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
   - 4.5. Diesel engines of 1,7 l
      4.5.1. A technical characteristics
      4.5.2. A method of removal of the engine
      4.5.3. Engine repair
      4.5.4. Replacement of engine oil and the oil filter
      + 4.5.5. Check, removal, installation and adjustment of a gear belt
      4.5.6. Check and adjustment timing
      4.5.7. Removal and installation of a head of the block of cylinders
      4.5.8. Removal and camshaft installation
      4.5.9. Removal and installation of the oil pallet
      4.5.10. Removal and installation of the oil pump
      4.5.11. Removal and installation перепускного the valve
      4.5.12. Removal and installation of the water pump
      4.5.13. Removal, check and thermostat installation
      4.5.14. Removal and installation of pistons and rods
      4.5.15. Removal and flywheel installation
      4.5.16. Replacement of sealing rings
      4.5.17. Replacement of support of the power unit
      4.5.18. Engine removal
      4.5.19. Engine repair
      4.5.20. Removal, repair and assemblage of the oil pump
      + 4.5.21. A head of the block of cylinders
      4.5.22. Check of elements of the engine
      4.5.23. Engine installation
+ 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





4.5. Diesel engines of 1,7 l

4.5.1. A technical characteristics
THE GENERAL DATA

Engine type
The four-cylinder, four-cycle engine with one camshaft of the top arrangement, indirect injection and компрессионным ignition
Diameter of the cylinder
82,5 mm
Piston stroke
79,50 mm
Volume
1699 sm3
Sequence of work of cylinders
1–3–4–2 (the cylinder №1 is located from outside a pulley of a cranked shaft)
The maximum capacity:
  – The engine 17D
4600 rpm
  – The engine 17DR
4600 rpm
The maximum twisting moment
105 Н.м. At 2400 rpm
Tension of a gear belt:
  – The engine 17D (it is measured by means of tool KM-510-A):
     • a new belt, the engine разогрет
7,5
     • a new belt, the engine cold
9,5
     • the used belt, the engine разогрет
5,0
     • the used belt, the engine cold
9,0
  – The engine 17DR
The tension is regulated automatically

Head of the block of cylinders

Definition of a thickness of a lining
  – выступание the piston to 0,80 mm:
     • a thickness
1,35 – 1,45 mm
     • marks
No
  – выступание the piston of 0,80-0,90 mm:
     • a thickness
1,44 – 1,55 mm
     • marks
One cut
  – выступание the piston over 0,90 mm:
     • a thickness
1,54 – 1,65 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
Backlash of a core of the valve in the directing plug:
  – The inlet valve
0,015 – 0,047 mm
  – The final valve
0,030 – 0,062 mm
Deepening of a plate of the valve
0,25 – 0,75 mm
Выступание the vortical chamber
0,00 – 0,02 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
Deformation of interfaced surfaces
Maximum of 0,05 mm

The valve

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 К1
+ 0,075 mm
  – Marks К2
+ 0,150 mm
 – Marks And
+ 0,250 mm
Corner of a facet of the valve in a head of cylinders
44

Camshaft and bearings

Camshaft marks
WITH
Shaft palpation
0,04 mm
Shaft free wheeling
0,09 – 0,21 mm
Height of lifting of cams (inlet and final valves)
5,80 mm

Cylinders

The cylinder
Diameter ( 0,005 mm)
Marks
Category 1
82,45 mm
5
82,46 mm
6
82,47 mm
7
Category 2
82,48 mm
8
82,49мм
99
82,50 mm
00
82,51 mm
01
82,52 mm
02
82,53 mm
03
Category 3
82,54 mm
04
82,55 mm
05
82,56 mm
06
82,57 mm
07
82,58 mm
08
82,59 mm
09
82,60 mm
1
The increased size (on 0,5 mm)
82,97 mm
7+0,5
82,98 mm
8+0,5
82,99 mm
9+0,5
83,00 mm
0+0,5
The increased size (on 1,0 mm)
83,48 mm
8+1,0
83,49 mm
9+1,0
83,50 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)
0,80 – 0,90 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 – 2,990 mm
Backlash in the lock:
  – компрессионные rings
0,2 – 0,4 mm
  – маслосъемное a ring
0,250 – 0,500
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
Maximum 8 г
Люфт on cranked to a shaft
0,070 – 0,242 mm
Working backlash of the bearing
0,019 – 0,063 mm

Marks of rods
Colour marks of loose leaves of bearings
Working backlash
I
The blue
0,025 – 0,054 mm
II
The black
0,027 – 0,056 mm
III
The brown
0,029 – 0,058 mm

Cranked shaft and bearings

Radial palpation
Maximum of 0,03 mm
Axial люфт
0,070 – 0,302 mm
Diameter of a neck of the radical bearing:
  – The nominal:
     • diameter
57,982 mm
     • marks
The green
     • diameter
57,995 mm
     • marks
The brown
  – The reduced size (on 0,25):
     • diameter
57,732 mm
     • marks
Green / Blue
     • diameter
57,745 mm
     • marks
Brown / Blue
  – The reduced size (on 0,50):
     • diameter
57,482 mm
     • marks
Green / White
     • diameter
57,495 mm
     • marks
Brown / White
The radical bearing:
  – A thickness of loose leaves
1,989 – 2,001 mm
  – A working backlash
0,015 – 0,041 mm
  – Ovality
0,005 mm a maximum
  – конусность
0,004 mm a maximum
The shatunnyj bearing:
  – Ovality
0,005 mm a maximum
  – конусность
0,004 mm a maximum

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
Pressure of oil (the engine разогрет also idles)
1,5 bar
The filter
Champion G105
Backlashes of the oil pump:
  – A backlash between teeths of gear wheels
0,175 – 0,225 mm
  – A backlash between a plane of an internal gear wheel and a plane of a casing of the pump
0,03 – 0,10 mm
  – A backlash between a plane of an external gear wheel and a plane of a casing of the pump
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
92 WITH
Temperature of full opening
107 WITH

The tightening moments

Bolts of fastening of a head 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
Warm up the engine  
  – A step 5
To tighten on a corner 30
  – A step 6
To tighten on a corner 15
Camshaft
Bolts of fastening of a cover of the case of a camshaft
8
Bolts of fastening of a persistent plate of a camshaft
8
Bolts of fastening of a pulley distributive вала:*
  – A step 1
75
  – A step 2
To tighten on a corner 60
  – A step 3
To tighten on a corner 5
Bolt of fastening of an intermediate pulley of a gear belt
40
Bolts of fastening of a pulley of the mechanism of a tension
25
Cranked shaft
Bolts of fastening of a pulley of a cranked shaft
20
Bolt of fastening of a pulley cranked вала:*
  – A step 1
145
  – A step 2
To tighten on a corner 30
  – A step 3
To tighten on a corner 10
Bolts of fastening of a flywheel:
  – A step 1
50
  – A step 2
To tighten on a corner 30
  – A step 3
To tighten on a corner 5
Bolts of fastening of a cover radical подшипника:*
  – A step 1
50
  – A step 2
To tighten on a corner 45
  – A step 3
To tighten on a corner 15
Bolts of fastening of a cover шатуна:*
  – A step 1
35
  – A step 2
To tighten on a corner 45
  – A step 3
To tighten on a corner 15
Greasing system
Bolts of fastening of the oil pump
6
Bolts of fastening of a cover of the oil pump
6
Fastening bolts маслозаборного a branch pipe
8
Bolts of fastening of the switch of a control paw of pressure of oil
30
Safety valve
30
The oil filter
15
Bolt of fastening of an arm маслозаборного a branch pipe
6
The oil pallet
Bolts of fastening of the oil pallet **
5
Masloslivnaja stopper of the oil pallet
45
Cooling system
Bolts of fastening of the water pump
20
Bolts of fastening of a tube of a cooling liquid
20
Bolts of fastening of a cover of the thermostat
8
Bolts, fastening the temperature gauge to a thermostat casing
11
Bolts, fastening a thermostat casing to a head of the block of cylinders
15
The steering amplifier
Bolts, fastening a basic arm of the pump of the amplifier of a steering to the block of cylinders
40
Support of the power unit
The left support:
  – Bolts, fastening a support arm to a transmission
60
  – Bolts, fastening a support to an arm
60
     • bolts, fastening a support to a body
65
The right support:
  – Bolts, fastening a support arm to the block of cylinders
60
  – Bolts, fastening a support to an arm
35
  – Bolts, fastening a support to a body
65
Back support:
  – Bolts, fastening a support arm to a transmission
60
  – Bolts, fastening a support to an arm
45
  – Bolts, fastening a support to a cross-beam
40
Other details
Bolts, fastening the vacuum pump to the camshaft case
28
Bolts, fastening a generator arm to the block of cylinders
40
Bolts, fastening an arm of the fuel pump to the block of cylinders
25
Bolts, fastening a starter arm to the block of cylinders
25
Bolts, fastening a starter to the block of cylinders:
  – From outside the engine
45
  – From outside transmissions
75
Bolts, fastening an oil separator of a ventilating hose картера the engine
15
Bolts, fastening a transmission to the block of cylinders
60

* At installation it is necessary to use new bolts.
** Before ввинчиванием grease a carving of bolts with the means interfering unscrewing of bolts.

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