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, service and installation of the oil pump

Removal

Engines of 1.7 l SOHC

 PERFORMANCE ORDER

  1. Remove a back cover of a belt of drive ГРМ (Removal and installation of a cover of drive ГРМ see).
  2. Remove литьевую pallet section картера (Removal and pallet installation картера see).
  3. Remove assemblage натяжителя and an intermediate roller (Removal and installation натяжителей chains of drive ГРМ (engines 2.0 see.
  4. On models with РКПП ask the assistant for the purpose of blocking of a cranked shaft from проворачивания to include the higher transfer and against the stop to squeeze out a pedal of a foot brake. On models with АТ turn out one of bolts of fastening of the hydrotransformer and draw last to картеру transmissions by means of a steel lath and suitable bolts with washers (Automatic transmission see the Head). If the engine is removed from the car, it is necessary to block a flywheel / приводной a disk (Removal, check of a condition and flywheel / installation приводного a disk see). Turn out a fixing bolt and remove a cogwheel.

  5. Disconnect an oil tube from the case of the oil filter and take tubes together with an arm aside.
  1. Disconnect electroconducting from the gauge of pressure of oil.
  1. Turn out six fixing bolts and remove the oil pump from directing plugs.
  1. Having hooked a screw-driver, take from the case of the pump an epiploon and will throw out it, — at assemblage the epiploon is subject to replacement without fail.

Engines of 1.7 l DOHC

The reduktsionnyj valve of pressure of oil will screw in the block of cylinders and cannot be removed without preliminary dismantle ТНВД.


 PERFORMANCE ORDER

  1. Remove a belt of drive ГРМ (Removal and installation of a belt of drive ГРМ see).
  2. Remove cogwheels of the oil pump and a cranked shaft (Removal and installation натяжителя a belt and cogwheels of drive ГРМ (engines 1.7 see.
  3. Remove cast section of the pallet картера (Removal and pallet installation картера see). Turn out fixing bolts, shift a cover of the oil pump to a pin of a cranked shaft, having accepted safety measures not to drop directing plugs. Remove the sealing ring established round a case part of the oil pump and will throw out it, — at assemblage the ring is subject to replacement without fail.
  4. With marker mark position of an external rotor of the pump, — at assemblage components should be established strictly in similar.
  1. Take internal and external rotors from the block of cylinders.


  1. In case of need remove ТНВД (see the Head of the Power supply system and release) and turn out редукционный the valve from a back part of the block of cylinders. The valve is to the right of the bottom arm of fastening ТНВД. Remove a sealing ring.

Engines of 2.0 l

The oil pump is built in a cover of drive ГРМ, the description of procedures of its removal and installation see Removal and installation of a cover of drive ГРМ.

The reduktsionnyj valve of the oil pump can be removed, without dismantling a cover of drive ГРМ. For dismantle of the valve it is enough to remove the pallet картера.

Check

Engines of 1.7 l SOHC

 PERFORMANCE ORDER

  1. On the pump removed from the engine turn out screws with crosswise шлицами and remove an internal cover of the pump.

  1. Check up sizes of backlashes between teeths of external and internal rotors, and also between an external rotor and the pump case (a radial backlash of an external rotor).
  1. By means of a steel ruler and щупа лезвийного type measure size of an axial backlash (люфта) rotors.
  1. If results of measurements fall outside the limits admissible ranges (Specifications see), make replacement of corresponding components. Pay attention that landing marks are put on a surface of an external rotor.
  1. The reduktsionnyj valve can be turned out from the pump case, for procleaning and check of a condition of components.

    And — the Piston редукционного the valve
    In — an assemblage Spring редукционного the valve
    With — the Thermostatic valve
    D — Zaglushka

  1. The gauge of emergency pressure of oil will screw in a back part of the pump. The defective gauge is subject to replacement (the engine Electric equipment see the Head).
  2. The thermostatic valve of an oil cooler / перепускной the filter valve will screw in the case of the oil filter.

Engines of 1.7 l DOHC

 PERFORMANCE ORDER

  1. Carefully clean all components and attentively study a condition of rotors, cases and pump covers. In case of revealing of damages and signs of excessive deterioration replace defective components. If the pump case in the block of cylinders has marks, address for consultation to experts of a firm car repair shop of company Opel.

  1. If the condition of components is found satisfactory, establish rotors in the case of pump assemblage. With the help щупов лезвийного type measure size of backlashes between an external rotor and the case of the pump and a backlash between teeths of an internal and external rotor. Measure size axial люфта rotors and check up a cover plane. If results of measurements fall outside the limits admissible ranges (Specifications see), replace the worn out components.


  1. If removed редукционный the valve, check up freedom of moving of the piston and smoothness of its return under the influence of effort developed by a spring. In case of need replace the valve in gathering.

Engines of 2.0 l

 PERFORMANCE ORDER

  1. Turn out fixing bolts and uncover the pump from the interior of a chain cover.
  1. With marker mark adjusting positions of both rotors.
  1. Take rotors from the pump case.


  1. Turn out заглушку the valve of adjustment of pressure of oil in the basis of the case of the pump.
  1. Take a spring, the plug and плунжер, — try to remember adjusting position of components. Remove with заглушки the valve a sealing ring.


  1. Turn out заглушку редукционного the valve from a back part of a cover of a chain, — the valve is established over three bolts in a back part of a cover.
  1. Take from a cover a spring and плунжер, — try to remember adjusting position of components. Remove with заглушки a sealing ring.
  1. Clear all components. Estimate degree of deterioration of rotors, cases of the pump and плунжеров valves. Replace defective components. If pump rotors are already marked, replace all pump in gathering.
  1. If the condition of all components does not cause doubts, collect them upside-down, paying attention to following moments:

    1. Track for correctness of orientation of rotors and плунжеров at their installation in pump assemblage;
    2. Do not forget to replace sealing rings заглушек, track, that заглушки have been tightened with demanded effort;
    3. Track, that bolts of fastening of a cover of the pump also have been tightened with demanded effort;
    4. In end fill the oil pump with pure impellent oil, manually turning an internal rotor.

Installation

Engines of 1.7 l SOHC

 PERFORMANCE ORDER

  1. If removed, establish a new sealing ring редукционного the valve and establish the valve in gathering in the block of cylinders, having tightened it with demanded effort.
  1. By means of cylindrical оправки (a replaceable face head of the corresponding size, or a piece of a pipe of suitable diameter) or heads plant in the case of the oil pump a new epiploon (sealing sponges inside), — track, that оправка rested only against rigid external edge of an epiploon. Make sure that an epiploon запрессован заподлицо with a case surface.

Before installation grease sealing sponges of an epiploon with pure impellent oil.

  1. Grease pump rotors with pure impellent oil and plant them in the pump case. Track correctness of combination of the adjusting labels put in the course of dismantle. Marks should be turned in the engine.
  1. Put a layer of suitable hermetic on an internal interfaced surface of an internal cover of the case of the pump and establish it on the case.
  2. Screw screws of fastening of a cover and tighten them with demanded effort.
  3. Carefully wipe interfaced surfaces of the case of the pump and the block. Check presence on the places of directing plugs of the pump. Remove all traces of hermetic from a carving part of bolts of fastening of the pump.
  1. Replace a lining and establish the pump on the block of cylinders, trying not to damage working edges of an epiploon about a cranked shaft. Achieve correct gearing of cuts in an internal rotor with corresponding ledges on a pin of a cranked shaft. Tighten fixing bolts with demanded effort.
  1. The further installation is made in an order, the return to an order of dismantle of components. Pay attention to following moments:

    1. Tighten all fixture with demanded effort;
    2. At installation of an oil tube маслоохладителя use do not forget to replace sealing elements;
    3. Check up oil level in the engine, in case of need make corresponding updating (Routine maintenance see the Head);
    4. Do not forget to replace a bolt of fastening of a cogwheel of a cranked shaft.

Engines of 1.7 l DOHC

 PERFORMANCE ORDER

  1. If removed редукционный the valve, replace a sealing ring and establish the valve in gathering in the block of cylinders, having tightened it with demanded effort.
  2. Grease pump rotors with pure impellent oil and establish them in the pump case, using preliminary put marks.
  1. Before installation, accurately hooking a screw-driver, remove epiploons of the oil pump and a cranked shaft. Establish new epiploons sponges in the engine and запрессуйте them заподлицо with the case by means of suitable cylindrical оправки (Engines of 1.7 l SOHC, item 2 see above).
  1. Make sure of absoluteness of cleanliness and dryness of interfaced surfaces of the oil pump and the block of cylinders. Check up presence on the places of directing plugs. Remove all traces of hermetic from carving parts of bolts of fastening of the pump.
  1. Lay new consolidation in a flute round a case part of the pump in a cover and put a layer of suitable hermetic on an interfaced surface of a cover of the pump.
  1. Accurately establish a pump cover into place, — try not to damage a sponge of epiploons of a cranked shaft and a rotor shaft. Combine a cover with directing plugs and press it to the block, supervising position of epiploons.
  2. With special hermetic for fixing of carving connections grease carving parts of fixing bolts. Screw bolts and tighten them with demanded effort. Pay attention that the longest bolt should be rolled in the bottom left aperture in a cover.
  3. Establish cogwheels and a belt of drive ГРМ (Removal and installation натяжителя a belt and cogwheels of drive ГРМ (engines 1.7 see.
  4. Establish the pallet картера (Removal and pallet installation картера see).
  5. In end, fill in in the engine pure oil (Routine maintenance see the Head).

Engines of 2.0 l

Removal, service and installation of the oil pump see.