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 installation of a head of cylinders

Removal

Do not suppose dirt hit in the power supply system and ТНВД!


Head dismantle should be made from completely cooled down engine. In advance prepare a new sealing lining of a head of cylinders.

Engines of 1.7 l SOHC

 PERFORMANCE ORDER

  1. Disconnect and remove the storage battery (the engine Electric equipment see the Head).
  2. Empty cooling system. Turn out fixing bolts and remove an air cleaner in gathering with air lines and a measuring instrument of weight of air (see the Head of System of cooling, heating).

  1. Disconnect the generator from an adjusting lath and the top back basic arm. Ослабьте the bottom bolt of fastening of the generator, remove a belt of a drive of the generator and develop the generator back.

    1 — Bolts of fastening of the top arm
    2 — the Adjusting bolt
    3 — the Nut of an adjusting bolt
    4 — the Adjusting lath

  1. Uncover газораспределительного the mechanism (Removal and cover installation газораспределительного the mechanism see).
  2. Liberate from clamps and the air sleeves laid between турбокомпрессором and интеркулером and интеркулером and the inlet pipeline (see the Head of the Power supply system and release).
  1. Disconnect from the vacuum pump (4) on a case left-hand side газораспределительного the mechanism a tube of the servo-driver of the brake amplifier and a vacuum line (2) and (3).
  1. Disconnect electroconducting from the gauge of temperature of a cooling liquid, the gauge of pressure of pressurisation and electromagnetic valve EGR.
  2. Disconnect electroconducting from the case газораспределительного the mechanism and take her aside.
  3. Ослабьте fixing collars also disconnect top радиаторный a hose from branch pipes on a flange and a radiator.
  1. Disconnect lines of giving and return of fuel from the case газораспределительного the mechanism.
  1. Release collars and disconnect a hose of a broad tank from the top forward branch pipe of the case of the thermostat and the case газораспределительного the mechanism. Take a hose aside.
  2. Remove fastening elements among themselves fuel lines, — try to remember adjusting position of components.
  3. Absolutely wipe штуцерные sockets of atomizers and exit ТНВД (4 pieces), then ослабьте them накидные nuts. Weakening nuts штуцерных connections ТНВД, keep unions from проворачивания the second key. Having released nuts, serially remove fuel tubes from the engine. Pure rags collect traces of the spilt fuel. In order to avoid hit in the dirt power supply system закупорьте atomizers, unions and tips of tubes pure plastic stoppers. Disconnect from the first atomizer a line of return of fuel.
  4. Give two nuts and disconnect electroconducting from candles накаливания 2nd and 3rd cylinders.
  5. Release штуцерный a socket and disconnect маслоподающую a tube турбокомпрессора from the block of cylinders (see the Head of the Power supply system and release).
  6. Disconnect маслоподающую a tube from турбокомпрессора (see the Head of the Power supply system and release).
  7. Turn out a fixing bolt and disconnect a returnable oil tube турбокомпрессора from the top part of the pallet картера. Remove sealing washers.
  8. Disconnect a basic arm of a final collector from the block of cylinders and a final collector. Turn out fixing nuts and disconnect a reception pipe of system of release of the fulfilled gases from a final collector.
  9. Turn out a fixing bolt and disconnect a basic arm of electroconducting and a tube of return of fuel from the left back part of a head of cylinders.
  10. Turn out two fixing bolts and remove the case of the thermostat from the right back part of a head of cylinders. Separate a casing from a metal tube of cooling in a back part of the block of cylinders, — pay attention to two sealing rings, and take him aside together with a heater hose.
  1. Operating in sequence, return specified, gradually, on a half-turn for the approach, in regular intervals ослабьте ten bolts of fastening of a head before possibility occurrence отдавания them manually.
  1. Remove bolts of fastening of a head together with washers.
  2. Remove the case газораспределительного the mechanism from a head, prepare eight pure polyethylene bags or plastic glasses and mark them according to numbering of valves. Remove levers of a drive of the valves, figured washers fixing them and hydrojacks, — spread out components on bags / to glasses according to the put marks.
  3. Having resorted to the help of the assistant remove heavy enough head of cylinders from the block. Remove a sealing lining, — try not to lose two directing plugs, established in the block of cylinders. If plugs are planted freely and easily taken out, take them and clean in a reliable place. Do not throw out an old lining, — it can be used as the sample at acquisition of the new.

The description of procedure of dismantling of a head of cylinders in case of need carrying out of its regenerative repair, see the General and engine major repairs.

Engines of 1.7 l DOHC

 PERFORMANCE ORDER

  1. Empty cooling system. Turn out fixing bolts and remove an air cleaner in gathering with air lines and a measuring instrument of weight of air (see the Head of System of cooling, heating).
  2. Remove a camshaft cogwheel (Removal and installation натяжителя a belt and cogwheels of drive ГРМ (engines 1.7 see.
  3. Turn out also bolts of fastening of a back cover газораспределительного ГРМ to the case газораспределительного the mechanism and a block head.
  4. Remove the case газораспределительного the mechanism (Removal and case installation газораспределительного the mechanism (engines of 1.7 l DOHC see), remove camshafts. Prepare 16 pure polyethylene bags or plastic glasses and mark them according to numbering of valves. Take from the landing nests in a head of cylinders pushers and combine them together with adjusting washers in in appropriate way the marked bags / glasses.
  5. Turn out three fixing bolts and remove from a final collector a thermofilter.
  6. Turn out bolts and nuts of fastening of a final collector to a head of cylinders. Remove washers. By means of a head of type TORX turn out two hairpins of fastening of a collector and, having pulled, remove a collector from the engine. The alternative way of dismantle of a final collector is stated in the Head of the Power supply system and release.
  1. Turn out fixing bolts and remove valve EGR.
  1. Disconnect from atomizers fuel tubes (see the Head of the Power supply system and release).Начисто wipe target штуцерные sockets ТНВД (4 pieces), then ослабьте them накидные nuts. Weakening nuts штуцерных connections ТНВД, keep unions from проворачивания the second key. Having released nuts, serially remove fuel tubes from the engine. Pure rags collect traces of the spilt fuel. In order to avoid hit in the dirt power supply system закупорьте atomizers, unions and tips of tubes pure plastic stoppers. Disconnect from the first atomizer a line of return of fuel.
  1. Disconnect a vacuum hose and a socket of electroconducting from electromagnetic valve EGR.
  1. Disconnect from ТНВД a hose of return of fuel.
  1. Disconnect electroconducting from the gauge of pressure of the pressurisation established behind valve EGR on an inlet collector.
  1. Disconnect electroconducting from candles накаливания (the engine Electric equipment see the Head).
  1. Release a collar and disconnect a hose of system of cooling from the left back part of a head of cylinders.
  1. Disconnect electroconducting from the gauge of temperature of a cooling liquid. Turn out fixing bolts and remove the case of the thermostat from the left back part of a head of cylinders.
  1. Operating with sequence, return specified, gradually, on a half-turn for the approach, in regular intervals ослабьте ten bolts of fastening of a head before possibility occurrence отдавания them manually.
  1. Remove bolts of fastening of a head together with washers.
  1. Having resorted to the help of the assistant remove heavy enough head of cylinders from the block. Remove a sealing lining, — try not to lose two directing plugs, established in the block of cylinders. If plugs are planted freely and easily taken out, take them and clean in a reliable place. Do not throw out an old lining, — it can be used as the sample at acquisition of the new.

The description of procedure of dismantling of a head of cylinders in case of need carrying out of its regenerative repair, see the General and engine major repairs.

Engines of 2.0 l

 PERFORMANCE ORDER

  1. Empty cooling system (see the Head of System of cooling, heating).
  2. Execute the operations described above (Removal and camshaft installation (ов see) and of components of a drive of valves — Removal, Engines of 2.0 l — subitem 1-13), — pay attention that for engine lifting it is required тележечный a jack, — for the purpose of loading distribution lay between a head of a jack and the pallet картера wooden брусок.
  1. Wipe absolutely places of connection of fuel hoses, turn out штуцерные bolts and remove sealing washers. Disconnect from the pump a hose of return of fuel, liberate hoses from intermediate clamps and take them aside from a head.


  1. Remove the inlet pipeline and a final collector (see the Head of the Power supply system and release). If the head is not subject to repair, it can be removed in gathering with the pipeline and a collector:

    1. On models with высоконапорным a turbo-supercharging remove inlet air lines and a metal tube with турбокомпрессора.
    2. Turn out bolts of fastening of a routeing trench of electroconducting to the top part of the inlet pipeline and take him aside from the engine. Disconnect the pipeline electroconducting of the gauge of position of a cranked shaft (CKP);
    3. Remove the fuel tubes going from ТНВД to atomizers. Disconnect vacuum hoses from the valve of switching of the inlet pipeline and valve EGR;
    4. Disconnect electroconducting from candles накаливания and remove a thermofilter турбокомпрессора;
    5. Disconnect oil tubes турбокомпрессора from the block of cylinders. Disconnect a vacuum hose of a diaphragm;
    6. Remove a starter thermofilter. Turn out fixing bolts and remove directing electroconductings and a basic arm of a final collector from a back part of the block of cylinders.
  1. Release collars and disconnect hoses of system of cooling from forward and back parts of the left wall of a head of cylinders.


  1. Turn out the top fixing bolt and take away the generator from a head of cylinders.
  1. Turn out three bolts of fastening of the right party of a head of cylinders to the top part of a cover газораспределительной chains and a unique bolt of fastening of a head to the block.
  1. Operating in sequence, return specified, gradually, on a half-turn for the approach, ослабьте ten main bolts of fastening of a head so that there was a possibility of their reversing by hand.
  1. Remove bolts complete with washers.
  2. By means of the assistant lift a head and remove it from the engine. Remove a sealing lining. Pay attention on two directing plugs established in the top part of a head of cylinders, — if plugs have free landing, remove them and clean in a reliable place. The old lining will be reasonable for keeping for the purpose of identification on it new.

Do not put a head on the bottom interfaced surface, enclose under a head wooden бруски so that they did not concern candles накаливания or sprays of atomizers which act from a plane of a head and can be damaged, if a head to put directly on a workbench.

The description of procedures of regenerative repair of a head of cylinders see the General and engine major repairs.

Preparation for installation

All engines

 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 easily to damage. 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).
  1. On the given engines the backlash size between a head and pistons is regulated by thickness of a lining. In the left forward corner of a lining are provided просечки by which quantity it is possible to define its thickness.

    A — Identification of a thickness of a sealing lining of a head of cylinders of the engine of 1.7 l SOHC (one просечка)
    B — Identification of a thickness of a sealing lining of a head of cylinders of the engine of 1.7 l DOHC (one просечка)
    C — Identification of a thickness of a sealing lining of a head of cylinders of the engine of 2.0 l (two просечки)

A.

B.

C.
    Quantity просечек Thickness of a lining, mm
    Engines of 1.7 l SOHC Engines of 1.7 l DOHC Engines of 2.0 l

    Without просечек

    1.30

    1.45

    1.20

    One просечка

    1.40

    1.50

    1.30

    Two просечки

    1.50

    1.55

    1.40


  1. The demanded thickness of a lining can be calculated also on size выступания the piston over a block surface (see further).
  1. Result the engine in position ВМТ of the end of a step of compression of the piston of the first cylinder. Establish on the block циферблатный a measuring instrument плунжерного type, press плунжер a measuring instrument to an interfaced surface of the block and null the device. Now move плунжер on a surface of the bottom of the piston of the first cylinder and measure its size выступания (on engines of 1.7 l SOHC — in three points of the bottom of each piston). Further, operating in a similar manner, define size выступания the piston of the fourth cylinder.

    A — size Measurement выступания pistons on engines of 1.7 l SOHC
    B — size Measurement выступания pistons on engines of 1.7 l DOHC
    C — size Measurement выступания pistons on engines of 2.0 l

A.

B.

C.
  1. Turn a cranked shaft on a half-turn for the purpose of reduction in positions ВМТ of pistons of 3rd and 2nd cylinders and repeat measurements. In summary return the engine in position ВМТ of the piston of the first cylinder.
  2. On engines of 1.7 l SOHC combine all 12 received results (on three on each piston) and divide result on 12; on engines of 1.7 l DOHC and 2.0 l the lining steals up on the maximum size выступания. By means of resulted below the table calculate a necessary thickness of a new lining.
Size выступания the piston, mm Demanded lining
Engines of 1.7 l SOHC Engines of 1.7 l DOHC Engines of 2.0 l

Less than 0.80

0.63—0.696

0.40—0.50

Without просечек

0.80—0.90

0.697—0.763

0.51—0.60

One просечка

0.90 and more

0.764—0.830

0.61—0.70

Two просечки

On engines of 1.7 l SOHC if any of pistons acts more strongly other more than on 0.05 mm, establish a lining большей thickness. For example, if the average size выступания makes 0.79 mm, and one of measurements makes 0.85 mm (a difference in 0.06 mm), use a lining with one просечкой.

Installation

Replacement of bolts of fastening of a head of cylinders is made without fail, without dependence from their current condition!

Engines of 1.7 l SOHC

  •  PERFORMANCE ORDER

    1. Pure rags dry wipe interfaced surfaces of the block and a head.
    1. Make sure of that two directing plugs are established in the nests. Lay on an interfaced surface of the block of cylinders a new sealing lining, — the lining keeps within marks by a mark «OBEN/TOP» upwards and forward on the engine.
    1. For the purpose of prevention of contact of pistons and valves turn a cranked shaft counter-clockwise on 90 °.
    2. By means of the assistant accurately establish a head on the block of cylinders, — track correctness of hit of directing plugs in reciprocal nests.
    1. Grease the hydrojacks fixing washers and levers of a drive of valves with pure impellent oil and establish components on the regular places. Grease rubbing surfaces of levers of a drive of valves молибденсодержащей with type greasing «Molikot And».
    1. Put a layer of suitable hermetic (consult on a car repair shop) on the top interfaced surface of a head of cylinders.
    1. Accurately establish the case газораспределительного the mechanism (with the camshaft enclosed in it) on a head of cylinders.
    2. Grease with a thin butter layer a carving part and the bottom party of heads of bolts pure impellent oil, then screw bolts and tighten them by hand.
    1. Operating in strictly certain sequence, in stages in regular intervals, tighten bolts of a head 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.
    1. Establish the thermostat case on the right party of a head of cylinders, using new sealing rings on the tube ends охладительного a path in a back part of the block of cylinders, and also between the case of the thermostat and a head of cylinders. Make sure that the metal tube in a back part of the block of cylinders was combined with the case. Tighten fixing bolts with demanded effort.
    1. Establish маслоподающую a tube on the block of cylinders and турбокомпрессор, having tightened with demanded effort штуцерные bolts.
    2. Establish a basic arm on the generator and турбокомпрессор, — track, that the fixture has been tightened with demanded effort.
    3. Put hermetic on an interfaced surface of a reception pipe of system of release of the fulfilled gases and a lining and establish them on a final collector. Tighten nuts with demanded effort.
    4. Attach a basic arm to a final collector and the block and tighten bolts of its fastening with demanded effort.
    5. Attach a returnable oil tube турбокомпрессора to the top part of the pallet картера, — do not forget to replace sealing washers.
    6. Establish a back cover of a belt of drive ГРМ, an arm of a support of a suspension bracket of the power unit, an intermediate roller, a cogwheel of a camshaft and газораспределительный a belt (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).
    7. Establish the right support of a suspension bracket of the power unit both the bottom and top sections of a cover газораспределительного belt ГРМ (Removal and installation of a cover of drive ГРМ see).
    8. Establish a pulley of a cranked shaft (Removal and installation of a pulley of a cranked shaft see). Establish a forward wheel and lower the car on the earth.
    9. Connect electroconducting to candles накаливания. Reliably tighten nuts.
    10. Establish hoses охладительного a path on a target branch pipe and fix last on a case cover газораспределительного the mechanism.
    11. Connect fuel lines ТНВД to the case газораспределительного the mechanism.
    12. Connect a hose охладительного a path to the case of the thermostat and the top branch pipe of a radiator. Reliably tighten fixing collars.
    13. Connect to the case of the thermostat electroconducting.
    14. Connect electroconducting sockets to the temperature gauge, the gauge of pressure of pressurisation and electromagnetic valve EGR.
    15. Connect ventilation hoses картера to a case cover газораспределительного the mechanism, reliably tighten fixing collars.
    16. Connect to the vacuum pump a vacuum hose and a tube of the servo-driver of the brake amplifier.
    17. Connection the air sleeve connecting турбокомпрессор with интеркулером, - track reliability of fixing of a branch pipe fixing collars.
    18. Establish the generator on an adjusting lath and tighten with demanded effort the bottom bolt of fastening of the generator.
    19. Establish belts of a drive of auxiliary units (Routine maintenance see the Head).
    20. Establish the case of an air cleaner with air lines and gauge MAF (see the Head of the Power supply system and release).
    21. Fill cooling system (see the Head of System of cooling, heating).
    22. Check up oil level in the engine, in case of need make corresponding updating.
    23. Tighten with demanded effort bolts of fastening of a wheel.
    24. Establish and connect the storage battery.
    25. Start the engine and check up it on presence of signs of development of leaks. Having warmed up the engine to normal working temperature, hold on bolts of fastening of a head of cylinders on a corner of 5th stage of a tightening (Specifications see).

    Engines of 1.7 l DOHC

  •  PERFORMANCE ORDER

    1. Pure rags dry wipe interfaced surfaces of the block and a head.
    1. Make sure of that directing plugs are established on the places.
    1. For the purpose of prevention of contact of valves with pistons turn a cranked shaft counter-clockwise on 60 ° from ВМТ.
    2. By means of the assistant establish a head on the block, — track hit of directing plugs in reciprocal nests.
    3. Grease with a thin butter layer a carving part and the bottom party of heads of bolts pure impellent oil, then screw bolts and tighten them by hand.
    1. Moving from the middle to edges, in stages in regular intervals, tighten bolts of a head with effort of 1st stage.
    1. In a former order hold on bolts on corners at first 2nd, then — 3rd, 4th and 5th stages, — take advantage of a goniometric nozzle, or put a paint or a marker basic labels.
    2. The further installation is made in an order, the return to an order of dismantle of components. Pay attention to following moments:

      1. Before installation газораспределительного a belt turn a cranked shaft in a normal direction (clockwise) before combination of labels ВМТ;
      2. After installation of atomizers and fuel tubes check up the power supply system on presence of signs of development of leaks (see the Head of the Power supply system and release);
      3. Make sure of correctness of a lining of electroconducting;
      4. Check up installation клапанных backlashes, in case of need make corresponding updating (Check and adjustment of backlashes of valves (engines of 1.7 l DOHC see));
      5. In end, fill cooling system (see the Head of System of cooling, heating).

    Engines of 2.0 l

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


     PERFORMANCE ORDER

    1. Pure rags dry wipe interfaced surfaces of the block and a head.
    1. Make sure of that directing plugs are established on the places. Lay on an interfaced surface of the block a new sealing lining.
    1. Make sure of that the cranked shaft is in ВМТ and it is blocked, cams of a drive of valves of the first cylinder are developed by working ledges upwards, and and a groove in a face surface of a pin of a shaft will develop in parallel a head cut (a control aperture above).
    2. By means of the assistant establish a head on the block of cylinders, — track hit of directing plugs in reciprocal nests. Establishing a head, pass in it газораспределительную a chain and fix it on a surface of a head by means of a screw-driver or a suitable core.
    3. Grease with a thin butter layer a carving part and the bottom party of heads of bolts pure impellent oil, then screw bolts and tighten them by hand.
    1. Operating in strictly certain sequence, in stages in regular intervals, tighten bolts of a head with effort of 1st stage.
    1. In a former order hold on bolts on corners at first 2nd, then — 3rd, 4th, 5th and 6th stages, — take advantage of a goniometric nozzle, or put a paint or a marker basic labels.
    2. Screw bolts of fastening of a head to a cover газораспределительной to a chain and the block of cylinders and tighten them with demanded effort.
    3. Develop the generator in regular position and tighten the top bolt of its fastening with demanded effort (the engine Electric equipment see the Head).
    4. Attach hoses of system of cooling to a head of cylinders and fix their collars.
    5. Establish the inlet pipeline, a final collector and accompanying components (see the Head of the Power supply system and release).
    6. Establish a camshaft asterisk (Removal and installations of chains and asterisks of drive ГРМ, check of a condition of components (engines 2.0 see.
    7. Establish new sealing washers on штуцерные sockets топливопроводов ТНВД. Tighten sockets with demanded effort (see the Head of the Power supply system and release).
    8. In end, fill cooling system (see the Head of System of cooling, heating).