Opel ASTRA H 2004 Service Manual page 3

Oil cooler module ...................................................................................................................................... 149
Sump .......................................................................................................................................................... 149
Module thermostat petrol engine Z 18 XER DOHC-I ............................................................................... 149
Simtec 75.1 electronic control module petrol Z 18 XER DOHC-I ............................................................ 150
2.2. Petrol engines - general inspection procedures ............................................................... 151
Checking the pressure loss in the engine (1,4-1,6 l) .................................................................................. 151
Checking the pressure loss in the engine (1,8 l) ........................................................................................ 156
Checking the pressure loss in the engine (2,0 l) ........................................................................................ 160
Checking compression (1,4-1,8 liter engines) ........................................................................................... 164
Check compression (engine 2.0 l) ............................................................................................................. 166
Checking the engine oil pressure (engine 2.0 liters) .................................................................................. 168
Check tightness of the engine (CO content in the cooling system) ........................................................... 168
Measurement of oil .................................................................................................................................... 169
Check tension Poly-V belt (engine 2.0 l) ................................................................................................... 170
Checking the synchronization of the timing mechanism (motor 2,0 l) ...................................................... 170
Adjusting the tension of the toothed belt (engine 2.0 l) ............................................................................. 172
Checking the tension of the toothed belt (engine 2.0 l) ............................................................................. 174
Replacing the front lower lid toothed belt (engine 2.0 l) ........................................................................... 178
Replacing the toothed belt (engine 2.0 liters) ............................................................................................ 179
2.3. Removing and installing the power unit .......................................................................... 183
General and safety by disconnecting power unit ....................................................................................... 183
Removing sealant ...................................................................................................................................... 184
Removing and installing the power unit (engine 1.4 l) .............................................................................. 185
Removing and installing the power unit (engine 2.0 l) .............................................................................. 202
2.4. The mechanical part of the engine ................................................................................... 219
Removing and installing the flywheel (engine 1.4 liters) .......................................................................... 219
Removing and installing the flywheel (engine 2.0 liters) .......................................................................... 220
Replacing the rear flange of the crankshaft ............................................................................................... 221
Replacing the valve stems seals (installed cylinder head) ......................................................................... 223
Removing and installing the crankshaft (engine 1.4 liters) ....................................................................... 228
Checking the axial free motion of the crankshaft ...................................................................................... 244
Removing and installing cylinder head (engine 2.0 l) ............................................................................... 245
Removing and installing cylinder head (engine 1,4-1,6 l) ......................................................................... 248
2.5. Inspection, and repair operations components of the mechanical part of the engine . 257
Checking the gap in the connecting rod bearings ...................................................................................... 257
Checking the gap in the connecting rod bearings ...................................................................................... 258
Replace connecting rod bearings ............................................................................................................... 259
Replacing piston rings ............................................................................................................................... 260
Replacing the piston rod with .................................................................................................................... 262
2.6. Cooling ................................................................................................................................ 265
Filling and removing air from the cooling system ..................................................................................... 265
Checking the tightness of the cooling system ............................................................................................ 266
Replacing the auxiliary electric fan (2.0 liter engines) .............................................................................. 266
Replacing the radiator (2.0 liter engines) .................................................................................................. 269
Removal and installation of coolant pump ................................................................................................ 272
Replacing the intercooler ........................................................................................................................... 273
2.7. The system of fuel injection gasoline engines .................................................................. 273
Removing and installing fuel injectors ...................................................................................................... 273
Replacing the fuel line pressure (High pressure pump - pressure chamber) .............................................. 276
Fuel Pump Module .................................................................................................................................... 278
Replacement module dosage ..................................................................................................................... 280
Replacing the fuel pressure regulator ........................................................................................................ 282
Replacing the damping body fuel return ................................................................................................... 283
Replacing the fuel level sensor .................................................................................................................. 284
Fuel Tank ................................................................................................................................................... 287
Replacing the tube fuel filler (petrol engines) ........................................................................................... 288
Vapor Fuel System .................................................................................................................................... 294
Replacing the front vent tube ..................................................................................................................... 295
Removing and installing tanks with activated charcoal ............................................................................. 296
Removing and installing the sensor mass air flow..................................................................................... 297
Replacing boost pressure sensor (Z 20 LEH) ............................................................................................ 297
Removing and installing the thermostat housing (engine 2.0 l) ................................................................ 298
Exhaust system (Z 14 XEP, Z 14 XEL, Z 16 XEP) ................................................................................... 300
Exhaust system (Z18 XE) .......................................................................................................................... 300
Exhaust system (Z 20 LEL) ....................................................................................................................... 300
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