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 installations of chains and asterisks of drive ГРМ, check of a condition of components (engines 2.0 )

Correctly to establish phases газораспределения, special fixing adaptations Opel which can be made be required and is independent (Check and adjustment of phases газораспределения (engines 2.0 see. If any of these variants is not accessible, charge performance of the given operation to experts of car-care centre. If the problem has to be solved make-shifts, before removal of components mark their adjusting position of chains on asterisks.


The scheme of a lining of chains and positioning of asterisks of drive ГРМ on engines of 2.0 l

1 — the Asterisk of a cranked shaft
2 — the Asterisk of bottom chain ТНВД

3 — the Asterisk of top chain ТНВД
4 — a camshaft Asterisk

Removal

The top chain and asterisks

 PERFORMANCE ORDER

  1. Disconnect a negative wire from the battery and uncover газораспределительного the mechanism (Removal and cover installation газораспределительного the mechanism see).
  2. Establish 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. Block a cranked shaft in the given position.
  3. For the purpose of maintenance of an easy approach to a cover of asterisk ТНВД 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). Also remove a belt of a drive of auxiliary units (Routine maintenance see the Head). Mark position 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 a support to an arm of a head of cylinders and three bolts of fastening to its mudguard. Prop up the right party of the engine тележечным a jack, having lifted it as it is possible above, without loading thus excessively other support and lines of communication (hoses, cables, electroconducting plaits).
  4. The scheme of a lining of chains of drive ГРМ on engines of 2.0 l — see an illustration the Scheme of a lining of chains and positioning of asterisks of drive ГРМ engines of 2.0 l.
  5. Remove both натяжителя (Removal and installation натяжителей chains of drive ГРМ (engines 2.0 see).
  6. Turn out the bottom bolt of fastening of a rack of a tension roller auxiliary приводного a belt and a bolt of an axis of its basis. Remove assemblage натяжителя from the engine.

For installation the new bolt of fastening of an asterisk of a camshaft and new bolts of fastening directing to the top chain is required.


Needlessly do not remove a rack from assemblage натяжителя, otherwise at installation it should be ground in.

  1. Turn out fixing bolts.
  1. Cнимите a cover of asterisks ТНВД from a cover газораспределительной chains ГРМ.
  1. Special adaptations block asterisks ТНВД and a camshaft (Removal and installation of a belt of drive ГРМ see). At absence near at hand special adaptations mark adjusting position of a chain on asterisks, and also position of asterisks concerning the landing flanges.
  1. Turn out fixing bolts.
  1. Cнимите успокоитель the top chain from the top part of a head of cylinders.

Fastening bolts успокоителя the top chain before removal should be heated up a thermal pistol (the powerful hair dryer) for the purpose of a softening of hermetic fixing a carving and considerably will facilitate a problem.

  1. Keeping a camshaft рожковым a key for лыски, turn out a bolt of fastening of its asterisk. For the purpose of simplification of a problem of combination of labels at installation, tie up a chain to an asterisk.

If used fixing adaptations, remove them before easing of a bolt of an asterisk, then establish again.

  1. If established, remove fixing ТНВД a core, then turn out bolts of fastening of asterisks ТНВД to a flange. Remove asterisk ТНВД for the top chain and a camshaft asterisk. Liberate an asterisk and remove the top chain.

The bottom chain ГРМ and asterisks

 PERFORMANCE ORDER

  1. Remove the top chain of drive ГРМ and asterisks (see above).
  2. Uncover chains of drive ГРМ (Removal and installation of a cover of drive ГРМ see).
  3. Mark chain position on asterisks and asterisks on flanges.
  1. Separate asterisk ТНВД from a flange and remove it together with an engine chain, — try to remember adjusting position of components.
  1. Remove an asterisk from a pin of a cranked shaft.
  1. Take from a groove on a pin.

Check

 PERFORMANCE ORDER

  1. Survey teeths of asterisks on presence of traces выкрашивания, deterioration or other damages. In case of revealing of defects at least to one of asterisks it is subject to replacement complete with a steam room to it on corresponding chain. Together with asterisks it is replaced as well a chain.
  2. Check up a condition of cheeks and rollers of chains. Deterioration degree is defined by freedom of its stretching. The new chain practically should not be stretched. The worn out chain is subject to replacement. The chain is subject to replacement also at performance of major repairs of the engine, long use and occurrence of an excessive noise background of functioning of drive ГРМ. Though in it also there is no emergency, ordinary the chain is replaced in the complete set with asterisks, — attempt to save on small at times turns around the subsequent expensive repair. In case of absence of confidence of an estimation of a condition of components address for council to experts of car-care centre.
  3. Survey also успокоители chains and their boots натяжителей. The damaged and worn out components are subject to replacement.

Installation

The top chain and asterisks

 PERFORMANCE ORDER

  1. At installation of new components transfer on them adjusting labels from old details. Make sure that the cranked shaft is in position ВМТ of the end of a step of compression of the piston of the first cylinder and is blocked from проворачивания.
  2. Plant a chain on an asterisk of a camshaft and establish assemblage on the regular place.
  3. Establish asterisk ТНВД and enter it into gearing with a chain.
  4. Achieve combination of the landing labels put in the course of dismantle and fix asterisks on flanges of a camshaft and ТНВД, — in case of need untie an asterisk of a camshaft from a chain.
  1. Achieve combination of a label of installation of phases газораспределения asterisk ТНВД with an aperture in a flange, then screw bolts of fastening of an asterisk, having tightened them in the given stage only by hand.
  1. Screw the NEW bolt of fastening of an asterisk of a camshaft, having tightened while only by hand.
  1. Establish натяжитель the bottom chain (Removal and installation натяжителей chains of drive ГРМ (engines 2.0 see.
  1. Establish into place успокоитель the top chain (an adjusting ledge upwards). Screw NEW fixing bolts and tighten them with demanded effort.
  1. In the presence of special adaptations fix a camshaft, ТНВД and a cranked shaft from проворачивания, and also for confidence of correctness of position of components. If adaptations are absent, track for combination of the labels put in the course of dismantle.
  2. At application of fixing adaptations make mechanism adjustment газораспределения (Check and adjustment of phases газораспределения (engines 2.0 see, then take adaptations.
  3. If special adaptations were not used, achieve combination of the components of labels put in the course of dismantle, then tighten bolts of fastening of asterisks ТНВД with demanded effort. Tighten a bolt of fastening of an asterisk of a camshaft with effort for a stage 1, keeping a camshaft from проворачивания for лыски рожковым a key. Make sure that labels have not got off and hold on a bolt on corners, stages 2 and 3, — take advantage of a goniometric nozzle, or put a paint or a marker basic labels.
  4. Establish натяжитель the top chain (Removal and installation натяжителей chains of drive ГРМ (engines 2.0 see.
  5. Make sure of absoluteness of cleanliness and dryness of interfaced surfaces of a cover of asterisks ТНВД and chain covers. If the cover has been established with a lining, do not forget to replace last. Tighten fixing bolts with demanded effort. If a lining was not, lay in a flute of a cover a pillow of hermetic in the thickness approximately 2 mm, then press a cover, screw fixing bolts and tighten them with demanded effort.
  6. Establish on the engine натяжитель a belt of a drive of auxiliary units, — track, that axial bolts and bolts of fastening of a rack have been tightened with demanded effort. At rack replacement, or after the compelled dismantle old, grind in a rack back and forth motions, having seized a replaceable face head for шестигранную a basis part. Having made sure of correctness of functioning of a rack, establish приводной a belt (Routine maintenance see the Head).
  7. Establish the right support of a suspension bracket of the power unit on a head of cylinders, then lower the engine and clean a jack. Fix a support on a mudguard, — track correctness of combination of the landing labels put in the course of dismantle and tighten fixing bolts with demanded effort.
  8. Establish a cover газораспределительного the mechanism (Removal and cover installation газораспределительного the mechanism see).
  9. Establish a reception pipe of system of release of the fulfilled gases, the case of an air cleaner and the gauge of position of a cranked shaft (see the Head of the Power supply system and release). If adaptations for camshaft fixing were used, establish on a head of cylinders the vacuum pump (the Brake system see the Head).

The bottom chain and asterisks

 PERFORMANCE ORDER

  1. If new components are established, transfer on them adjusting labels from old details.
  2. Establish шпонку a cranked shaft, then plant on a pin an asterisk, — track hit шпонки in шпоночный a groove.
  3. Make sure of correctness of installation of flange ТНВД (cut in a flange should be combined with an aperture in the pump case). The cranked shaft should be established in position ВМТ of the end of a step of compression of the piston of the first cylinder and is blocked.
  4. Achieving combination put in the course of dismantle of labels, enter an asterisk of the pump about gearing with a chain and establish assemblage on the engine. Put on a chain an asterisk of a cranked shaft. Make sure that labels have not got off, and cut in a pump flange was combined with an aperture in an asterisk.
  5. Establish a cover (Removal and installation of a cover of drive ГРМ see). Establish the top chain of drive ГРМ, (see above).