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



Installation of a cranked shaft and check of working backlashes of radical bearings

It is recommended to replace loose leaves of radical bearings without dependence from their condition.


 PERFORMANCE ORDER

  1. Installation of a cranked shaft is the procedure first step actually engine assemblages. It is meant that at the given stage the cranked shaft and the engine block already are properly cleaned, checked up and subjected necessary regenerative repair.
  2. Turn the engine upside down.
  3. Give fixing bolts, remove covers of radical bearings and spread out them on a workbench as installation on the engine.
  4. If yet have not done it, take from the beds in the block and covers old loose leaves of radical bearings. Wipe beds pure неворсящейся rags — they should be irreproachably pure.

Check of working backlashes of radical bearings

Try not to touch surfaces of new loose leaves barehanded in order to avoid undesirable contact of bearings to traces of oil always present on fingers and chemically aggressive substances.


 PERFORMANCE ORDER

  1. Wipe backs of new loose leaves of radical bearings and enclose the halves equipped with an oil flute in the beds in the block (if old loose leaves are used, track that they kept within strictly on the former places). The remained halves of loose leaves enclose in corresponding covers of bearings. Track, that uvulas of loose leaves have entered into reciprocal landing grooves in beds of the block and covers. Oil apertures in the block should appear in the correct image combined with apertures in loose leaves.

In no event make attempts to begin to knock the loose leaf resistant to installation in the bed a hammer. Grease with nothing bearings at the given stage!

  1. Remember that the combined loose leaf equipped with persistent half rings keeps within the top bed of the third radical bearing on all engines, except a diesel engine of 1.7 l DOHC where the second bearing is persistent, and in the latter case half rings are delivered as separate components and should keep within special cuts in bearing beds маслосгонными flutes outside.
  1. Wipe surfaces of bearings in the block and radical necks of a cranked shaft pure неворсящейся rags.
  2. Check up passableness of oil apertures of a shaft, in case of need clean them. Any containing in маслотоках extraneous particles, eventually, inevitably get to bearings.
  3. Carefully wiped cranked shaft accurately lay in radical bearings of the block (do not use any greasing).
  4. Before to establish a shaft definitively, it is necessary to check up sizes of working backlashes in its radical bearings.
  1. Cut the calibrated plastic wire from measuring set Plastigage pieces, in the length width of loose leaves are hardly shorter, and lay on one slice of a wire along each of radical necks of a shaft, in parallel their axis.
  1. Wipe surfaces of loose leaves in covers and establish the last on the regular places (track correctness of orientation of marks). Try not to shift laid along necks of a shaft pieces of the calibrated wire. Slightly oil a carving of fixing bolts and screw them, having fixed covers.
  2. Moving on a spiral from the centre outside, in three stages tighten bolts of fastening of covers with demanded effort (Specifications see), — do not suppose проворачивания a shaft in the course of a fixture tightening!
  3. Turn out bolts and cautiously remove covers of radical bearings. Combine the removed covers as their arrangement on the engine. Try not to damage the flattened out calibrated wire and do not turn a shaft. If any of covers does not give in to removal, for clearing it is accurate обстучите its hammer with soft the brisk.
  1. On the width of the flattened out threads measured on a scale, put on packing of set Plastigage, define size of working backlashes of bearings. Compare results of measurements to requirements (Specifications see).
  1. If the backlash size leaves for admissible limits, probably, loose leaves not that standard size (Check of a condition radical and шатунных bearings of a cranked shaft see) have been established. Before to look for new loose leaves, make sure that under enclosed at the given stage extraneous particles have not got. If the calibrated wire is flattened out from one end more than from another, it testifies to presence конусности necks (Check of a condition of a cranked shaft see).
  2. Cautiously remove the flattened out calibrated wire from necks, having scratched out all its traces any not too strong tool (for example, edge of an old credit card). As a last resort, it is possible to take advantage of own nail, — the main thing that on a surface of necks / of loose leaves does not remain scratches and задиров.

Definitive installation of a cranked shaft

 PERFORMANCE ORDER

  1. Cautiously take a cranked shaft from the engine.
  2. Wipe surfaces of bearings in the block and in regular intervals grease with their thin layer молибденсодержащей or assembly impellent greasing. Do not forget to grease also also persistent surfaces.

Try not to admit greasing hit on backs of loose leaves!

  1. Make sure of absoluteness of cleanliness of necks of a cranked shaft, then grease (the same greasing or pure impellent oil) surfaces of pins contacting to epiploons. Lay a shaft on the regular place. Wipe and grease loose leaves in covers of bearings. Track, that persistent loose leaves have been laid in bed of corresponding bearings in the block (Check of working backlashes of radical bearings, item 2 see above).
  1. Establish covers of bearings on the engine. On all engines, except a diesel engine of 1.7 l DOHC, at first are established covers of 1st and 4th bearings (the first the bearing nearest to drive ГРМ) is, — track that the marks put on covers were read at a sight at the engine behind. In a cover of 5th (back) bearing before installation it is necessary to fill lateral flutes with type hermetic № 90485251. On diesel engines the same order (without the fifth cover), however, interfaced surfaces of the first cover before installation it is necessary to grease of 1.7 l DOHC slightly the hermetic, the arrows beaten out on covers should specify towards drive ГРМ.
  1. Slightly grease a carving part and the bottom surfaces of heads of fixing bolts with pure impellent oil, then screw and by hand tighten bolts.
  1. Moving on a diagonal from the centre to edges, in regular intervals tighten all bolts with effort of the first stage, then, in the same order hold on them on corners of stages 2 and 3 (Specifications see), — take advantage of a goniometric nozzle, or put a paint or a marker basic labels. Having held on bolts, fill a little more hermetic in flutes of a back cover while it not begins to be squeezed out of them, — surpluses wipe pure rags.
  1. Knock on end faces of pins of a shaft with a hammer through brass or lead выколотку for the purpose of alignment of persistent surfaces and усадки a shaft before a definitive tightening of fixture.
  2. Some times turn a cranked shaft manually, checking freedom of its rotation.
  3. In summary with the help щупа лезвийного type or циферблатного a measuring instrument define size axial люфта a shaft (Removal of a cranked shaft see). If persistent surfaces of a shaft are not worn out and not damaged, and bearings are replaced new, the size люфта should not fall outside the limits an admissible range.
  4. Establish shatunno-piston assemblages (Installation of shatunno-piston assemblages and check of size of working backlashes in шатунных bearings of a cranked shaft see).
  5. At a corresponding complete set plant in a back pin of a cranked shaft the new directing plug of a primary shaft of a transmission.
  6. On diesel engines of 1.7 l DOHC make replacement of a forward epiploon, make sure of absoluteness of cleanliness and dryness of interfaced surfaces of its case and the block of cylinders. Grease interfaced surfaces with hermetic, check up presence on the places of directing plugs and press the epiploon case to the block. Having greased with hermetic a carving part of fixing bolts, screw them in the apertures and tighten with demanded effort. Establish a back epiploon.
  7. On other engines installation of new epiploons of a cranked shaft is made according to the instructions stated in corresponding sections (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 or Procedure of repair of diesel engines of 1.7 l and 2.0 l without their extraction from the car see).
  8. At a corresponding complete set establish on covers of radical bearings a cast bridge sheaf, screw and tighten with demanded effort bolts of its fastening.
  9. The further assemblage of the engine is made in conformity by the instructions resulted in corresponding sections (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 or Procedure of repair of diesel engines of 1.7 l and 2.0 l without their extraction from the car see).