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
   - The general and engine major repairs
      Removal of the power unit from the car - methods and safety measures
      Removal, separation and engine installation
      Alternative variants of schemes of regenerative repair of the engine
      Sequence of dismantling of the engine
      Dismantling of a head of cylinders
      Cleaning and check of a condition of a head of cylinders
      Assemblage of a head of cylinders
      Removal of shatunno-piston assemblages
      Removal of a cranked shaft
      Cleaning and check of a condition of the block of cylinders
      Хонингование mirrors of cylinders
      Check of a condition of components of shatunno-piston group
      Check of a condition of a cranked shaft
      Check of a condition radical and шатунных bearings of a cranked shaft
      Engine assembly order
      Installation of piston rings
      Installation of a cranked shaft and check of working backlashes of radical bearings
      Installation of shatunno-piston assemblages and check of size of working backlashes in шатунных bearings of a cranked shaft
      Trial start and обкатка the engine after 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



The general and engine major repairs

In the given Part descriptions of procedures of removal and installation of the power unit, and also the general major repairs of a head of cylinders and internal components of the engine are placed.

Brought to attention of readers the material contains a wide spectrum of the information — from a practical advice on acquisition of necessary spare parts, to a detailed step-by-step statement of an order of performance of procedures of removal, check of a condition, regenerative repair and installation of internal components of the engine.

Descriptions of procedures are made on the basis of the assumption that the engine is completely removed from the car and is established on the assembly stand or a strong workbench. All information, concerning procedures of repair of the engine, which performance is possible without extraction of last of the car (in situ) it is resulted above — see Procedures of repair of petrol engines SOHC without their extraction from the car, Procedure of repair of petrol engines DOHC without their extraction from the car and Procedure of repair of diesel engines of 1.7 l and 2.0 l without their extraction from the car.

No means always it is possible to define easily the moment when there is a necessity for carrying out of major repairs of the power unit. In attention the whole set of various factors should be accepted.

High run at all unessentially is a sign of that the engine requires major repairs. On the other hand, also it is impossible to consider the insignificant period of operation as a sufficient guarantee of a working order of the power unit. Perhaps, a major factor defining service life of the engine, frequency and a regularity of performance of procedures of the general and car routine maintenance is. At normal leaving the engine will reliably serve throughout many and many thousand kilometres of run whereas the careless relation to performance of procedures of routine maintenance together with a negligent manner of driving necessities of performance of major repairs of the power unit after very short term can already lead.

It is possible to consider the excessive expense of engine oil as a signal about necessity of carrying out of check of a condition of piston rings, маслоотражательных caps and-or directing plugs of valves. Naturally, first of all, it is necessary to make sure that oil losses are not connected with development of its external leaks. Address for the help to the qualified expert who will help to define the general condition of the engine of your car on the basis of results of check компрессионного pressure in cylinders and measurements of depth of depression at various initial parametres (address to corresponding sections).

Loss of developed capacity, infringement of stability of turns, excessive noise background клапанного the mechanism, the raised expense of fuel usually are characteristic enough signs of necessity of performance of major repairs of the engine, in particular, when all these factors are shown simultaneously. If performance of a full spectrum of options does not help with elimination of problems, carrying out of the general mechanical works on engine restoration will be a unique way out.

Major repairs of the power unit mean restoration of all its working parametres to level, characteristic for the new engine. During major repairs replacement of piston rings and restoration of mirrors of cylinders (проточка and-or хонингование) is without fail made. In case of performance проточки cylinders selection of pistons of the corresponding repair size is made. Replacement radical and шатунных bearings is usually carried out, can be in case of need made проточка and restoration of necks of a cranked shaft.

Service of the valves which condition at the moment of occurrence of necessity for performance of major repairs of the engine almost for certain leaves much to be desired is without fail carried out. In parallel with performance of the general repair of the power unit regenerative repair of such auxiliary components, as a starter and the generator is usually made also. As a result of repair engine parametres come back to the values peculiar to the new unit, thus last can serve smoothly still many and many thousand kilometres of run.

Such critical components of system of cooling as hoses, приводные belts, the thermostat and the water pump at carrying out of major repairs of the engine SHOULD be replaced with the new without fail. Besides, it is necessary to check up attentively a radiator condition (see the Head of System of cooling, heating). In case of revealing of signs of development of leaks or infringement of passableness it is necessary to replace a radiator also. Many firm car repair shops do not give a guarantee on operation of the restored engine without performance of professional cleaning and radiator repair. Do not forget to check up also a condition of the oil pump (Procedures of repair of petrol engines SOHC without their extraction from the car see, Procedures of repair of petrol engines DOHC without their extraction from the car and Procedure of repair of diesel engines of 1.7 l and 2.0 l without their extraction from the car — corresponding sections).

Before to start performance of major repairs of the engine, attentively familiarise with materials of the present Part for the purpose of theoretical preparation for forthcoming work. We will notice that engine major repairs at all do not demand from the executor of high vocational training, however take away a lot of time. It is necessary to plan refusal of using the car for the term of not less than two weeks, in particular in need of the reference behind the help in a mechanical workshop for the purpose of performance of a separate recovery work. Spend small marketing, having checked up presence on sale of required spare parts, tools and the equipment. Beforehand prepare all necessary materials. The most part of works can be executed with application of a usual set of the metalwork tool, however some of checks by definition of suitability of separate components to the further use demand application of the precision measuring equipment. In doubtful situations address for the help to experts of a workshop of car-care centre who always will help you to be defined with the decision on necessity of replacement or regenerative repair of any internal component of the engine.

Before to give any of details for carrying out of regenerative repair to a car-care centre workshop, spend full dismantling of the engine and all its internal components. Do not forget that a determinative in a question on expediency of performance of major repairs of the engine is the condition of the block of its cylinders. Often it appears to replace the worn out engine restored more cheaply and more reliably. Never start acquisition of replaceable components until very carefully do not study a block condition. Remember that time is main затратным the factor at performance of major repairs of the engine that is why, it is senseless to translate it on installation of the worked well together or non-standard knots and components.

In summary we will notice that all efforts on performance of regenerative repair of the worn out components will appear spent for nothing at the negligent relation to the requirement of observance of cleanliness at unit assemblage.