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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 shatunno-piston assemblages and check of size of working backlashes in шатунных bearings of a cranked shaft

At performance of major repairs of the engine replacement of piston wheels and loose leaves шатунных bearings is recommended to be made without dependence from their condition.

Preparation

Before installation of shatunno-piston assemblages of a wall of cylinders should be carefully wiped, from their upper edges traces of step deterioration are completely removed and the facet is removed. It is meant that the cranked shaft is already established on the regular place in the block (Installation of a cranked shaft and check of working backlashes of radical bearings see).

 PERFORMANCE ORDER

  1. Uncover the bottom head шатунной assemblages of the first cylinder (make sure available the marks factory or put in the course of dismantle). Take from a head of a rod and its cover loose leaves of the old bearing and carefully wipe their beds pure неворсящейся rags.

Check of a working backlash шатунного the bearing


The scheme of a correct arrangement of locks of piston rings of petrol engines


The scheme of a correct arrangement of locks of piston rings of diesel engines of 1.7 l DOHC and 2.0 l


The scheme of a correct arrangement of locks of piston rings of diesel engines of 1.7 l SOHC



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 a back of the new top loose leaf and will put it to bed the bearing in a rod head. Track, that the directing uvula of the loose leaf has got to a reciprocal flute in a rod. At all застукивайте the loose leaf in bed a hammer. Grease with nothing the bearing at the given stage.
  2. Wipe a back of the second loose leaf and lay it in a cover of the bottom head of a rod. Again track, that the uvula has got to a reciprocal groove. Do not apply some any greasing — extremely important that interfaced surfaces of the bearing and a rod remained absolutely pure and dry.
  3. Arrange piston rings locks, as shown (illustrations the Scheme of a correct arrangement of locks of piston rings of petrol engines, the Scheme of a correct arrangement of locks of piston rings of diesel engines of 1.7 l DOHC and 2.0 l or the Scheme of a correct arrangement of locks of piston rings of diesel engines of 1.7 l SOHC see).
  4. Pull on bolts of fastening of a cover of the bearing pieces of a rubber hose approaching on diameter.
  5. Grease the piston and piston rings with pure impellent oil. Put on the piston оправку the tool for обжимания rings. Leave a skirt of the piston acting of оправки the tool approximately on 6.4 mm for its free refuelling in the cylinder. Rings should be pressed out заподлицо with a forming surface of the piston.
  6. Turn a cranked shaft so that the neck of the first crank has appeared in position НМТ. Grease with impellent oil a mirror of the first cylinder.
  7. Having developed assemblage by labels in the necessary party (Removal of shatunno-piston assemblages see), accurately fill a rod in the first cylinder of the block. Get in the cylinder a piston skirt, densely having pressed to a surface of the block a bottom edge оправки the tool for обжимания rings.
  8. Обстучите an upper edge оправки for a guarantee of density of its pressing to the block on all perimetre of a bottom edge.
  1. Accurately tapping on the bottom of the piston with the wooden handle of a hammer, enter the piston in the cylinder, simultaneously directing the bottom head of a rod on a neck of a corresponding crank of a cranked shaft. Piston rings can unexpectedly jump out from under оправки the tool, therefore constantly watch pressing density to its block. Do not hurry up, at occurrence of the slightest resistance immediately stop застукивание the piston. Find out the reason of jamming and eliminate it.

At all do not undertake attempts to push the piston in the cylinder force, is can lead to its mechanical damage or destruction of piston rings!

  1. After introduction of shatunno-piston assemblage in the engine, before definitive installation of a cover of the bottom head of a rod, it is necessary to check up a working backlash шатунного the bearing of a cranked shaft.
  1. Cut off a piece of the calibrated plastic wire from measuring set Plastigage, in the length width of the loose leaf шатунного are hardly shorter than the bearing, and lay it along the first шатунной necks of a cranked shaft, in parallel an axis of last.
  1. Wipe a bearing surface in a cover of the bottom head of a rod and establish a cover on a rod. Track, that the label on a cover has appeared is turned in the same party, as a label on a rod.
  2. Slightly grease the bottom end faces of fixing nuts with pure impellent oil, screw them and in three stages tighten with demanded effort.

In case of need in order to avoid key jamming, take advantage of a thin-walled face head. At occurrence of signs of jamming of a key between a nut and a rod, slightly raise a head and continue a tightening. Do not suppose проворачивания a cranked shaft in the course of performance of all procedure.

  1. Give nuts and cautiously uncover a rod. Try not to damage the flattened out piece of the calibrated wire.
  1. On width of the flattened out wire measured on a scale, printed on packing to set Plastigage, define size of a working backlash in the bearing. Compare result of measurement to requirements (Specifications see).
  1. If the size of a backlash falls outside the limits an admissible range before to look for loose leaves of other standard size, check up, whether the dirt / oil has got under backs enclosed in bed in a rod and a cover of loose leaves. Once again measure diameter of a neck of a shaft. Расплющивание from one end it is more than wire than from another tells about presence конусности necks.

Definitive installation of shatunno-piston assemblage

 PERFORMANCE ORDER

  1. Cautiously scratch out a nail or edge of an old credit card all traces of the calibrated wire from a neck and-or bearing surface.
  2. Make sure of absoluteness of cleanliness both подшипниковых surfaces, then in regular intervals grease with their thin layer молибденсодержащей or assembly impellent greasing. For providing of access to a surface of the top loose leaf it is necessary to push a little the piston in the cylinder, — do not forget to put on bolts of a cover of a rod protective hoses in order to avoid damage of a surface of a neck of a shaft. Try not to admit выскакивания from the cylinder of piston rings.
  3. Return a rod into place, cautiously having put on its bottom head a neck of the crank, remove from bolts protective hoses, establish a cover, and in three stages tighten fixing bolts / of a nut with demanded effort (Specifications see).

Track correctness of combination of labels on a cover of a rod and its bottom head.

  1. Repeat all procedure for the remained shatunno-piston assemblages.
  2. Do not lose sight of following important points:
    1. Watch that on backs of loose leaves and their bed in rods and covers the dirt has not got;
    2. Watch, that each assemblage was established in the cylinder (even in case of installation of new components as backlashes of piston rings were adjusted to concrete cylinders);
    3. Pistons should settle down in marks in a demanded direction (Removal of shatunno-piston assemblages see);
    4. Do not forget to grease before installation of assemblages by impellent oil of a mirror of cylinders;
    5. Do not forget to grease bearings (after check of working backlashes in the last) before definitive installation of covers.
  3. Having finished installation of shatunno-piston assemblages, check up freedom of rotation of a cranked shaft, having turned it some times manually.
  4. In summary it is necessary to check up once again axial люфт a cranked shaft (Removal of a cranked shaft see).
  5. Compare results of measurement axial люфта to requirements (Specifications see). If люфт was in norm before dismantling of the engine and the old shatunno-piston assemblages are used, no surprises should be. In case of a size exit люфта for admissible limits after replacement of rods, the last are necessary for removing from the engine and to give to a workshop of car-care centre for corresponding machining.