Opel Kadett E

1984-1991 of release

Repair and car operation



Opel Kadett E
+ 1. The maintenance instruction
+ 2. Weekly checks and service in a way
+ 3. Maintenance service
- 4. The engine
   + 4.1. Engine OHV (with a camshaft in the block of cylinders)
   + 4.2. Engines OHC
   + 4.3. Engine DOHC with 16 valves
   - 4.4. Diesel engines 16D and 16DА
      4.4.1. A technical characteristics
      4.4.2. A method of removal of the engine
      4.4.3. Engine repair
      4.4.4. Replacement of engine oil and the oil filter
      4.4.5. Check, removal, installation and adjustment of a gear belt
      + 4.4.6. A mechanism drive timing
      4.4.7. Removal and installation of a head of the block of cylinders
      4.4.8. Removal and camshaft installation
      4.4.9. Removal and installation of the oil pallet
      4.4.10. Removal and installation of the oil pump
      4.4.11. Removal and installation перепускного the valve
      4.4.12. Removal and installation of the water pump
      4.4.13. Removal, check and thermostat installation
      4.4.14. Removal and installation of pistons and rods
      4.4.15. Removal and flywheel installation
      + 4.4.16. Replacement of sealing rings
      4.4.17. Replacement of support of the power unit
      + 4.4.18. Removal of the engine from a transmission
      4.4.19. Engine and transmission division
      4.4.20. Engine repair
      4.4.21. Removal, repair and assemblage of the oil pump
      + 4.4.22. A head of the block of cylinders
      4.4.23. Check and restoration of details of the engine
      + 4.4.24. Check of elements of the engine
      4.4.25. Replacement of pushers, persistent linings and hydraulic pushers
      4.4.26. Engine assemblage.
      4.4.27. Connection of the engine with a transmission
      4.4.28. Engine and transmission installation
   + 4.5. Diesel engines of 1,7 l
+ 5. System of cooling, heating and ventilation
+ 6. Fuel and exhaust systems
+ 7. Start and gymnastics system
+ 8. Ignition system
+ 9. Coupling
+ 10. Transmissions and power shafts
+ 11. Brake system
+ 12. A suspension bracket and a steering
+ 13. A body
+ 14. Electric schemes





4.4. Diesel engines 16D and 16DА

4.4.1. A technical characteristics
THE GENERAL DATA

Engine type
The four-cylinder, four-cycle engine, with one camshaft of the top arrangement, not direct injection and компрессионным ignition
Marks:
  – To 1985 г
16D
  – With 1986 г
16DA
Diameter of the cylinder
80,00 mm
Piston stroke
79,50 mm
Volume
1598 sm3
Sequence of work of cylinders
1–3–4–2 (the cylinder №1 is located from outside a pulley)
Compression degree
23: 1
The maximum twisting moment:
  – 16D
96 Nanometers at 2400 rpm
  – 16DA
95 Nanometers at 2400 rpm

Gear belt

Belt tension (it is measured by means of tool KM-510-A):
  – A new belt, the engine разогрет
9,0
  – A new belt, the engine cold
6,5
  – The used belt, the engine разогрет
8,0
  – The used belt, the engine cold
4,0

Head of the block of cylinders

Definition of a thickness of a lining:
  – A ledge of the piston to 0,75 mm:
     • a thickness
1,3 mm
     • marks
No
  – A ledge of the piston 0,75 – 0,85 mm:
     • a thickness
1,4 mm
     • marks
One cut
  – A ledge of the piston over 0,85 mm:
     • a thickness
1,5 mm
     • marks
Two cuts
Adjustment of backlashes of valves
It is carried out by automatically hydraulic pushers
Width of a saddle of the valve in a head of cylinders:
  – The inlet
1,3 – 2,0 mm
  – The final
1,3 – 2,6 mm
Люфт a valve core in the directing plug:
  – The inlet valve
0,015 – 0,047 mm
  – The final valve
0,030 – 0,062 mm
Deepening of a head of the valve
0,25 – 0,75 mm
Ledge of the vortical chamber
0,00 – 0,04 mm
Polishing of an interfaced surface
Maximum of 0,025 mm
Height of a head of the block of cylinders:
  – The maximum
106,10 mm
  – The minimum
105,75 mm
Неплоскостность interfaced surfaces
Maximum of 0,15 mm

Valves

Length of the valve
123,25 mm
Diameter of a plate of the valve:
  – The inlet
36 mm
  – The final
32 mm
Diameter of a core of the valve (nominal):
  – The inlet
7,970 – 7,985 mm
  – The final
7,955 – 7,970 mm
Internal diameter of the directing plug of the valve (nominal)
8,000 – 8,017 mm
Diameter of a core of the valve after растачивания plugs:
  – Marks 1
+0,075 mm
  – Marks 2
+0,150 mm
  – Marks And (the inlet valve) or To (the final valve)
+0,250 mm
Corner of a facet of the valve in a head of cylinders
44

Camshaft and bearings

Diameter of a neck of the bearing (nominal):
  – №1
42,455 – 42,470 mm
  – №2
42,705 – 42,720 mm
  – №3
42,955 – 42,970 mm
  – №4
43,205 – 43,220 mm
  – №5
43,455 – 43,470 mm
Diameter of the bearing (nominal):
  – №1
42,500 – 42,525 mm
  – №2
42,750 – 42,775 mm
  – №3
43,000 – 43,025 mm
  – №4
43,250 – 43,275 mm
  – №5
43,500 – 43,525 mm
Diameters of necks and bearings after processing
-0,1 mm
Camshaft marks:
  – The alphabetic
IN
  – Colour – a standard shaft
No
  – Colour – after processing
The violet
Radial palpation
Maximum of 0,03 mm
Axial люфт
0,04 – 0,14 mm
Height of lifting of cams (inlet and final valves)
6,12 mm
Ovality and конусность the cylinder
0,013 mm a maximum

Cylinders

The cylinder
Diameter ( 0,005 mm)
Marks
Category 1
79,95 mm
5
79,96 mm
6
79,97 mm
7
Category 2
79,98 mm
8
79,99 mm
99
80,00 mm
00
80,01 mm
01
80,02 mm
02
80,03 mm
03
Category 3
80,04 mm
04
80,05 mm
05
80,06 mm
06
80,07 mm
07
80,08 mm
08
80,09 mm
09
80,10 mm
1
The increased size (on 0,5 mm)
80,47 mm
7+0,5
80,48 mm
8+0,5
80,49 mm
9+0,5
80,50 mm
0+0,5
The increased size (on 1,0 mm)
80,97 mm
7+1,0
80,98 mm
8+1,0
80,99 mm
9+1,0
81,00 mm
0+1,0

Pistons

The manufacturer
Mahle or Alcan
Marks of the manufacturer:
  – Mahle
m
  – Alcan
D
Diameter:
  – Mahle
On 0,030 mm it is less, than diameter of the cylinder
  – Alcan
On 0,020 mm it is less, than diameter of the cylinder
Marks on categories correspond to marks of cylinders. A piston ledge in the top dead point (it is used for definition of a thickness of a lining of a head of the block of cylinders)
0,65 – 0,95 mm
Assembly backlash:
  – Mahle
0,020 – 0,040 mm
  – Alcan
0,015 – 0,035 mm

Piston rings

Thickness:
  – компрессионные rings
1,978 – 1,990 mm
  – маслосъемное a ring
2,975 – 3,010 mm
Backlash in the lock of rings
0,2 – 0,4 mm
Backlash between a piston ring and a lateral surface of a flute of a ring
It is not defined
Displacement of locks of piston rings rather each other
180

Piston fingers

Length
64,7 – 65,0 mm
Diameter
25,995 – 26,000 mm
Backlash:
  – Between a piston finger and the piston
0,007 – 0,011 mm
  – Between a piston finger and a rod
0,014 – 0,025 mm

Rods

Difference between the next rods in weight
4 г
Marks on weight:
  – 785 г
Black / 1
  – 789 г
Blue / 2
  – 793 г
Green / 3
  – 797 г
Yellow / 4
  – 807 г
White / 5
  – 805 г
Grey / 6
Люфт on cranked to a shaft
0,07 – 0,24 mm

Cranked shaft and bearings

Diameter of a neck of the radical bearing:
  – The nominal
57,982 – 57,995 mm
  – The reduced size (on 0,25)
57,732 – 57,745 mm
  – The reduced size (on 0,50)
57,482 – 57,495 mm
Diameter of a neck шатунного the bearing:
  – The nominal
48,971 – 48,987 mm
  – The reduced size (on 0,25)
48,721 – 48,737 mm
  – The reduced size (on 0,50)
48,471 – 48,487 mm
Ovality and конусность bearings of a cranked shaft
Maximum of 0,004 mm
Shaft palpation
Maximum of 0,03 mm
Люфт
0,07 – 0,30 mm
Working backlash of the radical bearing
0,015 – 0,040 mm
Working backlash шатунного the bearing
0,019 – 0,063 mm

Marks of loose leaves of bearings

Loose leaves
Colour
Marks
The standard size:
  – The top loose leaves of radical bearings, except an average
The brown
413N or 403N
  – The top average loose leaf of the radical bearing
The brown
400N or 410N
  – The bottom loose leaves of radical bearings, except an average
The green
414N or 404N
  – The bottom average loose leaf of the radical bearing
The green
401N or 411N
  – Loose leaves шатунного the bearing
No
419N
The reduced size (0,25):
  – The top loose leaves of radical bearings, except an average
Brown-blue
415А or 405А
  – The top average loose leaf of the radical bearing
Brown-blue
402А or 412А
  – The bottom loose leaves of radical bearings, except an average
Green-blue
416А or 406А
  – The bottom average loose leaf of the radical bearing
Green-blue
403А or 413А
  – Loose leaves шатунного the bearing
The blue
420А
The reduced size (0,50):
  – The top loose leaves of radical bearings, except an average
Brown-white
236В or 407
  – The top average loose leaf of the radical bearing
Brown-white
238В or 414В
  – The bottom loose leaves of radical bearings, except an average
Green-white
237В or 408
  – The bottom average loose leaf of the radical bearing
Green-white
239В or 415В
  – владыши шатунного the bearing
The white
421В

Flywheel

Palpation
Maximum of 0,5 mm
The maximum deterioration of a frictional surface
Maximum of 0,3 mm

Greasing system

System type
The oil pallet, giving under pressure, полнопоточный the filter
The filter
Champion G105
Pressure of oil (the engine разогрет also idles)
1,5 bar
Backlashes of the oil pump:
  – A backlash between teeths of gear wheels
0,1 – 0,2 mm
  – A backlash between an external gear wheel and a pump casing
0,03 – 0,10 mm
  – A backlash between a plane of gear wheels and a pump plane
0,03 – 0,10 mm

The water pump

Type
The centrifugal pump
Drive
From a cranked shaft клинообразным a belt

The thermostat

Temperature of the beginning of opening
91 WITH
Temperature of full opening
106 WITH
Marks
91

The tightening moments

The engine 16D
Bolts of fastening of a pulley of a cranked shaft
20
The central bolt of a pulley of a cranked shaft
155
Bolts, fastening a starter to the block of cylinders of the engine
45
Bolts, fastening a starter to the block of cylinders of the engine
45
Bolt of a pulley of a camshaft:
– A step 1
75
  – A step 2
To tighten on a corner 30
Bolts of covers of radical bearings
80
Bolts of covers шатунных bearings
50
Заглушка редукционного the valve of the oil pump
30
Bolts of the oil pallet
5
Bolts of a head of the block цилиндров:*
  – A step 1
25
  – A step 2
To tighten on a corner 90
  – A step 3
To tighten on a corner 90
  – A step 4
To tighten on a corner 45
  – A step 5
To tighten on a corner 30
  – A step 6
To tighten on a corner 45
Bolts, fastening the vacuum pump to a cover of a head of the block of cylinders
28
The switch of a control lamp of pressure of oil
30
Bolts, fastening an oil separator of system of ventilation картера the engine
15
Bolts of an arm of the right support of the engine
50
Bolts of other support of the engine
40
Masloslivnaja stopper
45
Bolts of the water pump
25
Bolts, fastening a thermostat casing to a head of the block of cylinders
15
Bolts, fastening the gauge of temperature of a cooling liquid to a thermostat casing
8
Engines 16DA
The central bolt of a pulley cranked вала:*
  – A step 1
130
  – A step 2
To tighten on a corner 45
Fastening bolts маховика:*
  – A step 1
50
  – A step 2
To tighten on a corner 30
Bolts of covers radical подшипников:*
  – A step 1
50
  – A step 2
To tighten on a corner 45
Bolts of covers шатунных подшипников:*
  – A step 1
35
  – A step 2
To tighten on a corner 30
Bolts of a head of the block цилиндров:*
  – A step 1
25 Nanometers
  – A step 2
To tighten on a corner 90
  – A step 3
To tighten on a corner 90
  – A step 4
To tighten on a corner 45
  – A step 5
To tighten on a corner 30
  – A step 6
To tighten on a corner 45
Candles накаливания
20

* At installation it is necessary to use new bolts.

On the main page