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 of shatunno-piston assemblages

Before to start extraction from the engine of shatunno-piston assemblages, it is necessary to remove a head of cylinders, the pallet картера and маслозаборную a tube, the bridge of covers of radical bearings / маслоотражательную a plate / balancing assemblage (depending on a complete set) (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).


 PERFORMANCE ORDER

  1. By means of a special vertical drill completely remove traces of step deterioration from the top part of cylinders — operate according to the instructions of the manufacturer enclosed to a vertical drill. The step is formed on piston stroke border, approximately in 6.4 mm under the top cut of the cylinder at the expense of mechanical development of metal and нагарообразования, to define its presence it is possible to the touch a finger nail. Attempts of extraction of shatunno-piston assemblages without removal of step development are fraught with damage of pistons.
  1. Having finished preparation of cylinders, turn the engine upside down so that the cranked shaft has appeared from above.
  1. Before to remove rods from a cranked shaft, estimate size axial люфта their landings to corresponding necks of the last. Densely enter an edge () measuring щупа in a backlash between a lateral wall of the bottom head of a rod and a crank cheek, completely having chosen люфт a rod on a shaft neck. The total thickness of the picked up edges щупа also will equal to size axial люфта a rod. Compare result of the spent measurement to requirements (Specifications see). If the size axial люфта exceeds the limiting admissible value, the given rod is subject to replacement. Axial люфт a new rod, or old on new to a shaft, it can appear less than the bottom admissible limit, in this case the rod can be pierced, — consult with experts of car-care centre. Serially check up all remained rods.
  1. Make sure available on the bottom heads of rods and their covers of identification labels of an accessory to the cylinder, in case of need put labels independently by means of small кернера or a marker.
  1. Turn a cranked shaft so that pistons of 1st and 4th cylinders have appeared in positions НМТ.
  2. In stages (on 1/2 turns for the approach) ослабьте nuts / bolts of fastening of a cover of the bottom head of a rod of the first cylinder so that there was a possibility отворачивания them manually. Uncover a rod together with the loose leaf of the bearing placed in it, — try not to drop last.

On some engines the cut of the bottom head of rods is formed by разламывания preparations with preservation of the form of a break by special processing for better quality of a joint. At dismantle of covers from rods of this kind observe extreme care, - do not damage interfaced surfaces.

  1. For protection of a neck of a shaft and a cylinder mirror pull on hairpins of fastening of the bottom head of a rod pair of pieces of a hose approaching on the size.
  2. Take from a head of a rod the bearing loose leaf, then, having rested the wooden handle of a hammer against bearing bed in the bottom head, push out shatunno-piston assemblage from the block at the top the cylinder. At resistance occurrence immediately stop extraction of assemblage and make sure of completeness of removal of step deterioration in the top part of the cylinder.
  3. Operating in a similar manner, take from the engine shatunno-piston assemblage of 4th cylinder, then turn the engine on 180 clockwise and take assemblages of 2nd and 3rd cylinders.

Extraction start only after the rod will be located strictly in parallel a cylinder axis!

  1. In order to avoid casual mechanical damage of bearings and loss of components, establish into place loose leaves and fix covers of bearings on the bottom heads of the rods, by hand having tightened fixing bolts / of a nut.
  2. Do not remove pistons from rods (Check of a condition of components of shatunno-piston group more in detail see).