Opel Kadett E

1984-1991 of release

Repair and car operation



Opel Kadett E
+ 1. Maintenance instruction
+ 2. Weekly checks and service in a way
+ 3. Maintenance
- 4. Engine
   + 4.1. The OHV engine (with a camshaft in the block of cylinders)
   + 4.2. OHC engines
   + 4.3. The DOHC engine with 16 valves
   - 4.4. Diesel engines 16D and 16DА
      4.4.1. Technical characteristics
      4.4.2. Method of removal of the engine
      4.4.3. Engine repair
      4.4.4. Replacement of engine oil and oil filter
      4.4.5. Check, removal, installation and adjustment of a gear belt
      + 4.4.6. Drive of the mechanism of a gazoraspredeleniye
      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 of the perepuskny 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. Engine removal with a transmission
      4.4.19. Engine and transmission division
      4.4.20. Engine repair
      4.4.21. Removal, repair and assembly of the oil pump
      + 4.4.22. 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 laying and hydraulic pushers
      4.4.26. Engine assembly.
      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 charging system
+ 8. Ignition system
+ 9. Coupling
+ 10. Transmissions and power shafts
+ 11. Brake system
+ 12. Suspension bracket and steering
+ 13. Body
+ 14. Electric circuits



4.4. Diesel engines 16D and 16DА

4.4.1. Technical characteristics

GENERAL INFORMATION

Engine type
The four-cylinder, four-cycle engine, with one camshaft of the top arrangement, not direct injection and kompressionny ignition
Marking:
  – to 1985 g
16D
  – from 1986 g
16DA
Diameter of the cylinder
80,00 mm
Piston stroke
79,50 mm
Volume
1598 cm3
Sequence of operation of cylinders
1–3–4–2 (the cylinder No. 1 is located from a pulley)
Extent of compression
23: 1
Maximum torque:
  – 16D
96 Nanometers at 2400 rpm
  – 16DA
95 Nanometers at 2400 rpm

Gear belt

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

Head of the block of cylinders

Determination of thickness of laying:
  – a piston ledge to 0,75 mm:
     • thickness
1,3 mm
     • marking
No
  – a piston 0,75 ledge – 0,85 mm:
     • thickness
1,4 mm
     • marking
One cut
  – ledge of the piston over 0,85 mm:
     • thickness
1,5 mm
     • marking
Two cuts
Adjustment of gaps 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:
  – inlet valve
0,015-0,047 mm
  – 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
At most 0,025 mm
Height of a head of the block of cylinders:
  – the maximum
106,10 mm
  – the minimum
105,75 mm
Not planeness of interfaced surfaces
At most 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 a plug rastachivaniye:
  – marking 1
+0,075 mm
  – marking 2
+0,150 mm
  – marking 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):
  – No. 1
42,455-42,470 mm
  – No. 2
42,705-42,720 mm
  – No. 3
42,955-42,970 mm
  – No. 4
43,205-43,220 mm
  – No. 5
43,455-43,470 mm
Diameter of the bearing (nominal):
  – No. 1
42,500-42,525 mm
  – No. 2
42,750-42,775 mm
  – No. 3
43,000-43,025 mm
  – No. 4
43,250-43,275 mm
  – No. 5
43,500-43,525 mm
Diameters of necks and bearings after processing
- 0,1 mm
Camshaft marking:
  – the alphabetic
In
  – the color – a standard shaft
no
  – the color – after processing
the violet
Radial palpation
At most 0,03 mm
Axial люфт
0,04-0,14 mm
Height of lifting of cams (inlet and final valves)
6,12 mm
Ovality and cylinder konusnost
0,013 mm at most

Cylinders

Cylinder
Diameter (± 0,005 mm)
Marking
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

Producer
Mahle or Alcan
Marking of the producer:
  – 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
Marking on categories corresponds to marking of cylinders. A piston ledge in the top dead point (it is used for determination of thickness of laying of a head of the block of cylinders)
0,65-0,95 mm
Assembly gap:
  – Mahle
0,020-0,040 mm
  – Alcan
0,015-0,035 mm

Piston rings

Thickness:
  – kompressionny rings
1,978-1,990 mm
  – maslosjemny ring
2,975-3,010 mm
Gap in the lock of rings
0,2-0,4 mm
Gap between a piston ring and a lateral surface of a flute of a ring
It is not defined
Shift of locks of piston rings relatively each other
180 °

Piston fingers

Length
64,7-65,0 mm
Diameter
25,995-26,000 mm
Gap:
  – 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 g
Marking on weight:
  – 785 g
Black / 1
  – 789 g
Blue / 2
  – 793 g
Green / 3
  – 797 g
Yellow / 4
  – 807 g
White / 5
  – 805 g
Gray / 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 of the shatunny 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 konusnost of bearings of a cranked shaft
At most 0,004 mm
Shaft palpation
At most 0,03 mm
Люфт
0,07-0,30 mm
Working gap of the radical bearing
0,015-0,040 mm
Working gap of the shatunny bearing
0,019-0,063 mm

Marking of loose leaves of bearings

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

Flywheel

Palpation
At most 0,5 mm
Maximum wear of a frictional surface
At most 0,3 mm

Greasing system

System type
The oil pallet, giving under pressure, the polnopotochny filter
Filter
Champion G105
Pressure of oil (the engine is warmed up and idles)
1,5 bar
Gaps of the oil pump:
  – a gap between teeths of gear wheels
0,1-0,2 mm
  – a gap between an external gear wheel and a pump casing
0,03-0,10 mm
  – a gap between the plane of gear wheels and the pump plane
0,03-0,10 mm

Water pump

Type
Centrifugal pump
Drive
From a cranked shaft wedge-shaped belt

Thermostat

Temperature of the beginning of opening
91 ° With
Temperature of complete opening
106 ° With
Marking
91

Tightening moments

Engine 16D
Bolts of fastening of a pulley of a cranked shaft
20
Central bolt of a pulley of a cranked shaft
155
The bolts, fixing a starter to the block of cylinders of the engine
45
The bolts, fixing a starter to the block of cylinders of the engine
45
Bolt of a pulley of a camshaft:
  – step 1
75
  – step 2
To tighten on a corner 30 °
Bolts of covers of radical bearings
80
Bolts of covers of shatunny bearings
50
Cap of the reduktsionny valve of the oil pump
30
Bolts of the oil pallet
5
Bolts of a head of the block цилиндров:*
  – step 1
25
  – step 2
To tighten on a corner 90 °
  – step 3
To tighten on a corner 90 °
  – step 4
To tighten on a corner 45 °
  – step 5
To tighten on a corner 30 °
  – step 6
To tighten on a corner 45 °
The bolts, fixing the vacuum pump to a cover of a head of the block of cylinders
28
Switch of a control lamp of pressure of oil
30
The bolts, systems of ventilation of a case of the engine fixing an oil separator
15
Bolts of an arm of the right support of the engine
50
Bolts of other support of the engine
40
Masloslivny stopper
45
Bolts of the water pump
25
The bolts, fixing a thermostat casing to a head of the block of cylinders
15
The bolts, temperatures of cooling liquid fixing the sensor to a thermostat casing
8
Engines 16DA
Central bolt of a pulley cranked вала:*
  – step 1
130
  – step 2
To tighten on a corner 45 °
Fastening bolts маховика:*
  – step 1
50
  – step 2
To tighten on a corner 30 °
Bolts of covers radical подшипников:*
  – step 1
50
  – step 2
To tighten on a corner 45 °
Bolts of covers shatunny подшипников:*
  – step 1
35
  – step 2
To tighten on a corner 30 °
Bolts of a head of the block цилиндров:*
  – step 1
25 Nanometers
  – step 2
To tighten on a corner 90 °
  – step 3
To tighten on a corner 90 °
  – step 4
To tighten on a corner 45 °
  – step 5
To tighten on a corner 30 °
  – step 6
To tighten on a corner 45 °
Glow plugs
20

* At installation it is necessary to use new bolts.