Opel Astra A

1991-1998 of release

Repair and operation of the car



Opel Astra A
+ 1. Maintenance instruction
+ 2. Maintenance
- 3. Engines
   + 3.1. SOHC engines
   + 3.2. DOHC engines
   - 3.3. Diesel engines
      3.3.1. Gear belt
      3.3.2. The 1,7 l diesel engine with a turbo-supercharging
      3.3.3. Tension of a gear belt
      3.3.4. The diesel TC4EE1 engine of 1,7 l with a turbo-supercharging
      3.3.5. Head of the block of cylinders
      3.3.6. The diesel TC4EE1 engine with a turbo-supercharging
      3.3.7. Check of a head of the block of cylinders and the block of cylinders on straightforwardness
      3.3.8. Camshaft
      3.3.9. Gas distribution phases
      3.3.10. Camshaft case cover oil separator
      3.3.11. Check and adjustment of gaps in the drive of valves
      3.3.12. Removal and installation of valves
      3.3.13. Replacement of oil scraper caps
      3.3.14. Grinding of valves
      3.3.15. Grinding in of valves
      3.3.16. Check of a gap in the directing plugs of valves
      3.3.17. Check of the directing plugs of valves
      3.3.18. Check of a compression
      3.3.19. Wedge-shaped belt
      3.3.20. Oil case
      3.3.21. Oil pump
      3.3.22. Safety valve
      3.3.23. Thermostat
      3.3.24. Check of kalilny candles
      3.3.25. Check of system of preliminary heating
      3.3.26. Removal of air from fuel system
      3.3.27. Check and adjustment of turns of idling
      3.3.28. Removal and installation of nozzles
      3.3.29. Check of an advancing of injection of fuel
      3.3.30. Heating of the fuel filter
      3.3.31. Replacement of the filtering element of the air filter
      3.3.32. Discharge of water from the fuel filter
      + 3.3.33. Useful tips
   + 3.4. Engine electric equipment
+ 4. Ventilation and heating
+ 5. Power supply system
+ 6. System of decrease in toxicity
+ 7. Coupling
+ 8. Transmissions
+ 9. Half shafts
+ 10. Brake system
+ 11. Suspension bracket and steering
+ 12. Body
+ 13. Electric equipment
+ 14. Electrical circuitries


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3.3.6. The diesel TC4EE1 engine with a turbo-supercharging

Removal and installation

PERFORMANCE ORDER
1. Remove an inlet collector.
2. Disconnect fuel pipelines from TNVD and nozzles. To remove pipelines completely, without bending them.
3. Disconnect a drain fuel-supply line from nozzles.
4. Remove the radiator fan.
5. Uncover a gear belt.
6. To install the piston of the 1st cylinder in VMT.
7. Remove the cogged pulley of the camshaft.
8. Weaken and take off a gear belt.
9. Turn off three bolts of fastening of a back cover of a gear belt.
10. Turn off bolts 1 and 2 fastenings of the case of the thermostat.
11. Disconnect a cooling system hose from a turbocompressor, previously having removed a fastening collar.
12. Disconnect pipelines of giving and discharge of oil between a turbocompressor and the block of cylinders.
13. Turn off bolts of fastening of a turbocompressor.
14. Pick up the phone of the maslomerny probe.
15. Weaken bolts of fastening of a head of cylinders in the shown sequence.
16. Remove a head of cylinders, having wrung out a back cover of a gear belt aside.
17. Establish new laying of a head of cylinders.

Prevention

Depending on the size of a vystupaniye of the piston laying of different thickness is established. When replacing laying to pay attention to its designation. Designation is on lateral face of laying in the form of one, two tags, or their absence (see the tab. Designation of laying).


18. Check pistons and valves for wear, if necessary to replace them. If wear is insignificant, then it is enough to establish laying of bigger thickness. For this purpose it is necessary to measure the indicator piston vystupaniye size.

Prevention

To carry out an inhaling of bolts in three steps. To use for this purpose only the checked and serviceable dynamometer key. Instead of it it is possible to use an angular washer for control of an inhaling of threaded connections.


19. Tighten bolts of a head of cylinders in that order the moment of 40 Nanometers.
20. Hold on bolts in the same sequence on a corner 60–75 °.
21. Hold on bolts in the same sequence on a corner 60–75 °.

Prevention

The subsequent tightening of bolts (for example, after 1000 km of a run) is not necessary.


22. Establish a tube of the maslomerny probe.
23. Establish and fix a turbocompressor.
24. Fix pipelines of giving and discharge of oil between a turbocompressor and the block of cylinders.
25. Clear the docking plane of the case of the thermostat, to install the thermostat assembled and to tighten bolts of its fastening the moment of 30 Nanometers.
26. Screw three bolts of fastening of a back cover of a gear belt and to tighten their moment 8 Nanometers.
27. Install the cogged pulley of the camshaft and to tighten a bolt of its fastening the moment of 10 Nanometers.
28. Put on a gear belt and to pull it.
29. Establish new sealing laying under a cover of the case of the camshaft and to fix a cover by bolts.
30. Install the radiator fan.
31. Establish a cover of a gear belt.
32. Fix fuel pipelines at TNVD and nozzles by the moment of 25 Nanometers.
33. Fix the pipeline of discharge of fuel at nozzles.
34. Establish an inlet collector.
35. Check an injection advancing.
36. Start and warm up the engine up to the temperature of oil of 60 °C.
37. Check the level of cooling liquid.
38. Check the speed of idling and the maximum speed, if necessary to modify.

Designation of laying

LAYING
THICKNESS, MM
VYSTUPANIYE OF THE PISTON, MM
without tag
1,4
0,58 – 0.64
with one tag
1,45
0,65 – 0,70
with two tags
1,50
0,71 – 0.78

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