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





4.5.3. Engine repair
THE GENERAL DATA

It is not always easy to come to a conclusion about expediency of full major repairs of the engine as it is necessary to be based on variety of objective indicators.

The big run is not a sufficient indicator of necessity of carrying out of major repairs. On the other hand, small run does not exclude necessity of carrying out of major repairs. The most important indicator, most likely, is timeliness of current maintenance service of the engine. At timely change of oil and the filter, and also at performance of all other necessary works on service, the engine serves reliably throughout many thousand kilometres of run. On the contrary, insufficient on volume or untimely maintenance service can be at the bottom of sharp reduction of a resource of the engine.

The raised expense of oil specifies in deterioration of the piston rings, directing plugs of valves and маслоотражательных caps. It is necessary to be convinced that leaks are not at the bottom of the raised expense of oil, and only after that to do a conclusion about unfitness of piston rings and directing plugs of valves. To define a malfunction plausible reason, measure a compression in engine cylinders.

Check up pressure of oil a manometre screwed to the place of the gauge of pressure of oil, and compare result of check to standard value. If pressure of oil low deterioration radical and шатунных bearings or details of the oil pump can be the reason.

Capacity loss, "failures" in engine work, a detonation or the metal knocks, the raised noise from the gear mechanism, specify the raised expense of fuel in necessity of carrying out of major repairs, especially, if all these signs of abnormal work are shown simultaneously. If performance of all adjustments does not lead to improvement unique means of elimination of abnormal work of the engine are major repairs.

Major repairs consist in restoration of details of the engine to a condition specified in specifications for the new engine. At major repairs carrying out pistons and piston rings are replaced, chiseled or хонингуются cylinders. After repair of cylinders which is carried out in a specialised workshop, installation of repair pistons is required. Шатунные and radical loose leaves of a cranked shaft, and also a cover of basic necks of a camshaft also are subject to replacement, if necessary follows прошлифовать necks of a cranked shaft before restoration of normal backlashes with шатунными and radical loose leaves.

Valves, as their condition at the moment of repair, as a rule, not absolutely satisfactory are subject to repair also. During engine major repairs repair of such units, as a starter, the generator and the ignition distributor also is carried out. As a result repaired engine should possess qualities of the new unit and sustain considerable run without refusals.


The prevention

At major repairs it is necessary to replace such important details of system of cooling, as hoses, drive belts, the thermostat and the pump of a cooling liquid. The radiator should be surveyed on tightness and cleanliness of internal channels. If you have bought the repair engine, or the block of cylinders of an incomplete complete set some suppliers do not give a guarantee on operation of these units without qualitative washing of a radiator. At engine major repairs also it is recommended to replace the oil pump.


Before the beginning of major repairs of the engine familiarise with the description of corresponding procedures that there was an impression of forthcoming amount of works and requirements to them. At observance of all norms and rules, in the presence of all necessary tools and adaptations major repairs to execute simply, considerable expenses of time however be required.

Roughly it is required not less than two weeks, especially if for repair and restoration of details it is necessary to address in a specialised workshop. Check up presence of spare parts and in advance take care of acquisition of necessary special tools and the equipment. Almost all works can be executed by means of a standard tooling though exact measuring devices will be necessary for check and definition of suitability of those or other details. Frequently check of a condition of details carry out in specialised workshops in which also receive recommendations about replacement or restoration of those or other details.
The prevention

To address in car-care centre workshops follows only after full dismantling of the engine and check of a condition of all details, especially the block of cylinders to solve, which operations on service and repair will be carried out in workshops.


As the condition of the block of cylinders is the defining factor of decision-making on its further repair or about purchase new (or repair) the block of cylinders to buy spare parts or to carry out operations on machining of accompanying details follows only after careful check of its technical condition. Make it a rule that the true price of repair is time – then it is not necessary to pay for installation of the worn out or restored details.

In summary we will notice that assemblage of any units should be carried out with all carefulness in a pure premise to avoid the further refusals of the repaired engine and to provide its reliable work.

At independent performance of major repairs various variants are possible. The decision on replacement of the block of cylinders, shatunno-piston group and a cranked shaft depends on variety of factors from which the most important is the condition of the block of cylinders. Other reasons are repair cost, access possibility to the equipment of workshops of car-care centre, presence of spare parts, time planned for work, and also personal experience.

If check shows that the block of cylinders and the majority of details are in a satisfactory condition and can be used further the most expedient from the economic point of view is purchase of separate spare parts. The block of cylinders, shatunno-piston group and a cranked shaft should be surveyed especially carefully. Even if insignificant deterioration of the block of cylinders is found out, cylinders are subject obligatory хонингованию.

The block of cylinders of an incomplete complete set

The block of cylinders of an incomplete complete set contains the block of cylinders with established krivoshipno-shatunnym the mechanism and piston group. All interfaced details are picked up for the dimensional groups, all backlashes correspond to norms. On the block the mechanism, a head of the block of cylinders and hinged units are separately mounted not a part of this repair complete set a camshaft, клапанный. Expenses for machining are minimum or are not required absolutely.

The repair engine (the block of cylinders of a full complete set)

The repair engine delivered in spare parts contains all complete set of the block of cylinders of an incomplete complete set, and also the oil pump, the oil pallet, a head of the block of cylinders, a cover of a head of the block of cylinders, a camshaft, клапанный the mechanism, gear wheels of a drive of a camshaft, a gear belt and belt casings. All details are established with new bearings, consolidations and linings. On the complete set inlet both final collectors and hinged units are mounted only.

Carefully think over, what of alternatives to you is better approaches, before purchase or before registration of the order for spare parts consult in a local workshop of car-care centre, with suppliers of spare parts, and also with experts in restoration of engines.

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