt) was developed by a working ledge upwards. Turn a cranked shaft on 90 °, having resulted it in position ВМТ, and establish a belt of drive ГРМ (Removal and installation of a belt of drive ГРМ see).
  1. Fill a shaft of the vacuum pump in an aperture in the left end face of the case газораспределительного the mechanism and fix a tube arm турбокомпрессора the top bolt of fastening of the pump. Make sure that the shaft of a drive of the vacuum pump has properly entered into gearing with a camshaft pin. Tighten bolts of fastening of the pump with demanded effort.
  1. Connect to the vacuum pump a vacuum hose of the servo-driver of the brake amplifier.
  2. Establish into place a sleeve connecting интеркулер with the inlet pipeline, and also laid between the compressor and интеркулера an air line. Establish fixing clamps and reliably tighten bolts of fastening of arms.
  3. Establish and connect the storage battery.

Engines of 1.7 l DOHC

 PERFORMANCE ORDER

  1. Grease pushers with pure impellent oil and establish strictly on former in the places, — track correctness of installation of all washers.
  1. For the purpose of prevention of risk of an input of valves in contact to the bottoms of pistons turn a cranked shaft approximately on 60 ° counter-clockwise. Grease washers of pushers and a support of camshafts with pure impellent oil and lay shaft on support. Make sure that the compensatory section of a gear wheel of a final camshaft is blocked with the basic gear wheel. Make sure that the label on an external surface of a gear wheel of a final camshaft is located between two labels on an external surface of a gear wheel of an inlet camshaft and approximately on one line with a case cut газораспределительного the mechanism.

If the final camshaft was replaced, it is necessary to get adaptation Vauxhall KM-6092 for compression of a spring of a compensatory gear wheel before installation.

  1. Make sure of absoluteness of cleanliness and dryness of interfaced surfaces of support and covers of camshafts. Grease interfaced surfaces, and also cams of camshafts with pure impellent oil.
  1. Interfaced surfaces of the first support and its cover grease with suitable hermetic (consult on a car repair shop).
  1. Establish on the places of a cover of support with №1 on №4, — covers are marked and should be established by arrows in a direction of a belt of drive ГРМ.
  1. Screw nuts of fastening of covers, having tightened them while only by hand.
  2. Remove fixing sections of a gear wheel of a final camshaft a bolt / a core, then establish a cover of 5th support.
  1. Operating in strictly certain sequence, gradually, on one turn for the approach, tighten nuts of fastening of covers, smoothly loading клапанные springs. Continue a tightening in former sequence until covers will not nestle on support, then hold on all fixture with demanded effort.

The tightening of nuts in any order is fraught with destruction of covers of basic bearings of a camshaft, thus it is necessary to change all head of cylinders as it is cast and processed together with covers of support, and covers in an individual order on the market are not delivered.

  1. Establish a new epiploon of a camshaft (Replacement of an epiploon of a camshaft (engines 1.7 see).
  2. Establish a cogwheel of a camshaft and a belt of drive ГРМ (Removal and installation натяжителя a belt and cogwheels of drive ГРМ (engines 1.7 and Removal and installation of a belt of drive ГРМ see).
  3. Check up backlashes in valves, in case of need make their adjustment (Check and adjustment of backlashes of valves (engines of 1.7 l DOHC see)), then establish a cover газораспределительного the mechanism (Removal and cover installation газораспределительного the mechanism see).
  4. Establish to the place of an atomizer (see the Head of the Power supply system and release).

Engines of 2.0 l

 PERFORMANCE ORDER

  1. If removed, grease with pure impellent oil pushers and establish them on the former places in a head of cylinders. Establish transitive tubes of atomizers (see the Head of the Power supply system and release).
  1. Establish on the places levers of a drive of valves (labels on their top surface to transitive tubes of atomizers).
  1. Grease cams and подшипниковые camshaft necks with pure impellent oil and lay a shaft on the regular place. Make sure that the cranked shaft on the former is blocked in position ВМТ and develop a camshaft working ledges of cams of a drive of valves of the first cylinder upwards so that the groove in an end face of a pin of a camshaft has appeared is parallel to the top cut of a head, and an aperture of the control of phases газораспределения — in position «at 12 o'clock».


  1. Make sure of absoluteness of cleanliness and dryness of interfaced surfaces подшипниковых support of a camshaft and their covers. Grease cams and camshaft necks with pure impellent oil.
  1. Grease with hermetic interfaced surfaces of 5th (extreme left) shaft support, then establish in a head of cylinders directing plugs.
  1. Establish on the places of a cover of support of a camshaft. Covers are numbered as it should be with 1 on 5 and at a sight from the forward party of the engine of figure should be read correctly.
  1. By hand tighten bolts of fastening of covers, then, moving on a spiral from the middle to edges, gradually, on one turn for the approach, tighten bolts of all covers, smoothly loading клапанные springs. Continue to tighten fixture until covers will not nestle on support, and in summary tighten bolts with demanded effort.

The tightening of nuts in any order is fraught with destruction of covers of basic bearings of a camshaft, thus it is necessary to change all head of cylinders as it is cast and processed together with covers of support, and covers in an individual order on the market are not delivered.

  1. Watching correctness of combination of the labels put in the course of dismantle, put on a chain for asterisks ТНВД and a camshaft. Plant a camshaft asterisk on a pin of the last (also track correctness of combination of labels). Screw and tighten the NEW fixing bolt.
  1. Fill into place успокоитель the top chain (an adjusting ledge upwards), screw NEW fixing bolts and tighten from with demanded effort.
  2. At presence near at hand special fixing adaptations, make adjustment of phases газораспределения (Check and adjustment of phases газораспределения (engines 2.0 see). Having finished adjustment, remove adaptations.
  1. If possibility of use of special adaptations is absent, achieve combination of the landing labels of an asterisk put in the course of dismantle and a camshaft. Keeping a camshaft рожковым a key for лыски, tighten a bolt of fastening of an asterisk with effort of 1st stage. Make sure of correctness of combination of labels, hold on a bolt consistently corners of stages of 2 and 3 tightenings, — take advantage of a goniometric nozzle, or put a paint or a marker basic labels.
  1. Establish натяжитель the top chain (Removal and installation натяжителей chains of drive ГРМ (engines 2.0 see).
  2. Make sure of absoluteness of cleanliness and dryness of interfaced surfaces of covers of asterisks ТНВД and drive ГРМ. If covers has been planted on a lining, do not forget to replace last. Screw fixing bolts and tighten them with demanded effort. If the lining has not been provided, fill a flute of a cover with a pillow of hermetic in the thickness approximately 2 mm, then press a cover, screw fixing bolts and tighten them with demanded effort.
  3. Establish натяжитель a belt of a drive of auxiliary units, having tightened fixing and axial bolts with demanded effort. At replacement натяжителя, or after its dismantling it is necessary to make rack grinding in, — take advantage of a face head, having put on it on шестигранную a basis part. If the rack functions normally, establish a belt of a drive of auxiliary units (Routine maintenance see the Head).
  4. Establish on a head of cylinders assemblage of the right support of a suspension bracket of the power unit. Lower the unit, then fix a support on a mudguard, having tracked correctness of combination of the landing labels put in the course of dismantle. Tighten fixing bolts with demanded effort.
  5. Establish a cover газораспределительного the mechanism (Removal and cover installation газораспределительного the mechanism see).
  6. Establish a reception pipe of system of release of the fulfilled gases, the case of an air cleaner and the gauge of position of a cranked shaft (see the Head of the Power supply system and release).
  7. Establish assemblage of the vacuum pump (the Brake system see the Head).