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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



Check and adjustment of phases газораспределения (engines 2.0)


The blocking adaptations necessary for performance of check and adjustment of phases газораспределения

And — the Core of fixing of a cranked shaft (an equivalent of special tool KM-929)
In — the Core of fixing of flange ТНВД (an equivalent of special tool KM-927)

With — the Adaptation for camshaft blocking (an equivalent of special tool KM-932)


Dimensional characteristics of the adaptation for blocking of a cranked shaft (mm)


Dimensional characteristics of the adaptation for blocking of flange ТНВД (mm)

For carrying out of the given checks the following special tools Opel (or their equivalents) be required:

  1. The adaptation for camshaft blocking (КМ-932)
  2. The adaptation for blocking of flange ТНВД (КМ-927)
  3. The adaptation for blocking of a cranked shaft (КМ-929)
  4. The lever of an asterisk of a camshaft (КМ-933).

In case of need suitable tool can be made own forces of the mechanic-fan according to the presented dimensional characteristics.

By means of the adaptation for blocking of a camshaft the groove in a camshaft pin is fixed in parallel interfaced surface of a head of cylinders.


 PERFORMANCE ORDER

  1. Disconnect a negative wire from the battery. Remove a belt of a drive of auxiliary units (Routine maintenance see the Head). Turn out the bottom bolt of fastening of a rack of a tension roller and an axial bolt of the basis натяжителя. Remove assemblage натяжителя from the engine.

Do not remove a rack from assemblage натяжителя, otherwise there will be a necessity for polishing of working surfaces.

  1. Remove the vacuum pump of the servo-driver of the brake amplifier of brakes (the Brake system see the Head).
  2. For the purpose of simplification of access to a cover of asterisk ТНВД and to the pump execute following preparatory operations:
    1. 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).
    2. Mark position of an arm 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 the right support of the engine to an arm of a head and three bolts of fastening of a support of the engine to a mudguard. Prop up the right party of the engine тележечным a jack. Lift the engine as far as possible above, without overloading, however, the remained support and lines of communication (tubes, hoses, electroconducting plaits).
  3. Uncover газораспределительного the mechanism (Removal and cover installation газораспределительного the mechanism see) and result the piston of the first 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.
  4. Remove the gauge of position of a cranked shaft (CKP) (see the Head of the Power supply system and release).
  5. Turn out fixing bolts and uncover asterisks ТНВД a cover of a chain of drive ГРМ.
  1. Make sure that risk on a pulley of a cranked shaft it was combined with an adjusting label on a cover газораспределительной chains and pass in an aperture under gauge CKP installation fixing core, having entered it into gearing with cut in a shaft body.


  1. Having blocked a cranked shaft, pass fixing core through an aperture in flange ТНВД and push its end in an aperture in the pump.
  1. Then fill the adaptation for camshaft blocking in a groove in a pin of the last.
  1. If all fixing adaptations free on the regular places, hence, phases газораспределения become established correctly and updating is not required, — pass to performance of procedures (sm below subitem 22-27). If at least one tool does not manage to be established properly, make corresponding adjustment (see further), — pay attention to necessity of replacement of a bolt of an asterisk of a cranked shaft and a sealing ring of a bolt натяжителя.
  2. Take the adaptations blocking a camshaft and flange ТНВД, turn out bolts of fastening of an arm of the right support to a head of cylinders.
  3. Take away a cap натяжителя the top chain ГРМ from a back part of a head of cylinders and remove плунжер, — try to remember its adjusting position. Remove a sealing ring and will throw out it, — at installation the ring is subject to replacement without fail.
  4. Keeping a camshaft for лыски рожковым a key, release and turn out a bolt of fastening of an asterisk. Screw a new bolt and tighten it while only by hand.
  5. Ослабьте bolts of fastening of asterisk ТНВД to a pump flange.
  1. Having blocked a cranked shaft from проворачивания, make sure that label ВМТ on an asterisk of top chain ГРМ is combined with an aperture for the control of phases газораспределения in flange ТНВД. Pass fixing core and tighten bolts of fastening of an asterisk with demanded effort.
  1. Push the end of a core of blocking of a camshaft a groove at an end face of a pin of the last, having combined directing pin with an aperture.
  2. Having established fixing adaptations on the regular places, establish the lever of an asterisk of a camshaft, — in the absence of the lever, take advantage of two bolts, having passed them in asterisk apertures. Then, operating as with the lever the big screw-driver, block an asterisk from проворачивания. Ask the assistant to keep tense the top party газораспределительной chains, — it is necessary to make small effort an asterisk, having left that all weak point of a chain on the party натяжителя.
  3. Having pulled the top chain, make sure that fixing ТНВД the core moves in the aperture with insignificant resistance. At закусывании a core ask the assistant to weaken pressure upon an asterisk, — if the core moves excessively freely, the effort should be increased a little.
  1. Having pulled demanded image the top chain, fix a camshaft рожковым a key and tighten a bolt of fastening of its asterisk with effort of 1st stage. Check up freedom of a course fixing ТНВД a core, then hold on a bolt of fastening of an asterisk on a corner, at first 2nd, then 3rd stages of a tightening, — take advantage of a goniometric prefix to воротку, or put a marker basic labels.
  1. Remove all blocking adaptations and establish a new sealing ring on a cap натяжителя the top chain of drive ГРМ. Fill плунжер in a head of cylinders (the deaf end to a chain), establish a cap and tighten it with demanded effort.

At installation new натяжителя ослабьте it, completely, before click having drowned the central core of a cap, — now the core натяжителя should freely утапливаться and smoothly come back in a starting position.

  1. Turn a cranked shaft on two full two turns (720 °) in a normal direction (Reduction of the piston of the first cylinder in position of the top dead point of the end of a step of compression (ВМТ), for the purpose of reduction of the piston of the first cylinder in ВМТ the end of a step of compression see, — make sure of possibility of unobstructed installation of all fixing adaptations.
  1. Make sure of absoluteness of cleanliness and dryness of interfaced surfaces of covers of asterisk ТНВД and drive ГРМ. If the cover has initially been established on a lining, replace last. Tighten bolts of fastening of a cover with demanded effort. If the lining has not been provided, impose on an interfaced surface of a cover a pillow of hermetic in the thickness approximately 2 mm, establish a cover and tighten with demanded effort bolts of its fastening.
  1. Establish on the engine натяжитель a belt of a drive of auxiliary units, having tightened both bolts with demanded effort. If strut acted in film from assemblage натяжителя, grind in its several consecutive back and forth motions, having established a head on шестигранную a basis part. If the rack functions regularly, establish a belt of a drive of auxiliary units (Routine maintenance see the Head).
  2. If removed, establish on a head of cylinders an arm of the right support of a suspension bracket of the power unit and clean propping up engine a jack. Establish the right support on a mudguard and combine it with the labels put in the course of dismantle on an arm of a head of cylinders. Screw fixing bolts and tighten them with demanded effort. Establish a cover газораспределительного the mechanism (Removal and cover installation газораспределительного the mechanism see).
  3. Establish into place a reception pipe of system of release of the fulfilled gases and the air cleaner case (see the Head of the Power supply system and release).
  4. Establish on a head of cylinders the vacuum pump of the servo-driver of the brake amplifier (the Brake system see the Head).
  5. Establish on the block of cylinders gauge CKP (see the Head of the Power supply system and release) and connect a negative wire to the battery.