Opel Omega

since 1993-1999 of release

Repair and car operation



Opel Omega
+ 1. Maintenance instruction
+ 2. Maintenance
- 3. Repair of engines
   + 3.1. SOHC engines in volume 2,0 liters
   + 3.2. DOHC engines in volume 2,0 liters
   + 3.3. Engines in volume 2,5 and 3,0 liters
   + 3.4. Partition of all petrol engines
   + 3.5. Diesel engine in volume 2,0 liters
   - 3.6. Diesel six-cylinder 2,5-liter engine
      3.6.1. Removal and engine installation
      3.6.2. Head of cylinders
      3.6.3. Cam-shaft
      3.6.4. Compression check
      3.6.5. Multiridge maple belt
      3.6.6. Pallet of a case and laying
      + 3.6.7. System of cooling of the diesel engine of 2,5 liters
+ 4. Heating system and ventilation
+ 5. Fuel, exhaust systems
+ 6. System of start of the engine
+ 7. Ignition system
+ 8. Coupling
+ 9. Transmissions
+ 10. Main transfer, semi-axes
+ 11. Brake system
+ 12. Suspension bracket and steering
+ 13. Body
+ 14. Body electric equipment


3.6.2. Head of cylinders

GENERAL INFORMATION

Arrangement of elements of a final collector

1. Final collector

2. Turbonagnetatel

3. A bar of the adjusting valve of forced air

4. Connection of a return oil pipeline

5. Case of a szhimatel

6. Valve of adjustment of pressure of forcing

7. Oil pipeline

Details of an inlet collector

1. Laying

2. Inlet collector

3. The sensor of temperature of forced air

4. Laying

5. The valve of return of the fulfilled gases

Prevention

Remove a head of cylinders only on the cooled engine.

Final and inlet collectors unscrew from a head of cylinders and remain on the car.


The faulty head of cylinders is distinguished on various signs.

CARS WITHOUT THE CONDITIONER

Removal

PERFORMANCE ORDER
1. Disconnect a cable of weight of the battery.

Prevention

Data from electronic memory, for example, a protective code of a radio receiver are thus erased.


2. Remove the bottom guard of an impellent compartment.
3. Merge cooling liquid (as well from the block of cylinders).
4. Merge engine oil.
5. Take out a vacuum hose with a corner on the brake amplifier.
6. Disconnect thin vacuum tubes on the return valve of a vacuum hose.
7. Unscrew a tube of forcing of air on a head of cylinders and disconnect air hoses after weakening of collars.
8. Unscrew the top guard of the engine and remove it (1, 2, 3 – the screw).
9. Remove a hose of ventilation of the engine on a cover of a head of cylinders, and also a hose of soaked-up air from the case of the air filter and a turbonagnetatel, for this purpose weaken and shift back collars.
10. Unscrew a final collector on a head of the block of cylinders. Thus at first evenly weaken bolts outside inside at first on a half of turn, then completely weaken. Unscrew a final collector (3 bolts) on a turbonagnetatel.

Prevention

Cover openings of a turbonagnetatel with a pure rag and watch, that no extraneous subjects got in the supercharger as there can be serious damages of the engine.


11. Remove laying of a final collector on the engine. Consider adjusting situation: brackets of laying are turned from the engine.
12. Remove an inlet collector on a head of cylinders.
13. For this purpose disconnect a cable on the sensor of temperature of forced air, disconnect a vacuum hose on the valve of return of the fulfilled gases and on the bottom party of an inlet collector.
14. Weaken a tube of forced air and disconnect it.
15. Unscrew an inlet collector on a head of cylinders and on the holder and remove with laying.
16. With laying it is not necessary to unscrew the valve of return of the fulfilled gases.
17. Unscrew injection pipelines by means of the cut-through cap key from TNVD and nozzles.

Prevention

Do not change a form of a bend of pipelines.


18. Disconnect a hose of cooling liquid from the thermostat case, for this purpose it is necessary to weaken a hose collar.
19. Remove multiridge maple a belt.
20. Remove a natyazhitel of a multiridge maple belt. For this purpose unscrew bolts (1 and 2) a damper, and also a stopper (3), at removal and installation watch laying.

Prevention

The damper of a natyazhitel can be stored only in standing situation. If storage rules are casually broken, it can be made again suitable, having several times compressed it in vertical situation.


21. Unscrew bolts (1) and (2).

Installation

PERFORMANCE ORDER
1. Remove laying (1) head of cylinders. The thickness of laying is designated by openings. There is laying with 2 and 3 labels. Laying of former thickness should be established.
2. If works on the krivoshipno-shatunny mechanism were carried out, the thickness of laying should be defined anew (it is carried out from a workshop).
3. Clear a sealing surface of the block of cylinders a suitable shaber.
4. Watch, that dirt did not get to openings of the block of cylinders.
5. Close openings a rag.

Prevention

Openings of bolts of a head of cylinders should be free from oil and the remains of cooling liquid. Blow openings the compressed air or wrap up a screw-driver a rag and dry openings. Otherwise at a vvinchivaniye there is a pressure that can lead to cracking of the block of cylinders or the wrong moment of an inhaling.


6. Clear a sealing surface of a head of cylinders.
7. Check flatness of a surface of the block and a head of cylinders.

Prevention

Sealing surfaces cannot be processed.


8. Correctly insert directing plugs (1 and 2).
9. Insert a new sealing level (2) into a groove of a sealing surface of the block of cylinders (1 – connection).
10. On a junction to put OPEL 15 03 294 hermetic.
11. Impose new laying of a head of former thickness. The inscription of "TORAHS" should be turned up to a head of cylinders. Channels should not be closed by laying.
12. Before installation of a head of cylinders be convinced that the label (1) asterisk of TNVD is turned up.
13. Otherwise remove a verifying core on a flywheel and turn the crankshaft on 1 turn forward while the label will not be turned up and the verifying core can be inserted again.
14. If the cam-shaft acted in film, after installation of a shaft it is necessary to make a pause of 10 minutes before establishing a head. Otherwise hydropushers will not manage to sit down and there will be a danger of collision of pistons with valves.
15. Carefully establish a head on laying by means of the assistant. Thus the cam-shaft should be fixed in position VMT of the piston of the 1st cylinder.
16. Carry out a chain through a head.
17. Use new bolts of a head of cylinders.
18. Cover bolts with engine oil on a carving and surfaces of a prileganiye of their heads.
19. Tighten bolts by means of a dinamometrichesky key cross-wise from within outside with effort of 80 N of m.
20. On the second pass weaken bolts on a spiral from within outside on 180 ° (1/2 turns).
21. On the third pass tighten bolts cross-wise on a spiral from within outside with effort of 50 N of m.
22. On the fourth pass tighten bolts on 90 ° further (1/4 turns).
23. On the fifth pass tighten bolts for 90 °.
24. Precisely to maintain a corner 90 °, it is expedient to put the corresponding markings on a cover of a case of a cam-shaft.
25. For this purpose establish a key on a bolt and at distance 90 ° put a mark with chalk, if necessary cut out from a cardboard a template 90 °.
26. Such template is available and for HAZET 6690 firm.

Prevention

After assembly of the engine and 25 minutes of warming up bolts of a head of cylinders should be tightened on 90 °.


27. Screw in a pin of fastening of the top directing level of a driving chain.
28. Unscrew a fastening bolt from the block of cylinders.
29. Connect tips to glow plugs and both sensors of temperature of cooling liquid.
30. Connect the tip of the sensor of the beginning of injection on a nozzle of the 4th cylinder.
31. Establish a chain on an asterisk.
32. Tighten a hand a masloraspylitelny nozzle.
33. Wring out a natyazhitel of a chain the KM-822 lever, thus extend a pin of fastening (2) (1 – a bolt).
34. Check gazoraspredeleniye phases by means of the special adaptation (1). The crankshaft is in position VMT of the piston of the 1st cylinder. At the same time adjusting adaptation should adjoin from both parties to a sealing surface of a head of cylinders.

Prevention

It belongs only to new driving chains or having run to 20 000 km.


35. For the chains which have passed more than 20 000 km, as lengthening compensation on the admission party under the lock adaptation (1) it is necessary to enclose laying (flat щуп) (I) thickness of 4,61 mm. It corresponds to a corner 2 ° (II) on which will turn a cam-shaft.
36. In this situation screw an asterisk with a new masloraspylitelny nozzle (1 – the channel).
37. Holding a cam-shaft for a shestigrannik a wrench, tighten a bolt with effort of 20 N of m, then tighten on 35 ° a rigid key.
38. Precisely to maintain a corner 35 °, it is expedient to put the corresponding markings on a head of cylinders. For this purpose establish a key on a bolt and at distance 35 ° put a mark with chalk, if necessary to cut out from a cardboard a template. Such template is available and for HAZET 6690 firm.
39. Remove lock adaptations on cranked and distributive shaft and turn the crankshaft on 2 turns.
40. Again insert a verifying core into a flywheel (1 – a pin).
41. Now it should be inserted and the verifying adaptation of a cam-shaft, the same as to an asterisk inhaling.
42. If necessary repeat adjustment.
43. Insert the vacuum pump with new consolidation of round section and a new bolt (2), thus driving cams enter into a cam-shaft asterisk (1 – a bolt).
44. Grease consolidation before installation by vaseline or silicone greasing. Connect the vacuum pipeline.
45. Establish топливопроводы on the fuel filter.
46. Connect the top hose from a radiator to a head of cylinders, and also a hose of cooling liquid of a heater from a tube, fix collars.
47. Screw a natyazhitel of a multiridge maple belt.
48. Screw a damper on a head of cylinders with effort of 40 N of m, on the directing lever with effort of 20 N of m.
49. Screw a stopper on a finger and tighten with effort of 20 N of m.
50. Screw bolts.
51. Screw injection pipelines on TNVD and nozzles with effort of 25 N of m.
52. Establish a final collector, replace all laying.
53. Brackets of laying between a final collector and a head of cylinders are directed from a head. Screw a final collector on a turbonagnetatel (3 bolts) with effort of 45 N of m, on a head of cylinders with effort of 25 N of m, tighten bolts cross-wise from within outside.
54. Screw an inlet collector on a head of cylinders with effort of 25 N of m, replace all laying.
55. Screw on an inlet collector a support of the case of the oil filter and the pipeline of the valve of return of the fulfilled gases with effort of 25 N of m.
56. Insert a vacuum hose with an angular element on the amplifier of a brake.
57. Connect thin vacuum pipelines on the return valve of a vacuum hose.
58. Establish a cover of a head of cylinders with new laying (1) and screw from within outside with effort of 15 N of m. Observe the adjusting provision of laying on the back party of a head of cylinders.
59. Connect a hose of ventilation of a case, fix it a collar.
60. Screw the holder of the pipeline of cooling liquid on a cover of a head of cylinders.
61. Establish a hose of ventilation of a case on a cover of a head of cylinders, and also a hose of soaked-up air from the case of the air filter and a turbonagnetatel, fix collars.
62. Establish the top guard of the engine.
63. Screw a pipe of forced air on a head of cylinders, establish air hoses, fix collars.

CARS WITH THE CONDITIONER

Removal

PERFORMANCE ORDER
1. Remove the fan with the vyazkostny coupling and an air diffuzor on a radiator.
2. Disconnect the top hose of cooling liquid (1) from a radiator on a head of cylinders, and also a hose of cooling liquid of a heater from a tube (2) after weakening of shlangovy collars.
3. Remove both топливопровода (1 and 2) on the fuel filter. The submitting pipeline is a little thicker than the returnable.
4. Collect following fuel a thick rag.
5. Release pipelines from fastenings and slightly raise, turn on топливопроводы approximately on 130 ° counter-clockwise. Watch, that pipelines were not bent.
6. Unscrew the holder (1) pipeline of cooling liquid from a cover of a head of cylinders.
7. Disconnect a hose of ventilation of the engine from a cover of a head of cylinders, for this purpose weaken a hose collar.
8. Unscrew and uncover heads of cylinders.
9. Disconnect all cable tips.
10. Unscrew bolts (1 and 2) on the vacuum pump.
11. Disconnect the vacuum pipeline.

Prevention

The bolt (2) at the same time serves for fastening of the top directing level of a chain. It should be replaced always as for fixing has a micronotch.


12. Establish the piston of the 1st cylinder in situation VMT.
13. For this purpose establish a transmission in neutral situation and tighten the hand brake. Establish on the central bolt of a belt pulley the bent cap key or a face head with a treshchetka.
14. Slowly turn the crankshaft a hand clockwise while cams of the first cylinder will not be at the same time turned up.
15. In this situation the verifying core (1) (OPEL KM-813) through an opening in the block of cylinders can be inserted into an opening in a flywheel.
16. It is possible to use and other suitable core, for example, a drill.
17. Remove an available stopper and put a core.

Prevention

Insert a core only for check
provisions VMT, do not use it for crankshaft fixing.


18. Fix a cam-shaft the lock OPEL KM-811 (1) adaptation. The adaptation should adjoin both parties to a sealing surface of a cover of a head of cylinders. It holds a cam-shaft in position VMT of the piston of the 1st cylinder. If such adaptation is not present, make the similar adaptation independently.
19. Establish the KM-822 lever (1) between the top level of a natyazhitel and a finger of fastening and wring out a tension level in the arrow direction (2 – an installation site). The driving chain is thus weakened.
20. When weakening a driving chain by the lever (1) it is possible to insert a pin of fastening KM-823 into an opening of a natyazhitel (2 – an arrangement).
21. Previously unscrew a stopper in a pin installation site. Natyazhitel of a chain is fixed by a pin. Hold a cam-shaft for a shestigrannik a wrench.
22. Unscrew a masloraspylitelny nozzle (1) from a cam-shaft asterisk.
23. Remove an asterisk.
24. Unscrew bolts of the case of a drive of the distributive mechanism.
25. Unscrew a nut (1) fastening of a hairpin on the case of a drive of a cam-shaft.
26. Unscrew a bolt (1) fastening from the block of cylinders.
27. Disconnect tips from candles of an incandescence and from both sensors of temperature of cooling liquid on a head of cylinders.
28. Disconnect the tip of the sensor of the beginning of injection on a nozzle of the 4th cylinder (the 4th cylinder in front).
29. Unscrew a pin (1) fastening of the top directing level of a chain.
30. Weaken bolts of a head of cylinders in a certain sequence outside inside at first on a half of turn, then for a half of turn.
31. Remove a head of cylinders by means of the assistant.

Prevention

At removal watch, that the top directing level of a driving chain and a chain was not damaged did not remain to hang on a head of cylinders. Put a head on a wooden board not to damage a sealing surface.


Installation

PERFORMANCE ORDER
1. Establish the fan with the vyazkostny coupling and an air diffuzor on a radiator.
2. Check all tips and hoses, if necessary connect.
3. Fill in cooling liquid.
4. Establish multiridge maple a belt.
5. Check oil level in the engine, if necessary add. If the head of cylinders acted in film because of faulty laying of a head, replace oil and the oil filter as in engine oil there can be a cooling liquid.
6. Connect a weight cable to the battery. Establish time on hours, set a protective code of a radio receiver.

Prevention

Take out a verifying core and close an opening a stopper.


7. Establish the bottom guard of an impellent compartment.
8. Start the engine and warm up within 25 minutes.
9. Remove a head of cylinders.
10. Tighten bolts of a head of cylinders from within outside in a certain sequence a rigid key on 90 ° (1/4 turns), without weakening them previously.
11. Screw the holder of the pipeline of cooling liquid on a cover of a head of cylinders.
12. Establish a hose of ventilation of a case on a cover of a head of cylinders, and also a hose of soaked-up air from the case of the air filter and a turbonagnetatel, fix collars.
13. Screw the top guard of the engine.
14. Screw a tube of forced air on a head of cylinders, establish air hoses, fix collars.