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 cover installation газораспределительного the mechanism

Removal

Engines of 1.7 l SOHC

 PERFORMANCE ORDER

  1. Remove the air cleaner case in gathering with air lines and a measuring instrument of the expense of air (see the Head of the Power supply system and release).
  1. Ослабьте collars also disconnect hoses of system of ventilation картера, brought to the forward and back parties of a cover, — it is necessary to turn away two bolts of fastening of conducting to a camshaft cover, having raised conducting for access reception to a back hose of ventilation картера.
  1. Remove a pulley of a cranked shaft. Turn out fixing bolts and, uncover газораспределительного the mechanism together with a sealing lining.

Engines of 1.7 l DOHC

 PERFORMANCE ORDER

  1. Remove an air cleaner and inlet air lines in gathering with a measuring instrument of weight air (see the Head of the Power supply system and release).
  2. Remove from a cover газораспределительного the mechanism the engine management block (ECM) (see the Head of the Power supply system and release).
  3. Disconnect electroconducting, give fixing screws / a nut and remove an arm of fastening ECM.
  4. Turn out a fixing bolt, disconnect electroconducting and remove an elevating eye of the engine from a back right part of a head of cylinders. Ослабьте a bolt of fastening of the left back elevating eye.
  1. Ослабьте штуцерные sockets of fastening of fuel tubes to ТНВД.

Access to штуцерным to connections is limited, — composers of the present Management consider necessary to turn out a bolt of fastening of the case of the filter / маслоохладителя and to take spongy filling from space between ТНВД and the filter case.

  1. Disconnect lines of giving of fuel from atomizers.
  2. Give fixing bolts and remove external consolidations of atomizers.
  3. Turn out a bolt of fastening of a routeing trench of electroconducting to a back part of a head of cylinders. Release two clamps and remove a trench.
  4. Give bolts of fastening of the top cover of drive ГРМ to a drive клапанного the mechanism.
  5. Turn out fixing bolts and uncover газораспределительного the mechanism together with a sealing lining.
  6. Check up a condition of a sealing lining, in case of need make its replacement.

Engines of 2.0 l

 PERFORMANCE ORDER

  1. Turn out fixing screws and remove from a cover газораспределительного the mechanism the top plastic cover.
  2. Release fixing collars and disconnect a hose of system of ventilation картера from a back part of a cover. On models Zafira remove consolidation of an impellent compartment and a cover established before a windscreen обтекателя.
  1. On engines with низконапорным a turbo-supercharging (X20DTL or Y20DTL) ослабьте collars of fastening of a metal tube to assemblage турбокомпрессора and a rubber sleeve to the pipeline, turn out two fixing bolts and remove from the engine air line assemblage together with established between a tube and the compressor a sealing ring. On engines with высоконапорным a turbo-supercharging (Y20DTH) release clamps, turn out bolts of fastening of arms and remove the air sleeve laid between турбокомпрессором and интеркулером.
  1. On all models liberate electroconducting of candles накаливания from clamps on the back party of a cover. Turn out a bolt of fastening of a routeing trench of electroconducting of the inlet pipeline to a cover. Disconnect brought to the right party of a cover a vacuum hose.
  1. Turn out bolts of fastening of a cover and remove them together with sealing washers. Having raised a cover, remove it together with a sealing lining. Check up a condition of sealing linings and the washers, the failed elements replace.

Installation

Engines of 1.7 l SOHC

 PERFORMANCE ORDER

  1. Make sure that interfaced surfaces of a cover and the case are absolutely pure and dry. Accurately lay a sealing lining on a cover.
  1. Press a cover to the case, — track, that the sealing lining has not moved. Screw fixing bolts and tighten them with demanded effort.
  2. Attach hoses of system of ventilation картера and fix their collars.
  3. Establish inlet air lines and the air cleaner case.

Engines of 1.7 l DOHC

 PERFORMANCE ORDER

  1. Make sure of absoluteness of cleanliness and dryness of interfaced surfaces, lay in a cover flute a sealing lining. Check up a condition of a sealing ring in the bottom part of a cover, in case of need make replacement.
  1. Grease interfaced surfaces with hermetic, having tracked, that it has not got to an oil aperture in the right back part of a final camshaft. Consolidations of atomizers are marked by inscriptions «UPPER» and «OUTSIDE».


  1. Accurately lay a cover on the regular place, having tracked, that the sealing lining was not displaced. Establish the top section of a cover of drive ГРМ. Screw bolts of fastening of a cover газораспределительного the mechanism and tighten them with demanded effort.
  1. The further installation is made as it should be the return to an order of removal of components, — pay attention to following moments:
    1. All bolts should be tightened strictly with demanded effort;
    2. External consolidations of atomizers are marked by inscriptions «UPPER» (top) and «OUTSIDE» (external), — establish consolidations, having tracked, that they have appeared put on cones of atomizers;
    3. After engine start attentively examine it about revealing of signs of development of leaks.

Engines of 2.0 l

 PERFORMANCE ORDER

  1. Make sure of absoluteness of cleanliness and dryness of interfaced surfaces, lay in a cover flute a sealing lining.
  1. Put on sealing washers bolts of fastening of a cover. Establish bolts on a cover, having tracked fixing by the bottom coat hanger of their heads of sealing washers.
  1. Grease with hermetic semicircular cut in the right part of an interfaced surface of a head of cylinders and from both parties of a cover of the left bearing.


  1. Accurately lay a cover into place, screw and by hand tighten all fixing bolts.
  2. Tighten all fixing bolts with demanded effort.
  3. Connect to the unions vacuum hoses, fix in clamps electroconducting. Connect to a back part of a cover hose PCV.
  4. On models with низконапорным a turbo-supercharging establish an inlet air line and an air tube, — do not forget to replace a sealing ring. Track reliability of a tightening of collars and clamps. On models with высоконапорным a turbo-supercharging establish into place a sleeve connecting турбокомпрессор with интеркулером. Track reliability of a tightening of fixture.
  5. On all models establish a plastic cover and reliably tighten bolts of its fastening. On models Zafira establish into place consolidation of an impellent compartment and the panel forward обтекателя.