Opel Omega

since 1993-1999 release

Repair and operation of the car



Opel Omega
+ 1. Maintenance instruction
+ 2. Maintenance
- 3. Repair of engines
   + 3.1. SOHC engines of 2,0 liters
   + 3.2. DOHC engines of 2,0 liters
   + 3.3. 2,5 and 3,0 liters engines
   + 3.4. Partition of all petrol engines
   + 3.5. 2,0 liters diesel engine
   - 3.6. 2,5 liters diesel six-cylinder engine
      3.6.1. Removal and installation of the engine
      3.6.2. Head of cylinders
      3.6.3. Cam-shaft
      3.6.4. Check of a compression
      3.6.5. Multiridge maple belt
      3.6.6. Pallet of a case and laying
      + 3.6.7. Cooling system of the diesel engine 2,5 liters
+ 4. Heating system and ventilation
+ 5. Fuel, exhaust systems
+ 6. System of start of the engine
+ 7. System of ignition
+ 8. Coupling
+ 9. Transmissions
+ 10. Main transfer, half shafts
+ 11. Brake system
+ 12. Suspension bracket and steering
+ 13. Body
+ 14. Body electric equipment
785173a6



3.6.2. Head of cylinders

GENERAL INFORMATION

Arrangement of elements of a final collector

1. Final collector

2. Turbocharger

3. A bar of the adjusting valve of the forced air

4. Connection of the 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 the 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 CONDITIONER

Removal

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

Prevention

At the same time data from electronic memory, for example, a protective code of the radio receiver are erased.


2. Remove the lower guard of a motive 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 backpressure 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 the soaked-up air from the case of the air filter and a turbocharger, for this purpose weaken and shift collars back.
10. Unscrew a final collector on a head of the block of cylinders. At the same time at first evenly weaken bolts outside inside at first half way, then completely weaken. Unscrew a final collector (3 bolts) on a turbocharger.

Prevention

Cover turbocharger openings with a pure rag and you watch that no foreign objects 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 the forced air, disconnect a vacuum hose on the valve of return of the fulfilled gases and on the lower party of an inlet collector.
14. Weaken a tube of the forced air and disconnect it.
15. Unscrew an inlet collector on a head of cylinders and on the holder and remove with laying.
16. The valve of return of the fulfilled gases with laying does not need to be unscrewed.
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. Take off multiridge maple a belt.
20. Remove a natyazhitel of a multiridge maple belt. For this purpose unscrew bolts (1 and 2) of a damper, and also a stopper (3), at removal and installation you monitor laying.

Prevention

The damper of a natyazhitel can be stored only upright. If rules of storage are incidentally violated, it can be made suitable again, having several times squeezed it in vertical position.


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

Installation

PERFORMANCE ORDER
1. Remove laying (1) of a head of cylinders. Thickness of laying is designated by openings. There is laying with 2 and 3 tags. Laying of former thickness has to be established.
2. If works on the krivoshipno-conrod mechanism were carried out, thickness of laying has to be determined anew (it is carried out from a workshop).
3. Clear the sealing surface of the block of cylinders a suitable shaber.
4. You 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 have to be free from oil and the remains of cooling liquid. Blow openings compressed air or wrap up the screw-driver a rag and dry openings. Otherwise at a vvinchivaniye there is 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 the 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. To apply OPEL 15 03 294 sealant on a junction.
11. Impose new laying of a head of former thickness. Inscription "TORAHS" has to be turned to a head of cylinders up. Channels should not be closed by laying.
12. Before installation of a head of cylinders be convinced that the tag (1) of an asterisk of TNVD is turned up.
13. Otherwise remove a test core on a flywheel and turn the crankshaft on 1 turn forward until the tag is turned up and a test core it is possible to insert again.
14. If the cam-shaft was removed, 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. At the same time the cam-shaft has to be recorded in the provision of 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 dynamometer key cross-wise from within outside with 80 N.' effort 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 50 N.' effort 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 apply the corresponding markings on a cam-shaft case cover.
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 also for HAZET 6690.

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 plugs to glow plugs and both sensors of temperature of cooling liquid.
30. Connect the plug 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, at the same time extend a pin of fastening (2) (1 – a bolt).
34. Check gas distribution phases by means of special adaptation (1). The crankshaft is in the provision of VMT of the piston of the 1st cylinder. At the same time adjusting adaptation has to adjoin to a sealing surface of a head of cylinders on both sides.

Prevention

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


35. For the chains which passed more than 20 000 km as compensation of lengthening on the party of an admission under lock adaptation (1) it is necessary to enclose laying (the flat probe) (I) 4,61 mm thick. 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 hexagon a wrench, tighten a bolt with 20 N.' effort 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 a template from a cardboard. Such template is available also for HAZET 6690.
39. Remove lock devices on cranked and distributive shaft and turn the crankshaft on 2 turns.
40. Again insert a test core into a flywheel (1 – a pin).
41. Now also the test device of a cam-shaft, the same as to an asterisk inhaling has to be inserted.
42. If necessary repeat adjustment.
43. Insert the vacuum pump with new consolidation of round section and a new bolt (2), at the same time driving cams enter a cam-shaft asterisk (1 – a bolt).
44. Grease consolidation before installation by vaseline or silicone lubricant. Connect the vacuum pipeline.
45. Install fuel-supply lines 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 by collars.
47. Screw a natyazhitel of a multiridge maple belt.
48. Screw a damper on a head of cylinders with 40 N.' effort of m, on the directing lever with 20 N.' effort of m.
49. Screw a stopper on a finger and tighten with effort 20 N. of m.
50. Screw bolts.
51. Screw injection pipelines on TNVD and nozzles with 25 N.' effort 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 turbocharger (3 bolts) with 45 N.' effort of m, on a head of cylinders with 25 N.' effort of m, tighten bolts cross-wise from within outside.
54. Screw an inlet collector on a head of cylinders with 25 N.' effort of m, replace all laying.
55. Screw on an inlet collector a support of the case of an oil filter and the pipeline of the valve of return of the fulfilled gases with 25 N.' effort of m.
56. Insert a vacuum hose with an angular element on the amplifier of a brake.
57. Connect thin vacuum pipelines on the backpressure 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 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 by 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 the soaked-up air from the case of the air filter and a turbocharger, fix collars.
62. Establish the top guard of the engine.
63. Screw a pipe of the forced air on a head of cylinders, establish air hoses, fix by collars.

CARS WITH THE CONDITIONER

Removal

PERFORMANCE ORDER
1. Remove the fan with the viscous coupling and the air diffuser 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 hose collars.
3. Remove both fuel-supply lines (1 and 2) on the fuel filter. The giving pipeline is a little thicker than returnable.
4. Collect the following fuel by a thick rag.
5. Exempt pipelines from fastenings and slightly raise, turn off fuel-supply lines approximately on 130 ° counterclockwise. You watch that pipelines were not bent.
6. Unscrew the holder (1) of the 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 a head of cylinders.
9. Switch-off all cable plugs.
10. Unscrew bolts (1 and 2) on the vacuum pump.
11. Switch-off the vacuum pipeline.

Prevention

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


12. Install the piston of the 1st cylinder in the provision of VMT.
13. For this purpose install the transmission in neutral situation and tighten the emergency brake. Establish on the central bolt of a belt pulley a curved cap key or a face head with a treshchetka.
14. Slowly turn the crankshaft a hand clockwise until cams of the first cylinder are at the same time turned up.
15. In this situation the test 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 also other suitable core, for example, a drill.
17. Remove the available stopper and put a core.

Prevention

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


18. Record a cam-shaft lock OPEL KM-811 (1) adaptation. Adaptation has to adjoin both parties to a sealing surface of a cover of a head of cylinders. It holds a cam-shaft in the provision of VMT of the piston of the 1st cylinder. If there is no such adaptation, manufacture similar adaptation independently.
19. Install the KM-822 (1) lever between the top level of a natyazhitel and a finger of fastening and wring out a tension level in the direction of an arrow (2 – an installation site). At the same time the driving chain is weakened.
20. When weakening a driving chain the lever (1) it is possible to insert a pin of fastening of 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 hexagon a wrench.
22. Unscrew a masloraspylitelny nozzle (1) from a cam-shaft asterisk.
23. Remove an asterisk.
24. Unscrew bolts of the case of the drive of the distributive mechanism.
25. Unscrew a nut (1) of fastening of a hairpin on the cam-shaft drive case.
26. Unscrew a bolt (1) of fastening from the block of cylinders.
27. Disconnect plugs from candles of an incandescence and from both sensors of temperature of cooling liquid on a head of cylinders.
28. Switch-off the plug 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) of fastening of the top directing chain level.
30. Weaken bolts of a head of cylinders in a certain sequence outside inside at first half way, then for a half-turn.
31. Remove a head of cylinders by means of the assistant.

Prevention

At removal you watch that the top directing level of a driving chain was not damaged and the chain 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. Install the fan with the viscous coupling and the air diffuser on a radiator.
2. Check all plugs 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 was removed because of faulty laying of a head, replace oil and an oil filter as in engine oil there can be a cooling liquid.
6. Connect a weight cable to the battery. Determine time on hours, set a protective code of the radio receiver.

Prevention

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


7. Establish the lower guard of a motive 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 the soaked-up air from the case of the air filter and a turbocharger, fix by collars.
13. Screw the top guard of the engine.
14. Screw a tube of the forced air on a head of cylinders, establish air hoses, fix by collars.