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 cover of drive ГРМ

Removal

Engines of 1.7 l SOHC

The top section

 PERFORMANCE ORDER

  1. Remove an air cleaner 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. Turn out fixing screws and remove the top section of a cover газораспределительного a belt.

The bottom section

 PERFORMANCE ORDER

  1. Remove the top section of a cover (see above).
  2. Remove a pulley of a cranked shaft (Removal and installation of a pulley of a cranked shaft see).
  1. Turn out fixing bolts and remove from the engine the bottom section of a cover together with a sealing lining. Check up a lining condition, in case of need make replacement.

Back cover

 PERFORMANCE ORDER

  1. Remove a belt of drive ГРМ (Removal and installation of a belt of drive ГРМ see).
  2. Remove cogwheels of a camshaft and ТНВД, an intermediate roller and assemblage натяжителя (Removal and installation натяжителя a belt and cogwheels of drive ГРМ (engines 1.7 see.
  1. Mark adjusting position of the right support of a suspension bracket of the power unit, then turn out three bolts of its fastening.
  1. Turn out six fixing bolts and remove a back cover from the engine.

Engines of 1.7 l DOHC

The top section

 PERFORMANCE ORDER

  1. Disconnect a negative wire from the battery.
  2. Remove an air cleaner in gathering with air lines (see the Head of the Power supply system and release).
  3. Prop up the engine тележечным a jack, — for the purpose of loading distribution lay between a head of a jack and the pallet картера wooden брусок.
  4. Mark adjusting components of the right support of a suspension bracket of the power unit. Turn out three bolts of fastening of a support.
  1. Turn out fixing bolts and separate an arm of a support from an adapter on the engine block.
  1. In case of need disconnect electroconducting from the generator (the engine Electric equipment see the Head).
  1. Turn out a fixing bolt with a head of type TORX. Release clamps of fastening of a routeing trench of electroconducting and remove last from the right back part of a head of cylinders.
  1. Liberate hoses from clamps on the top cover, turn out eight разнодлинных fixing bolts and remove the top section of a cover.

The bottom section

 PERFORMANCE ORDER

  1. Remove a belt of a drive of auxiliary units (Routine maintenance see the Head), — preliminary mark with a paint or a marker a direction of its rotation. Cock a lay brake, поддомкратьте redock of the car and establish it on props. Remove the right forward wheel and (at a corresponding complete set) protection картера.
  2. Remove the top section of a cover (see above).
  3. Remove a pulley of a cranked shaft (Removal and installation of a pulley of a cranked shaft see).
  1. Turn out three fixing bolts and remove the bottom section of a cover from the case of the oil pump.
  1. Remove an adapter of fastening of a support of a suspension bracket the saga.
  1. Temporarily screw on the regular place a bolt of fastening of an arm натяжителя газораспределительного a belt.

Back cover

 PERFORMANCE ORDER

  1. Remove a belt of drive ГРМ (Removal and installation of a belt of drive ГРМ see).
  2. Remove directing roller and a roller натяжителя, cogwheels of a camshaft and ТНВД (Removal and installation натяжителя a belt and cogwheels of drive ГРМ (engines 1.7 see.
  3. Disconnect a spring натяжителя.
  1. Turn out four bolts of fastening and remove a back cover of belt ГРМ.

Engines of 2.0 l

 PERFORMANCE ORDER

  1. Remove the top chain and asterisks (Removal and installations of chains and asterisks of drive ГРМ, check of a condition of components (engines 2.0 see.
  2. Remove a head of cylinders (Removal and installation of a head of cylinders see).

Theoretically the cover can be removed without preliminary dismantle of a head, however such way is interfaced to risk of damage of a sealing lining of a head of cylinders.

  1. Remove the water pump (see the Head of System of cooling, heating), — before отпусканием a bolt temporarily remove blocking core not to break it (do not forget to establish a core into place after the bolt will be weakened)
  2. Remove the pallet картера (Removal and pallet installation картера see).
  3. Remove the generator (the engine Electric equipment see the Head).
  4. Turn out a cap bottom натяжителя from a back part of a cover and remove плунжер натяжителя, — try to remember adjusting position of components. Remove from a cap a sealing ring, — at installation the sealing ring is subject to replacement without fail.
  1. Turn out bolts of fastening of a cover of drive ГРМ to the block of cylinders, — bolts have various length and at installation should be rolled strictly on the former places.
  1. Accurately separate a cover from the block and remove it from the engine, — try not to lose directing plugs. If directing plugs have weak landing, remove them and combine in a reliable place.
  1. Turn out an axial bolt and remove from the block of cylinders boots натяжителей the top and bottom chains.
  1. Turn out fixing bolts and remove with блокираторов успокоитель the bottom chain, — try to remember adjusting position of components.
  1. Temporarily remove an asterisk bottom газораспределительной chains from flange ТНВД and remove a lining of a cover of drive ГРМ from the block of cylinders. Having removed a lining, establish an asterisk on the place on a pump flange.

Installation

Engines of 1.7 l SOHC and DOHC

Installation is made in an order, the return to an order of dismantle of components.

Engines of 2.0 l

Before installation of a cover composers of the present Management recommend to replace epiploons of a cranked shaft (Replacement of epiploons of a cranked shaft see).

 PERFORMANCE ORDER

  1. Make sure of absoluteness of cleanliness and dryness of interfaced surfaces of a cover and the engine block. Check up presence on the places of directing plugs, — in case of need establish plugs.
  2. Temporarily remove an asterisk from flange ТНВД and establish into place a sealing lining, having tracked correctness of its landing to directing plugs. Establish an asterisk back on flange ТНВД.
  3. Establish on the block of cylinders успокоитель the bottom chain, screw and tighten with demanded effort bolts of its fastening.

Успокоитель it is necessary to establish the step party outside.

  1. Establish into place boots натяжителей, screw an axial bolt and tighten it with demanded effort.
  1. Establish into place a cover of drive ГРМ, — achieve combination приводной a gear wheel of the oil pump with an asterisk of a cranked shaft, then push a cover into place, having tracked hit of directing plugs in the reciprocal.
  2. Screw bolts of fastening and in stages gradually tighten them with demanded effort.
  3. Plant a new sealing ring on a cap bottom натяжителя. Fill плунжер (the deaf end to a chain). Establish a cap on a cover of a chain and tighten it with demanded effort.

At installation new натяжителя unblock 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. Establish a pulley of a cranked shaft (Removal and installation of a pulley of a cranked shaft see).
  2. Establish a head of cylinders (Removal and installation of a head of cylinders see).
  3. Establish the top chain and asterisks of drive ГРМ (Removal and installations of chains and asterisks of drive ГРМ, check of a condition of components (engines 2.0 see.
  4. Establish the pallet картера (Removal and pallet installation картера see).
  5. Establish the water pump and the generator (Heads of System of cooling, heating and an engine Electric equipment see).
  6. Establish a belt of a drive of auxiliary units (Routine maintenance see the Head).
  7. In end, fill in in the engine oil and cooling liquid (Heads Routine maintenance and Systems of cooling, heating see). Start the engine and make sure of absence of signs of development of leaks.