Opel Astra, Zafira

Since 1998 of release

Repair and car operation



Opel Astra
+ Cars Opel Astra and Zafira
+ The operation manual
+ Routine maintenance
+ The engine
+ Systems of cooling, heating
- The power supply system and release
   - The power supply system
      Sbrasyvanie pressure in the power supply system of petrol engines
      Check of a condition and replacement of fuel lines and them штуцерных connections
      Removal of air from a fuel path of the diesel engine
      Removal of pollution from the power supply system of the diesel engine
      Removal and installation of components of an inlet air path
      Removal, installation and adjustment of a cable of gas - petrol models
      Removal and installation of a pedal of an accelerator
      Removal and installation of the fuel pump - petrol models
      Removal and installation of the gauge of a stock of fuel
      Removal and installation of a fuel tank
      Removal and installation of the case of a throttle - petrol models
   + System of injection of fuel of petrol engines
   + Systems of injection and turbo-supercharging of the diesel engine
   + Systems of release and decrease in toxicity of the fulfilled gases
+ Engine electric equipment
+ Manual transmission
+ Automatic transmission
+ Coupling and power shafts
+ Brake system
+ Suspension bracket and steering
+ Body
+ Onboard electric equipment



The power supply system

The general information and safety measures

Petrol models

The power supply system consists of the car of the fuel tank placed in it of an electric gasoline pump established in a back part, the fuel filter, injectors of injection, a regulator of pressure of fuel, assemblage of an air cleaner, the throttle case, and also laid under the bottom of the car and connecting a fuel tank with a fuel highway of lines of giving and fuel return. All models are equipped by electronic system of injection of the fuel, functioning under control of ECM (the System of injection of fuel of petrol engines see).

Accumulating in a tank and gasoline pipe lines during car parking fuel evaporations accumulate in the adsorber filled with activated coal, whence then are deduced in an inlet path and burnt process of normal functioning of the engine.

The information on the fuel expense is deduced on the panel of devices of the car.

Essential influence on the fuel expense renders style of driving. Some councils about reasonable use of a pedal of an accelerator on equipped with system of injection of fuel cars are more low resulted:

  1. In any weather (even in a frost) begin movement right after start realisation двигателяю
  2. At a car stop for a while more than 40 with, suppress двигателью
  3. Try to move always on as much as possible high передачею
  4. On distant trips try to support constant speed of movement. Avoid movement on excessively high speeds. Operate the car circumspectly, avoid causeless торможенийю
  5. Transport the car excessive cargo, in the absence of need remove from a roof top багажникю
  6. Regularly check pressure of a rating of tyres, — try not to suppose its excessive decrease.

Diesel models

The fuel system consists of the car of the fuel tank equipped built in влагоотделителем warmed up fuel filter established in a back part, the fuel pump of a high pressure (ТНВД), atomizers and connecting system components топливопроводных lines.

ТНВД takes away fuel from a tank and banishes it through the fuel filter where there is a catching of extraneous particles and a moisture. The surplus of fuel not spent by the engine is used for greasing of internal components of the pump then comes back back in a fuel tank.

Drive ТНВД is carried out from a cranked shaft by means of belt (engines 1.7) or chain (engines 2.0) transfers. Working turns of the pump make exactly half from turns of a cranked shaft. The high pressure necessary for opening of atomizers and fuel injection in forkamery/it is direct in cylinders, it is provided at the expense of application radial плунжерного the pump.

ТНВД has electronic control thanks to what the engine completely meets constantly toughened international requirements on decrease in toxicity of an exhaust. Control system basic elements are the electronic module of engine management (ECM), the block of management ТНВД built in pump assemblage and the complete set of information gauges (Systems of injection and a turbo-supercharging of the diesel engine see).

Four fuel atomizers inject the sprayed fuel in форкамеры cylinders (engines of 1.7 l SOHC), or is direct in combustion chambers (engines of 1.7 l DOHC and 2.0). Optimisation of process of combustion of a mix is provided at the expense of thin calibration of atomizers. Needles of atomizers are greased with the fuel accumulated in spring chambers, not demanded surplus of fuel on separate lines comes back in ТНВД.

On models 2.0 of l the inlet pipeline is equipped by the petal valve providing increase of efficiency of return of the engine on small turns. In the pipeline it is organised on two inlet channels on each of cylinders. One of channels is equipped operated on commands ECM by means of an electromagnet and a vacuum diaphragm with the petal valve. At engine turns more low 1500 in a minute the valve remains closed and air in the cylinder moves only on one of channels. Increase of turns leads to opening of valves and, according to increase in weight of combustion of air submitted to chambers.

On engines of 1.7 l DOHC the inlet pipeline consists from two divided metal partition of sections. In the top section of the pipeline valve EGR and the gauge of pressure of pressurisation are established.

For the purpose of increase of efficiency of return the engine is equipped высоконапорным (engine Y20DTH) or низконапорным (other engines) турбокомпрессором, providing redundancy of pressure in the inlet pipeline concerning atmospheric that allows to increase the mass expense of air submitted to cylinders, — fuel giving also proportionally increases. Established between a final collector and a reception pipe of system of release of the fulfilled gases, working from pressure of the fulfilled gases турбокомпрессор makes a fence of air from an air cleaner, at a corresponding complete set (except engines Y20DTL) banishes it through mounted at the left on a radiator of system of cooling the heat exchanger of an intermediate cooler (интеркулера) and under a pressure submits to the inlet pipeline. A problem интеркулера is cooling heated up at сжимании in a supercharger of air submitted to the engine. As cooled air has the big density, decrease in its temperature allows to lift efficiency of return of the engine even more.

Excessive increase of pressure in the inlet pipeline is prevented at the expense of application of the special safety valve providing tap of fulfilled gases from турбокомпрессора by means of pressure sensitive to change of an actuation mechanism. Valve operation occurs at the command of ECM. Sensitive to change of pressure the gauge-switch provides operation of the control lamp built in in an instrument guard warning the driver about excess of admissible pressure of pressurisation.

Greasing турбокомпрессора is made arriving on a special tube from the block of cylinders by impellent oil, — the turbine shaft "floats" in oil literally, — from a supercharger oil of a returnable line arrives back in the pallet картера. Турбокомпрессор it is equipped by the built in safety valve and the vacuum diaphragm, providing adjustment of pressure of pressurisation in the inlet pipeline. Internal components турбокомпрессора rotate with high speed and are very sensitive to quality of oil. Hit on rotating shovels of the turbine of extraneous particles can have the most serious consequences. In view of the compressor told before removal it is necessary to clear carefully its external surfaces, and also surfaces of the knots located in the neighbourhood. Removed components put in densely closed container. All apertures in the compressor at once stick with an adhesive tape, for rubbing of details use only неворсящуюся rags.

At all do not start турбированный the engine at the removed inlet air line, — depth of depression on a compressor input can increase in steps that increases risk всасывания in the turbine of extraneous subjects and their subsequent ejection with a great speed!

It is necessary to notice that on diesel models there is no accelerator cable, — instead of it on a pedal the gauge of its position is established.

It is provided also special запорный the valve отсечки fuel at ignition deenergizing.

The fuel system of diesel engines is extremely reliable. Under condition of use of pure fuel and a regularity of performance of procedures of service it should function regularly before the termination of service life of the car. At high run internal components ТНВД and atomizers can wear out, and demand carrying out of regenerative repair, — in view of complexity of a design of components it is necessary to charge repair performance to experts of car-care centre.

Security measures and rules of observance of cleanliness at work with fuel system

The general rules

Do not come nearer to a place of work with open fire or the lighted cigarette. Always keep in readiness the fire extinguisher.

Fuel steams are poisonous, — watch maintenance of normal ventilation of a workplace.

The fuel system is under pressure. At opening of system fuel can be pulled out from it under pressure, — before отпусканием штуцерных sockets turn their rags. Use goggles.

At work with components of the power supply system of the diesel engine observe special safety measures. In a special measure the given statement concerns procedures of service of atomizers. Remember that pressure of fuel upon an exit makes of atomizers about 1100 atmospheres, — do not substitute under a stream of a hand and other parts of a body.

Collars of tape and tightening type are applied to fastening шланговых connections. After a detachment of hoses it is necessary to replace tightening collars tape or worm. Fixing of locks of some collars demands application of special adaptations, — consult with experts firm HUNDRED Opel.

Before undocking штуцерных sockets carefully wipe them outside in order to avoid hit of a dirt in a path.

Removed components stack on a pure lining and turn in polyethylene or a paper, — avoid application for rubbing and оборачивания components ворсящейся rags.

If repair demands time, track, that all open apertures in knots and power supply system components have been carefully muffled.

Establish into place only pure details. Spare parts take out from packing only directly ahead of installation. Do not apply details which were stored unpacked (for example, in a tool box).

Avoid application of compressed air at an open fuel path. Whenever possible try not to move the car.

Do not apply some hermetics containing silicone. The particles which have got to the engine of silicone do not burn down and ljambda-probe damage can be at the bottom.

Security measures at removal of a fuel tank

Before tank removal merge from it fuel or pump out its pump specially provided for this purpose.

The fuel tank acts in film from the bottom party of the car. Before отпусканием assembly tapes, prop up a tank from below тележечным a jack, — lay between a tank and a jack head wooden брусок.

The empty tank is explosive and before recycling should be cut on a part, — try not to admit at tank cutting искрообразования. Will hand over most correctly a tank in special place of acceptance.

After tank installation start the engine and check up tightness of all connections.