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 натяжителя a belt and cogwheels of drive ГРМ (engines 1.7 )

Camshaft cogwheel

Removal

Engines SOHC

 PERFORMANCE ORDER

  1. Remove a belt of drive ГРМ (Removal and installation of a belt of drive ГРМ see).
  2. Uncover газораспределительного the mechanism (Removal and cover installation газораспределительного the mechanism see).
  3. Fix a camshaft from проворачивания, keeping it рожковым a key for шестигранную section. Turn out a fixing bolt and remove a camshaft cogwheel.

Engines DOHC

 PERFORMANCE ORDER

  1. Remove a belt of drive ГРМ, (Removal and installation of a belt of drive ГРМ see). Before отдаванием a bolt of fastening of a cogwheel, turn a cranked shaft on 60 ° back from position ВМТ for the purpose of prevention of input of valves in contact to pistons.
  2. For the purpose of prevention turning a camshaft completely screw a bolt fixing a cogwheel.
  1. Turn out fixing bolt and remove a cogwheel from a camshaft pin, — try to remember adjusting position of components. If the core blocking cogwheels has free landing, remove it from a camshaft and clean in a reliable place.

Installation

Engines SOHC

The new bolt of fastening of a cogwheel of a camshaft is required!


 PERFORMANCE ORDER

  1. Establish a cogwheel, screw the NEW fixing bolt and tighten it, while only by hand.
  2. Establish a belt of drive ГРМ (Removal and installation of a belt of drive ГРМ see).

Engines DOHC

 PERFORMANCE ORDER

  1. Make sure of that the blocking core is on the regular place, then establish a cogwheel on a camshaft, — track hit of a fixing core in a reciprocal aperture.
  2. Screw a bolt of fastening of a cogwheel, then achieve combination of adjusting apertures in a wheel and a head and screw bolt М6. Tighten a bolt of fastening of a cogwheel with demanded effort. Turn a cranked shaft on 60 ° clockwise before reduction risks on a cogwheel of a cranked shaft in position «at 12 o'clock» and its combination with a cast label on a cover of the oil pump.
  3. Establish a belt of drive ГРМ (Removal and installation of a belt of drive ГРМ see).

Cogwheel ТНВД

Removal

Engines SOHC

 PERFORMANCE ORDER

  1. Remove a belt of drive ГРМ (Removal and installation of a belt of drive ГРМ see).
  1. Insert adaptation KM-6011 into an aperture for fixing of a flange for the purpose of prevention проворачивания cogwheel ТНВД. At absence near at hand the special adaptation take advantage of a core in diameter of 9.5 mm and length 75 mm.
  1. Turn out three fixing bolts and remove a cogwheel.

Engines DOHC

 PERFORMANCE ORDER

  1. Remove a belt of drive ГРМ (Removal and installation of a belt of drive ГРМ see).

  2. For the purpose of prevention проворачивания shaft ТНВД against the stop screw bolt М8 fixing a cogwheel.

In case of need the cogwheel can be blocked a different way: by means of the adaptation in the form of a plug with screwed on the ends equipped with fixing nuts bolts.

  1. Release and turn out a nut of fastening of a cogwheel.
  1. Remove a cogwheel from shaft ТНВД, — try to remember adjusting position of components. If шпонка has weak landing in a pin of shaft ТНВД, remove it and clean in a reliable place.

The cogwheel has конусную landing to a pin of a shaft and in certain cases for its removal the stripper can be demanded.

Installation

Engines SOHC

 PERFORMANCE ORDER

  1. Plant a cogwheel on a pump shaft, — track cut combination on an asterisk with cut on a flange and an aperture for input of blocking core КМ-6011.
  2. Screw bolts of fastening of a cogwheel and tighten them, while only by hand.
  3. Establish a belt of drive ГРМ (Removal and installation of a belt of drive ГРМ see).

Engines DOHC

 PERFORMANCE ORDER

  1. Make sure of correctness of landing шпонки in a shaft pin, then establish a cogwheel, — track hit шпонки in шпоночный a groove.
  2. Screw a fixing nut and tighten it with demanded effort, having blocked a cogwheel from проворачивания a way вворачивания fixing bolt М8.
  3. If for asterisk fixing it was used вильчатое the adaptation, achieve combination of adjusting apertures and screw bolt М8.
  4. Establish a belt of drive ГРМ (Removal and installation of a belt of drive ГРМ see).

Cogwheel of a cranked shaft

Removal

Engines SOHC and DOHC

 PERFORMANCE ORDER

  1. Remove a pulley of a cranked shaft (Removal and installation of a pulley of a cranked shaft see).
  2. 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). Ослабьте a bolt of fastening of a cogwheel.
  3. Remove a belt of drive ГРМ (Removal and installation of a belt of drive ГРМ see).
  4. Turn out a fixing bolt with a washer and remove a cogwheel, — if the wheel does not give in, use a suitable stripper. At free landing шпонки in a shaft pin, take it and clean in a reliable place.
  5. On engines DOHC remove from a pin of a cranked shaft фланцевую the prorate, - try to remember adjusting position of components.

Installation

Engines SOHC and DOHC

 PERFORMANCE ORDER

  1. Installation is made in an order, the return to an order of dismantle of components, — track correctness of landing шпонки in a pin of a shaft and correctness of combination with it шпоночного a groove of a nave of a cogwheel.

On engines DOHC фланцевая the prorate is established by acting party outside.

Cogwheel of the oil pump (engines DOHC)

Removal

 PERFORMANCE ORDER

  1. Remove a belt of drive ГРМ (Removal and installation of a belt of drive ГРМ see).
  1. Having blocked a cogwheel of the oil pump from проворачивания by means of a replaceable face head with the extension piece, put on on one of bolts of fastening of a cover of the oil pump, turn out the central bolt of fastening of a cogwheel.
  1. Remove a cogwheel from a shaft of the oil pump, try to remember adjusting position of components.

Installation

 PERFORMANCE ORDER

  1. Establish a cogwheel, — track correctness of combination шпоночного a groove with шпонкой. Tighten a nut with demanded effort, blocking a cogwheel from проворачивания an asterisk in the way used at removal.
  2. Establish a belt of drive ГРМ (Removal and installation of a belt of drive ГРМ see).

Натяжитель in gathering

Removal

Engines SOHC

 PERFORMANCE ORDER

  1. Remove a belt of drive ГРМ (Removal and installation of a belt of drive ГРМ see).
  2. Turn out a fixing bolt and remove assemblage натяжитель from the engine.

Engines DOHC

 PERFORMANCE ORDER

  1. Remove a belt of drive ГРМ (Removal and installation of a belt of drive ГРМ see).

  1. Cautiously release a tension spring, then turn out fixing bolts and remove assemblage натяжителя.

Installation

Engines SOHC and DOHC

 PERFORMANCE ORDER

  1. Installation is made in an order, the return to an order of dismantle of components. On engines SOHC track combination of the directing lever (1) with reciprocal cuts in a cover of the oil pump (2).

On engines SOHC the definitive tightening of a fixing bolt натяжителя is made after installation газораспределительного a belt.

Intermediate roller

Removal

Engines SOHC and DOHC

 PERFORMANCE ORDER

  1. Remove belt ГРМ (Removal and installation of a belt of drive ГРМ see).
  1. Turn out a bolt of fastening and remove a roller from the engine.



On engines SOHC the intermediate roller acts in film together with the prorate.

Installation

Engines SOHC and DOHC

Installation is made in an order, the return to an order of dismantle of components. Track, that the fixture has been tightened with demanded effort.