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



Check of a condition radical and шатунных bearings of a cranked shaft

Typical examples of deterioration of bearings

Fatigue deformation

Arrows specify pockets and cavities

Wrong landing

Arrows specify заполированные to shine sites

Dirt hit

A — the Arrow specifies scratches
B — Arrows specify the extraneous particles introduced in a surface

Greasing lack

The arrow specifies a local wipe of a blanket

Excessive deterioration

The arrow specifies blanket operation on all area

Конусность necks

The arrow specifies radial deterioration of a local order

Condition check

In spite of the fact that bearings of a cranked shaft in the course of engine major repairs are subject to replacement without fail, old loose leaves should be kept for the purpose of attentive studying of their condition which results can give a lot of helpful information on the general condition of the engine. Examples of typical defects of loose leaves of bearings — see above Typical examples of deterioration of bearings.

The exit of bearings out of operation can occur owing to a lack of greasing, hit of particles of a dirt, overloads of the engine and corrosion development. Without dependence from character of defects, the reason of damage of loose leaves should be eliminated in the course of performance of major repairs of the engine in order to avoid relapse.

For survey take loose leaves of bearings from the beds in the block of the engine / the bottom heads of rods and radical / шатунных covers and spread out them as installation on a pure working surface. Organisation of placing of loose leaves will allow to adhere character of the revealed defects to a condition of corresponding necks of a shaft.

The dirt and extraneous particles get to the engine various ways. They can be left in the block in the course of unit assemblage, or get through filters or ventilation system картера. All particles getting to impellent oil, finally, sooner or later, appear in bearings. Often the metal sawdust formed in the course of normal operation of internal components of the engine takes root into a soft material of loose leaves. The probability of presence at bearings of traces of an abrasive is great, in particular, when the proper attention has not been given cleaning of the block after end of regenerative repair of the engine. Without dependence from a way which extraneous particles get to the engine, as a result they with high degree of probability appear introduced in a soft surface of loose leaves of bearings of a cranked shaft and easily come to light at visual survey of the last. Large particles usually are not late in loose leaves, but leave on their surface and a surface of necks of a shaft appreciable traces in the form of scratches, cavities and задиров. The best guarantee from such troubles is the responsible relation to cleaning of components after end of major repairs of the engine and carefulness of observance of cleanliness at assemblage. Frequent regular change of impellent oil also allows to prolong service life of bearings essentially.

Oil starvation can be a consequence of several various, but often interconnected phenomena. So, the engine overheat conducts to разжижению engine oil and to its replacement from working backlashes of bearings. The lack of greasing of bearings can speak in excessive size of working backlashes, and also usual leaks (internal or external). Often meeting reason of replacement of oil from backlashes of bearings is constant excess of turns of the engine. Passableness infringement маслотоков (usually connected with wrong combination of apertures at installation of components) also conducts to reduction of giving of greasing to bearings. Typical result of oil starvation is the full or local wipe / выщербливание a blanket of loose leaves from a metal substrate. Thus the working temperature can rise to such level that the substrate as a result of an overheat gets a bluish shade.

Essential influence on service life of bearings is rendered also peculiar to the owner of the car by a driving manner. Movement with small speed on the raised transfer leads to considerable overloads of the bearings, accompanied replacement of an oil film from their working backlashes. Such overloads lead to increase of plasticity of loose leaves and occurrence of cracks in a blanket (fatigue deformation). Thus the superficial material starts to crumble and separate from a steel substrate. Car operation in a city cycle (on short distances) conducts frequent trips to development of corrosion of bearings because the insufficient warming up of the engine involves loss of a condensate and allocation of chemically aggressive gases. The given products accumulate in impellent oil, forming slags and acids. At hit of such oil in bearings aggressive substances promote development of corrosion of loose leaves.

Wrong installation of loose leaves in the course of engine assemblage also can be at the bottom of their fast destruction. Too hard landing does not provide the demanded size of a working backlash of bearings that leads to their oil starvation. Result of hit under loose leaves (in the course of their installation) extraneous particles is formation of eminences the blanket with which is quickly wiped.

Selection of loose leaves

In case of deterioration or damage of loose leaves of bearings, and also when it is not possible to achieve correct size of a working backlash (see Installation of a cranked shaft and check of working backlashes of radical bearings or Installation of shatunno-piston assemblages and check of size of working backlashes in шатунных bearings of a cranked shaft), the situation can be corrected in the way described more low, by selection and installation of new loose leaves. Without dependence from a technique of definition of the demanded size of loose leaves working backlashes of bearings should be then are checked up with application of measuring set Plastigage (Installation of a cranked shaft and check of working backlashes of radical bearings see).

If it is not possible to correct properly size of working backlashes by selection of loose leaves, it is necessary to replace a shaft.


Usually selection of loose leaves is carried out by the experts making проточку of necks of a shaft. The standard size of new loose leaves is defined by depth проточки necks. Проточка it is usually carried out with step of 0.25 mm. In certain cases radical and шатунные necks are pierced on various depth. The pierced shaft usually in appropriate way is marked. So, for example, type "10-10" marks usually mean that both complete sets of necks are pierced on depth of 0.010 inches (0.25 mm) and it is necessary to select loose leaves of the corresponding size with belittling. Identification marks on the back party of the loose leaf are used by experts at definition of dimensional group of bearings.