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
   - 4.5. Diesel engines of 1,7 l
      4.5.1. Technical characteristics
      4.5.2. Method of removal of the engine
      4.5.3. Engine repair
      4.5.4. Replacement of engine oil and oil filter
      + 4.5.5. Check, removal, installation and adjustment of a gear belt
      4.5.6. Check and gazoraspredeleniye adjustment
      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 of the perepuskny 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 assembly of the oil pump
      + 4.5.21. 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 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



4.5. Diesel engines of 1,7 l

4.5.1. Technical characteristics

GENERAL INFORMATION

Engine type
The four-cylinder, four-cycle engine with one camshaft of the top arrangement, indirect injection and kompressionny ignition
Diameter of the cylinder
82,5 mm
Piston stroke
79,50 mm
Volume
1699 cm3
Sequence of operation of cylinders
1–3–4–2 (the cylinder No. 1 is located from a pulley of a cranked shaft)
Maximum capacity:
  – engine 17D
4600 rpm
  – engine 17DR
4600 rpm
Maximum torque
105 N of m at 2400 rpm
Tension of a gear belt:
  – the engine 17D (it is measured by means of the tool KM-510-A):
     • the new belt, the engine is warmed up
7,5
     • new belt, engine cold
9,5
     • the used belt, the engine is warmed up
5,0
     • the used belt, the engine cold
9,0
  – engine 17DR
The tension is regulated automatically

Head of the block of cylinders

Determination of thickness of laying
  – a piston vystupaniye to 0,80 mm:
     • thickness
1,35-1,45 mm
     • marking
No
  – vystupaniye of the piston of 0,80-0,90 mm:
     • thickness
1,44-1,55 mm
     • marking
One cut
  – vystupaniye of the piston over 0,90 mm:
     • thickness
1,54-1,65 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
Gap of a core of the valve in the directing plug:
  – inlet valve
0,015-0,047 mm
  – final valve
0,030-0,062 mm
Deepening of a plate of the valve
0,25-0,75 mm
Vystupaniye of the vortical chamber
0,00-0,02 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
Deformation of interfaced surfaces
At most 0,05 mm

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 a plug rastachivaniye:
  – marking К1
+ 0,075 mm
  – marking К2
+ 0,150 mm
 – marking And
+ 0,250 mm
Corner of a facet of the valve in a head of cylinders
44 °

Camshaft and bearings

Camshaft marking
With
Shaft palpation
0,04 mm
Free wheeling of a shaft
0,09-0,21 mm
Height of lifting of cams (inlet and final valves)
5,80 mm

Cylinders

Cylinder
Diameter (± 0,005 mm)
Marking
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

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)
0,80-0,90 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
2,975-2,990 mm
Gap in the lock:
  – kompressionny rings
0,2-0,4 mm
  – maslosjemny ring
0,250-0,500
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
At most 8 g
Люфт on cranked to a shaft
0,070-0,242 mm
Working gap of the bearing
0,019-0,063 mm

Marking of rods
Color marking of loose leaves of bearings
Working gap
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
At most 0,03 mm
Axial люфт
  0,070-0,302 mm
Diameter of a neck of the radical bearing:
  – the nominal:
     • diameter
57,982 mm
     • marking
The green
     • diameter
57,995 mm
     • marking
The brown
  – the reduced size (on 0,25):
     • diameter
57,732 mm
     • marking
The green / Blue
     • diameter
57,745 mm
     • marking
The brown / Blue
  – the reduced size (on 0,50):
     • diameter
57,482 mm
     • marking
The green / White
     • diameter
57,495 mm
     • marking
The brown / White
Radical bearing:
  – thickness of loose leaves
  1,989-2,001 mm
  – working gap
  0,015-0,041 mm
  – ovality
0,005 mm at most
  – konusnost
0,004 mm at most
Shatunny bearing:
  – ovality
0,005 mm at most
  – konusnost
0,004 mm at most

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
Pressure of oil (the engine is warmed up and idles)
1,5 bar
Filter
Champion G105
Gaps of the oil pump:
  – a gap between teeths of gear wheels
  0,175-0,225 mm
  – a gap between the plane of an internal gear wheel and the plane of a casing of the pump
0,03-0,10 mm
  – a gap between the plane of an external gear wheel and the plane of a casing of the pump
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
92 ° With
Temperature of complete opening
107 ° With

Tightening moments

Bolts of fastening of a head 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 °
Warm up the engine  
  – step 5
To tighten on a corner 30 °
  – 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:*
  – step 1
75
  – step 2
To tighten on a corner 60 °
  – 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:*
  – step 1
145
  – step 2
To tighten on a corner 30 °
  – step 3
To tighten on a corner 10 °
Bolts of fastening of a flywheel:
  – step 1
50
  – step 2
To tighten on a corner 30 °
  – step 3
To tighten on a corner 5 °
Bolts of fastening of a cover radical подшипника:*
  – step 1
50
  – step 2
To tighten on a corner 45 °
  – step 3
To tighten on a corner 15
Bolts of fastening of a cover шатуна:*
  – step 1
35
  – step 2
To tighten on a corner 45 °
  – 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
Bolts of fastening of a maslozaborny branch pipe
8
Bolts of fastening of the switch of a control paw of pressure of oil
30
Safety valve
30
Oil filter
15
Bolt of fastening of an arm of a maslozaborny branch pipe
6
Oil pallet
Bolts of fastening of the oil pallet **
5
Masloslivny stopper of the oil pallet
45
Cooling system
Bolts of fastening of the water pump
20
Bolts of fastening of a tube of cooling liquid
20
Bolts of fastening of a cover of the thermostat
8
The bolts, temperatures fixing the sensor to a thermostat casing
11
The bolts, fixing a thermostat casing to a head of the block of cylinders
15
Amplifier of a steering
The bolts, fixing a basic arm of the pump of the amplifier of a steering to the block of cylinders
40
Support of the power unit
Left support:
  – the bolts, support fixing an arm to a transmission
60
  – the bolts, fixing a support to an arm
60
     • the bolts, fixing a support to a body
65
Right support:
  – the bolts, support fixing an arm to the block of cylinders
60
  – the bolts, fixing a support to an arm
35
  – the bolts, fixing a support to a body
65
Back support:
  – the bolts, support fixing an arm to a transmission
60
  – the bolts, fixing a support to an arm
45
  – the bolts, fixing a support to a cross-piece
40
Other details
The bolts, fixing the vacuum pump to the camshaft case
28
The bolts, fixing a generator arm to the block of cylinders
40
The bolts, fixing an arm of the fuel pump to the block of cylinders
25
The bolts, fixing a starter arm to the block of cylinders
25
The bolts, fixing a starter to the block of cylinders:
  – from the engine
45
  – from a transmission
75
The bolts, fixing an oil separator of a ventilating hose of a case of the engine
15
The bolts, fixing a transmission to the block of cylinders
60

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