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



Removal, separation and engine installation

Removal

It is not necessary to forget that fuel is an inflammable liquid in the higher measure! At work with power supply system components observe all taken measures of fire safety. Do not smoke, do not come nearer to a place of work with open fire or the redurable not protected by a lamp shade. Do not make system service in the premise equipped working on natural gas and heating devices equipped with a control torch (such as водогреи and dryers for clothes). Do not forget that fuel is among the cancerogenic substances promoting development of a cancer. Try not to suppose fuel hit on open sites of a body, — use protective rubber gloves, at casual unforeseen contact carefully wash out hands warm water with soap. Immediately collect the spilt fuel and do not put the rags impregnated with PETROLEUM PRODUCTS near to sources of open fire. Remember that the power supply system equipped with injection of fuel of models constantly is under pressure. Before to start a detachment of fuel lines, dump residual pressure in system (see the Head of the Power supply system and release more in detail). At service of components of the power supply system put on goggles. Constantly hold near at hand the class fire extinguisher In!


The path of a central air of air also constantly is under pressure that is why before рассоединением refrigerator lines it is necessary to make a discharge of system in the conditions of a specialised workshop.


The standard complete set of all modern cars includes system SRS which basic components are safety pillows. Before to start performance of any works near to an arrangement of gauges of directed overloads SRS, around a steering column or the panel of devices, without fail disconnect system in order to avoid casual operation of pillows of the safety, fraught with reception of serious traumas.


Composers of the present Management recommend to make engine removal in gathering with transmission. Unit assemblage falls downwards and is taken from under the car in view of what it is necessary to take care of ways of reliable fixing of a vehicle in the lifted position.


 PERFORMANCE ORDER

  1. Tyre out the car on an equal horizontal platform with firm enough covering. Remove a cowl (the Body see the Head). Result forward wheels in rectilinear position, take a key from the lock of ignition and block a steering column.
  2. On diesel models 1.7 of l remove the block of management of a heater on the left side of the basic pallet of the storage battery. Remove the battery with the pallet (the engine Electric equipment see the Head).
  3. Prop up back wheels противооткатными boots, strongly cock a lay brake. Ослабьте bolts of fastening of forward wheels. Поддомкратьте redock of the car also establish it on props. Remove forward wheels. At a corresponding complete set remove protection картера.
  4. If the engine acts in film for the purpose of major repairs performance, merge from it oil and remove the oil filter (Routine maintenance see the Head).
  1. Execute following procedures (see the Head of the Power supply system and release):

    1. Remove an air cleaner in gathering with air lines;
    2. Remove a reception pipe and an average part of system of release of the fulfilled gases;
    3. Disconnect power supply system lines;
    1. On diesel models 1.7 of l DOHC disconnect fuel lines from ТНВД, — on other diesel models disconnect lines of giving and return of fuel from the fuel filter;
    1. Disconnect and take aside cables of gas and (at a corresponding complete set) a cable темпостата, - try to remember routes of a lining of cables;
    2. Disconnect a vacuum hose of the servo-driver of the brake amplifier, — try to remember a route of a lining of a cable;
    3. On diesel models release fixing collars, disconnect and take aside the air sleeves connecting турбокомпрессор with интеркулером and интеркулер with the inlet pipeline;
    4. Disconnect a hose from the vacuum pump and valve EGR, — take a hose aside;
    5. On petrol models disconnect a hose of the valve of ventilation of a fuel tank from the throttle case.
  1. On petrol models remove a forward bumper (the Body see the Head).
  2. On diesel models 1.7 of l SOHC release fixing and disconnect from branch pipes hoses маслоохладителя, laid between the block of cylinders and a radiator.
  1. Operating in conformity with the instructions resulted in the Head of System of cooling, heating execute following actions:

    1. Empty cooling system;
    2. Ослабьте collars also remove the top and bottom hoses of system of cooling from a radiator. Disconnect from the engine all hoses охладительного a path;
    3. On a back partition of an impellent compartment disconnect hoses охладительного a path from the heater heat exchanger: having compressed a collar, shift forward a ring and liberate a hose from штуцерного a socket, — pay attention that in top шланговых connections black rings are used.
    1. On equipped with a central air of air models disconnect from the engine and take aside lines of a refrigerator path;
    1. Having passed suitable bolts or cores in apertures of basic arms, fix on the place a radiator / system K/V condenser.
  1. Make an electroconducting detachment:

Petrol engines

  1. Turn a lock ring and disunite the big multicontact socket of conducting of the engine in a forward part of the assembly block of the relay in an impellent compartment.

 

    1. Sockets of all other brought to the main plait of electroconducting of plaits of an impellent compartment.
 

Diesel engines

  1. Turn a lock ring and disunite the big multicontact socket of conducting of the engine in a forward part of the assembly block of the relay in an impellent compartment.

 

    1. Turn out bolts and disconnect a loop from клеммного a tip плюсового wires of the battery and two loops from a tip of a negative wire.

 

    1. Open a cover of the impellent compartment of the assembly block located in the left back corner and take the relay of green colour and a safety lock with the колодками.

 

    1. On engines of 1.7 l DOHC lift the lever and disconnect from the block of engine management established over the inlet pipeline (ECM) an extreme back socket.
    2. Liberate plaits of electroconducting from all intermediate clamps and place them from above over the engine.
    3. On engines of 1.7 l SOHC disconnect electroconducting from following components:

      • Valve EGR;
      • The gauge of temperature of a cooling liquid (ECT);
      • The electronic module of management (ECM), — take out запорный an element;
      • Candles накаливания;
      • The gauge of position of a cranked shaft (CKP);
      • The gauge of temperature of oil;
      • The gauge-switch of fires of a backing.

 

    1. At last, turn out three bolts of fastening of electroconducting to a back part of a cover газораспределительного the mechanism and take away conducting from the engine, also liberate conducting from clamps on a forward part of the block of cylinders, — take all plaits aside from the engine.

 

  1. Merge трансмиссионное oil/ATF.
  1. On models with РКПП press a clamp at once for штуцерным a socket a hydraulic hose of a drive of a path of coupling (Coupling and power shafts see the Head). Accurately screw-driver having hooked lock скобу a socket, disconnect a hose from a coupling dome.
  1. Disconnect from transmission of draught of switching of transfers / a selector cable (the Manual transmission or Automatic transmission see the Head).
  1. On models with АТ disconnect from transmission electroconducting and hoses of a path of cooling ATF.
  1. Attach a rigging to elevating eyes and hang out the power unit.
  1. Remove both power shafts (Coupling and power shafts see the Head).
  2. Remove a forward stretcher (the Suspension bracket and a steering see the Head).
  3. Once again make sure that and nothing stirs all lines of communication to extraction of the power unit from an impellent compartment.
  1. Mark adjusting positions of components of support of a suspension bracket of the power unit and адаптерной transmission plates. Turn out three bolts of fastening of the right support of the engine to an arm on the block of cylinders, also give three bolts of fastening of a support to кузовному to an element. Turn out three bolts of fastening of the left support to адаптерной to a transmission plate. On the models equipped with a central air of air, disconnect electroconducting, give fixture, remove and tie up compressor K/V to the panel передка. In case of need liberate hoses of a refrigerator path from clamps behind the right support of a suspension bracket of the power unit.

At all do not open a refrigerator path!

  1. Get under the engine тележечный a jack. Lower the power unit, watching that not передавить hoses or electroconducting and not to damage a radiator / the fan. In case of need address to the help of the assistant, — it is possible, the unit should be inclined slightly, for its conclusion from an aperture of an impellent compartment. Fix the unit on a jack.
  2. Disconnect an elevating rigging and roll out from under the car a jack with the power unit fixed on it.

Branch of the engine from transmission

Models with РКПП

 PERFORMANCE ORDER

  1. Having removed the power unit, lay it on wooden бруски on a workbench or on pure to a floor in garage.
  2. On models with stamped steel pallets, turn out fixing bolts and remove with картера transmissions a flywheel cover.
  3. Remove a starter (the engine Electric equipment see the Head).
  4. Make sure of that the weight of the power unit is in regular intervals distributed on props. Turn out bolts of fastening of transmission to the engine, — try to remember an order of installation of all bolts and arms fixed by them.
  5. Accurately separate transmission from the engine, without supposing повисанием a box primary shaft on coupling.
  6. Remove freely planted directing plugs and clean them in a reliable place.

Models with АТ

 PERFORMANCE ORDER

  1. Having removed the power unit, lay it on wooden бруски on a workbench or on pure to a floor in garage.
  2. Remove a starter (the engine Electric equipment see the Head).
  3. For the purpose of providing of access to bolts of fastening of the hydrotransformer liberate from a pallet flange a rubber cover (covers). Turn out a bolt to which there is an access, then, turning for a pulley bolt a cranked shaft, serially turn away all other bolts of fastening of the hydrotransformer to приводному to a disk (on engines 1.4, 1.6 and 1.8 l are used three fixing bolts, on engines of 2.0 l — six).

At assemblage bolts are subject to replacement without fail.

  1. That the hydrotransformer has not dropped out at transmission branch, push it on a shaft deep into картера.
  2. Further operate in an order stated above (Models with РКПП see).

Connection of the engine with transmission

All models

Operate in an order, the return to an order of separation of the power unit.

Installation

 PERFORMANCE ORDER

  1. Сориентировав in the correct image, get the power unit under an impellent compartment of the car. Connect a rigging to elevating eyes of the engine. Get the block in an impellent compartment and arrange it so that there was a possibility of installation of support of a suspension bracket of the power unit. Establish support and while slightly tighten fixture.
  2. For усадки on support, move the unit every which way.
  3. Lower the unit and tighten fixture of support of its suspension bracket with demanded effort. Disconnect an elevating rigging and deduce from under the car тележечный a jack.
  4. The further installation is carried out in an order, the return to a dismantle order. Pay attention to following moments:
    1. All fixture tighten with demanded effort (Specifications to corresponding Heads of the Management see);
    2. Track correctness of a lining of plaits of electroconducting and reliability of fastening of their contact sockets. Make sure that conducting is laid on sufficient removal from heat sources;
    3. Restore initial connection of all hoses and tubes, — track reliability of a tightening of fixing collars;
    4. On models with РКПП, check up adjustment of a drive of a gear change, in case of need make corresponding updating (the Manual transmission see the Head);
    5. Fill cooling system (see the Head of System of cooling, heating);
    6. Fill in in transmission fresh oil (РКПП) or ATF (АТ) / make updating of level of a working liquid (Routine maintenance see the Head);
    7. Make adjustment of cables of gas (see the Head of the Power supply system and release) and (at a corresponding complete set) темпостата;
    8. After the first start of the engine attentively examine all surface of the power unit and a partition of an impellent compartment on presence of signs of development of leaks of working liquids.

If engine major repairs before to make its start were carried out — Trial start and обкатка the engine after major repairs see.