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
   - System of injection of fuel of petrol engines
      Principle of functioning of systems of injection of fuel
      Check of serviceability of functioning of system of injection of fuel
      Removal and installation of components of system of the central injection of fuel Multec
      Removal and installation of components of systems of the distributed injection of fuel Multec-S and Simtec-70
      The monitoring system of temperature of soaked up air (model with the central injection) - a principle of functioning and check of serviceability of functioning
      Removal and installation of the inlet pipeline
      Removal and installation of a final collector
   + 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



Removal and installation of components of systems of the distributed injection of fuel Multec-S and Simtec-70

The prevention in the beginning of section Sbrasyvanie pressure in the power supply system of petrol engines seeSbrasyvanie pressure in the power supply system of petrol engines.

System of injection Multec-S

Before definitively to affirm as opinion on an exit of injectors out of operation, try to add in fuel any of the automobile engines of additives approved by manufacturers. Make sure also that the fuel tank is not polluted.


 PERFORMANCE ORDER

  1. Dump pressure in the power supply system (Sbrasyvanie of pressure in the power supply system of petrol engines see), then disconnect a negative wire from the battery.
  2. Uncover маслозаливной mouths, turn out fixing screws and remove a protective casing of the engine.
  3. Disconnect electroconducting from the gauge of temperature of soaked up air (IAT), disconnect an inlet air line from an air cleaner and the throttle case. On models Zafira remove a sealing strip of an impellent compartment and a cover обтекателя, the windscreen established under a bottom edge. For the purpose of providing of access to an inlet air line give fixing nuts/bolts and remove the top cover of the panel передка.
  4. Disconnect ventilation hoses картера from a cover газораспределительного the mechanism.
  5. Disconnect all electroconducting laid in a plastic routeing trench, going along a fuel highway, - try to remember an order of packing of plaits. Following components are subject to a detachment:
  • The valve of a purge of a coal adsorber;
  • The gauge of position of a cranked shaft (CKP);
  • The gauge of emergency pressure of oil;
  • The step-by-step electromotor of system of stabilisation of turns of idling;
  • The gauge of temperature of a cooling liquid (ECT);
  • The gauge of position throttle заслонки (TPS);
  • The gauge of position of a camshaft (CMP);
  • The gauge of absolute pressure in the inlet pipeline (MAP);
  • Valve EGR;
  • The ignition module;
  • Ljambda-probe;
  • The top socket ECM;
  • The detonation gauge (KS);
  • Interference suppressor on the ignition module;
  • Two tyres of grounding of the pipeline;
  • Grey socket of the assembly block of the relay in a forward part of an impellent compartment.
  1. Disconnect a vacuum hose of a regulator of pressure of fuel in the left part of a fuel highway.
  2. Disconnect from a fuel highway топливопроводы, - pay attention to a difference in sizes штуцерных of connections.
  1. Turn out two fixing bolts and remove a fuel highway together with injectors and a plastic trench of electroconducting.
  1. In case of need injectors can be removed from a fuel highway, - release corresponding clamps. Sealing rings of injectors at installation of the last are subject to replacement without fail.
  2. Installation is made upside-down. Pay attention to following moments:
    1. Before installation grease new sealing rings with a small amount of impellent oil.
    2. At refuelling of injectors in a highway try not to admit displacement of sealing rings. Track reliability of fixing of injectors.
    3. At installation of a fuel highway try not to damage an atomizer. All fixture tighten with demanded effort.
    4. In end start the engine and check up a highway on presence of signs of development of leaks.

Regulator of pressure of fuel

 PERFORMANCE ORDER

  1. Uncover маслозаливной mouths, turn out fixing screws and remove a protective casing of the engine. Dump pressure in system (Sbrasyvanie of pressure in the power supply system of petrol engines see) and disconnect a negative wire from the battery.
  2. Disconnect from a regulator a vacuum hose.
  1. Turn out the fixing screw and remove an assembly collar of a regulator.
  1. Accurately liberate a regulator from a fuel highway together with sealing elements.
  2. Installation is made upside-down. Do not forget to replace sealing elements. In summary start the engine and check up a highway on presence of signs of development of leaks.

The step-by-step electromotor of system of stabilisation of turns of idling

 PERFORMANCE ORDER

  1. Uncover маслозаливной mouths, turn out fixing screws and remove a protective casing of the engine.
  2. Disconnect electroconducting from the gauge of temperature of soaked up air (IAT), disconnect an inlet air line from an air cleaner and the throttle case. On models Zafira remove a sealing strip of an impellent compartment and a cover обтекателя, the windscreen established under a bottom edge. For the purpose of providing of access to an inlet air line give fixing nuts / bolts and remove the top cover of the panel передка.
  3. Disconnect electroconducting from the step-by-step electric motor.
  1. Turn out two fixing screws and remove the electromotor from the throttle case.
  1. Installation is made upside-down. For check of serviceability of functioning of system of stabilisation of turns of idling measure size выступания плунжера () from the electric motor, - the result of measurement should make no more than 33 mm, - in case of need correct position плунжера. A carving part of fixing screws before installation grease анаэробным with hermetic.

The gauge of position throttle заслонки (TPS)

 PERFORMANCE ORDER

  1. Uncover маслозаливной mouths, turn out fixing screws and remove a protective casing of the engine.
  2. Disconnect electroconducting from the gauge of temperature of soaked up air (IAT), disconnect an inlet air line from an air cleaner and the throttle case. On models Zafira remove a sealing strip of an impellent compartment and a cover обтекателя, the windscreen established under a bottom edge. For the purpose of providing of access to an inlet air line give fixing nuts / bolts and remove the top cover of the panel передка.
  3. Make sure that ignition is switched off, then disconnect electroconducting from the throttle of gauge TPS established on the case.
  1. Turn out fixing bolts and remove the gauge.
  1. Installation is made upside-down. Track correctness of input of a potentiometer in gearing with an axis throttle заслонки. Before вворачиванием fixing bolts grease their carving part анаэробным with hermetic. Having tightened bolts with demanded effort, connect to the gauge electroconducting.
  1. Check up serviceability of functioning заслонки, then connect electroconducting and establish to the place of an inlet air line.

The gauge of temperature of a cooling liquid (ECT)

The gauge of temperature of a cooling liquid will screw in the thermostat case. The description of procedures of removal and gauge installation – see Check of serviceability of functioning, removal and installation of electric components of a chain of management of system of cooling of the engine.

The gauge of temperature of soaked up air (IAT)

The gauge is established in the inlet air line connecting the case of an air cleaner with the inlet pipeline.

 PERFORMANCE ORDER

  1. Make sure that ignition is switched off and disconnect from the gauge electroconducting.
  2. Operating extremely cautiously, accurately take the gauge block, - try not to damage an air line. Remove a sealing element of the gauge subject to obligatory replacement.
  3. Installation is made upside-down. Track, that the gauge flange was combined in the correct image with an aperture in an inlet air line.

The gauge of absolute pressure in the pipeline (MAP)

Gauge MAP is fixed on a partition of an impellent compartment, to the left of the inlet pipeline.

 PERFORMANCE ORDER

  1. Switch off ignition, disconnect from the gauge electroconducting and a vacuum hose. The gauge can be removed now from an arm.
  2. Installation is made upside-down.

The gauge of position of a cranked shaft (CKP)

 PERFORMANCE ORDER

  1. The gauge is established on the right in a back part of the block of cylinders and access to it is possible from under the car. Cock a lay brake, поддомкратьте redock of the car and establish it on props. At a corresponding complete set remove protection картера.
  2. Walk on electroconducting from the gauge, liberating a plait from intermediate clamps and remembering a route of its lining. Disunite a contact socket, - the gauge acts in film together with a plait part.
  1. Turn out a fixing bolt and remove the gauge.
  1. Installation is made upside-down. Track, that the fixture has been tightened with demanded effort. Make sure of correctness of a lining and reliability of fixing of a plait.
  2. In end measure distance between the gauge and teeths of a rotor of the gauge on a pulley of a cranked shaft, - if the result exceeds 1.0  0.7 mm, replace a basic arm of fastening of the gauge.

The gauge of position of a camshaft (CMP)

 PERFORMANCE ORDER

  1. Remove the top cover of drive ГРМ (the Engine see the Head).
  2. Walk on electroconducting from the gauge, liberating a plait from intermediate clamps and remembering a route of its lining. Disunite a contact socket.
  3. Turn out fixing bolts and remove the gauge in gathering with electroconducting from a head of cylinders.
  4. Installation is made upside-down. Before вворачиванием grease a carving part of fixing bolts анаэробным with hermetic. Tighten bolts with demanded effort. Track correctness of packing and reliability of fixing of electroconducting.

The detonation gauge (KS)

The detonation gauge is established on a back wall of the block of cylinders.

 PERFORMANCE ORDER

  1. For the purpose of providing of access cock a lay brake, поддомкратьте the car and establish it on props. The gauge can be removed from below the car.
  2. Make sure of that ignition is switched off, then walk on electroconducting from the gauge, liberating a plait from intermediate clamps and remembering a route of its lining. Disunite a contact socket.
  3. Turn out a fixing bolt and remove the gauge.
  4. Installation is made upside-down. Before installation make sure of absoluteness of cleanliness and dryness of interfaced surfaces. Tighten fixture with demanded effort. Track correctness of a lining of electroconducting.

The electronic module of engine management (ECM)

 PERFORMANCE ORDER

  1. Disconnect a negative wire from the battery and open a cover of the assembly block of the relay located in an impellent compartment.
  2. Turn out two fixing screws, uncover маслозаливной mouths and a protective casing of the engine.
  3. Release clamps and disconnect from ECM electroconducting. Turn out three fixing bolts and remove the module.
  4. Installation is made upside-down. Track correctness of connection of electroconducting.

At block replacement make its adaptable coding to the engine of your car in the conditions of car-care centre Opel workshop.

The relay of system of injection

The relay of system of injection is in the assembly block located in an impellent compartment.

 PERFORMANCE ORDER

  1. Remove from the assembly block a cover. The system relay is painted in purple colour. Make sure that ignition is switched off, then liberate the relay from колодки.

  1. Installation is made upside-down.

The central air gauge-switch

The gauge-switch of system of the conditioner will screw in one of lines of a refrigerator path and cannot be removed without a preliminary discharge of system (see the Head of System of cooling, heating). In view of the gauge-switch told replacement it is necessary to make in the conditions of a car-care centre workshop.

System of injection Simtec-70

Fuel highway with injection injectors

Before definitively to affirm as opinion on an exit of injectors out of operation, try to add in fuel any of the automobile engines of additives approved by manufacturers. Make sure also that the fuel tank is not polluted.


 PERFORMANCE ORDER

  1. Dump pressure in the power supply system (Sbrasyvanie of pressure in the power supply system of petrol engines see), then disconnect a negative wire from the battery.
  2. Uncover маслозаливной mouths, turn out fixing screws and remove a protective casing of the engine.
  3. Disconnect electroconducting from the gauge of measurement of weight of air (MAF), disconnect an inlet air line from an air cleaner and the throttle case. On models Zafira remove a sealing strip of an impellent compartment and a cover обтекателя, the windscreen established under a bottom edge. For the purpose of providing of access to an inlet air line give fixing nuts / bolts and remove the top cover of the panel передка.
  4. Disconnect ventilation hoses картера from a cover газораспределительного the mechanism and the throttle case.
  5. Disconnect all electroconducting laid in a plastic routeing trench, going along a fuel highway, - try to remember an order of packing of plaits. Liberate a plait from a trench.
  1. Turn out fixing bolts and disconnect tyres of grounding from a trench of electroconducting to the right of the inlet pipeline and ECM to the left of the pipeline.
  1. Turn out a bolt of fastening of a trench.
  1. Disconnect from a fuel highway топливопроводы, - pay attention to a difference in sizes штуцерных of connections.
  1. Turn out two fixing bolts and remove a fuel highway together with injectors and a plastic trench of electroconducting. Remove and will throw out the bottom sealing rings - at assemblage they is subject to replacement without fail.
  1. Release clamps and accurately remove a trench of electroconducting from injectors, - contact sockets are built in a trench and to replacement in an individual order are not subject.
  1. Release corresponding clamps and remove from a fuel highway injectors. Remove the top sealing rings, at ring installation is subject to replacement without fail.
  1. Installation is made upside-down. Pay attention to following moments:

    1. Before installation grease new sealing rings with a small amount of impellent oil.
    2. At refuelling of injectors in a highway try not to admit displacement of sealing rings. Track reliability of fixing of injectors.
    3. At installation of a fuel highway try not to damage an atomizer. All fixture tighten with demanded effort.
    1. At trench installation track correctness of connection of contact sockets of injectors.
    1. In end start the engine and check up a highway on presence of signs of development of leaks.

Regulator of pressure of fuel

 PERFORMANCE ORDER

  1. On models 1.8 of l adjustment of pressure of fuel is carried out by the module of the gasoline pump placed in a fuel tank, - the regulator is established under a pump cover, in an individual order on the markets of spare parts is not delivered and in default all pump assemblage (the description of procedures of removal and installation of pump assemblage – see Removal and installation of the fuel pump - petrol models) is subject to replacement. Disconnect from a regulator fuel lines, disconnect electroconducting disconnect got under a cover of the pump electroconducting. On engines of 2.0 l remove a protective casing of the engine. Dump pressure in the power supply system (Sbrasyvanie of pressure in the power supply system of petrol engines see) and disconnect a negative wire from the battery.
  1. Disconnect from a regulator a vacuum hose (1).
  2. Turn out the fixing screw and remove an assembly collar (2) regulators.
  1. Accurately liberate a regulator from a fuel highway together with sealing elements.
  2. Installation is made upside-down. Do not forget to replace sealing elements. In summary start the engine and check up a highway on presence of signs of development of leaks.

Regulator throttle заслонки - l models 1.8

On models 1.8 of l engine turns are supervised ECM by means of a regulator throttle заслонки. The gauge positions (potentiometer) throttle заслонки (TPS) is built in a regulator which is an integral part of the case of a throttle. In case of infringement of serviceability of functioning of any of elements, the throttle case is subject to replacement in gathering (Removal and installation of the case of a throttle - petrol models see).

The step-by-step electromotor of system of stabilisation of turns of idling - l models 2.0

 PERFORMANCE ORDER

  1. Disconnect electroconducting from the gauge of measurement of weight of air (MAF). Release a collar and disconnect a ventilation hose картера from a back part of a cover газораспределительного the mechanism, then disconnect an inlet air line. On models Zafira remove a sealing strip of an impellent compartment and a cover обтекателя, the windscreen established under a bottom edge. For the purpose of providing of access to an inlet air line give fixing nuts / bolts and remove the top cover of the panel передка.
  2. Disconnect electroconducting from the step-by-step electric motor.
  1. Turn out two fixing screws and remove the electromotor from the throttle case, - the sealing lining is subject to replacement without fail.

    A — the Detachment of a contact socket of electroconducting of the step-by-step electromotor
    B — Screws of fastening of the step-by-step electromotor

A.

B.
  1. Installation is made upside-down. Do not forget to replace a lining. All fixture tighten with demanded effort.

The gauge positions (potentiometer) throttle заслонки (TPS)

 PERFORMANCE ORDER

  1. On engines of 1.8 l the gauge is built in a regulator throttle заслонки. On engines of 2.0 l remove the throttle case (Removal and installation of the case of a throttle - petrol models see).
  2. Turn out fixing bolts and remove the gauge from the throttle case.
  3. Installation is made upside-down. Track correctness of input of a potentiometer in gearing with an axis throttle заслонки.

The gauge of temperature of a cooling liquid (ECT)

The gauge of temperature of a cooling liquid will screw in a back part of the inlet pipeline. The description of procedures of removal and gauge installation – see Check of serviceability of functioning, removal and installation of electric components of a chain of management of system of cooling of the engine.

The gauge of temperature of soaked up air (IAT)

Gauge IAT functions the measurement gauge теля carries out weights of air (MAF), - see more low.

The measurement gauge теля weights of air (MAF)

 PERFORMANCE ORDER

  1. Switch off ignition and disconnect from the gauge electroconducting.
  1. Release fixing collars, disconnect inlet air lines and remove the gauge from the engine. On models Zafira remove a sealing strip of an impellent compartment and a cover обтекателя, the windscreen established under a bottom edge. For the purpose of providing of access to an inlet air line give fixing nuts / bolts and remove the top cover of the panel передка.
  2. Installation is made upside-down. Track correctness of connection of air lines.

The gauge of position of a cranked shaft (CKP) - l models 1.8

 PERFORMANCE ORDER

  1. The gauge is established on an arm on the right in a back part of the block of cylinders, access to it is possible from under the car. For the purpose of providing of access, cock a lay brake, поддомкратьте redock of the car and establish it on props and remove protection картера.
  2. Walk from the gauge on an electroconducting plait, liberating it from intermediate clamps. Disunite a contact socket, - the gauge acts in film together with the piece of conducting built in in it.
  1. Turn out a fixing bolt and remove the gauge from the block of cylinders.

  1. Installation is made upside-down. Tighten a bolt of fastening of the gauge with demanded effort. Track correctness of packing and reliability of fixing of electroconducting.

The gauge of position of a cranked shaft (CKP) - l models 2.0

 PERFORMANCE ORDER

  1. Remove an air cleaner (Removal and installation of components of an inlet air path see).
  2. On equipped К/В models turn out a fixing bolt and remove directing tube щупа measurements of level of oil from a forward part of the block of cylinders.
  3. Walk from the gauge on an electroconducting plait, liberating it from intermediate clamps. Disunite a contact socket, - the gauge acts in film together with the piece of conducting built in in it.
  4. Turn out a fixing bolt and remove the gauge from the block of cylinders, - the sealing ring is subject to replacement without fail.
  5. Installation is made upside-down. Do not forget to replace a sealing ring, tighten a bolt of fastening of the gauge with demanded effort. Track correctness of packing and reliability of fixing of electroconducting.

The gauge of position of a camshaft (CMP)

 PERFORMANCE ORDER

  1. On engines of 1.8 l uncover маслозаливной mouths, turn out fixing screws and remove a protective casing of the engine. On engines of 2.0 l turn out fixing screws and uncover spark plugs the top part of a head of cylinders.
  2. Switch off ignition and disconnect from the gauge electroconducting.
  3. Remove the top cover of drive ГРМ (the Engine see the Head).
  1. Turn out fixing bolts and remove the gauge from a head of cylinders.
  1. Installation is made upside-down. Before вворачиванием grease a carving part of fixing bolts анаэробным with hermetic. Tighten bolts with demanded effort.

The detonation gauge (KS)

 PERFORMANCE ORDER

  1. The detonation gauge is established on a back wall of the block of cylinders. For the purpose of providing of access cock a lay brake, поддомкратьте the car and establish it on props. The gauge can be removed from below the car.
  2. On engines of 2.0 l remove a starter (the engine Electric equipment see the Head).
  3. Make sure that ignition is switched off, then walk on electroconducting from the gauge, liberating a plait from intermediate clamps and remembering a route of its lining. Disunite a contact socket.
  1. Turn out a fixing bolt and remove the gauge.
  1. Installation is made upside-down. Before installation make sure of absoluteness of cleanliness and dryness of interfaced surfaces. Tighten fixture with demanded effort. Track correctness of a lining of electroconducting. On engines of 2.0 l establish into place a starter (the engine Electric equipment see the Head).

The electronic module of engine management (ECM)


Fastening ECM on l models 2.0

1 — the grounding Tyre
2 — the management Module (ECM)

3 — the Contact socket of electroconducting
4 — the Contact socket of electroconducting


 PERFORMANCE ORDER

  1. Disconnect a negative wire from the battery. Open a cover of the assembly block of the relay located in an impellent compartment.
  2. On engines of 1.8 l ECM приболчен to a left-hand side of the inlet pipeline. On engines of 2.0 l the module fastens behind the storage battery.
  3. Release clamps and disconnect from ECM electroconducting. Disconnect the tyre of grounding from a module frame. On engines of 1.8 l, without disuniting, liberate a contact socket of electroconducting from a basic arm on frame ECM.
  1. Turn out three fixing bolts and remove ECM about cars, - pay attention that the bottom bolt of fastening of the module is used also for fastening of a basic arm of a contact socket of electroconducting (see an illustration Fastening ECM models 2.0).

  1. Installation is made upside-down. Track correctness of connection of electroconducting.

At block replacement make its adaptable coding to the engine of your car in the conditions of car-care centre Opel workshop.

The relay of system of injection

The relay of system of injection is in the assembly block located in an impellent compartment.

 PERFORMANCE ORDER

  1. Remove from the assembly block a cover. The system relay is painted in purple colour. Make sure that ignition is switched off, then liberate the relay from колодки.

  1. Installation is made upside-down.

The central air gauge-switch

The gauge-switch of system of the conditioner will screw in one of lines of a refrigerator path, and cannot be removed, without a preliminary discharge of system (see the Head of System of cooling, heating). In view of the gauge-switch told replacement it is necessary to make in the conditions of a car-care centre workshop.

Electromagnet of management of functioning the valve of switching of the inlet pipeline

The electromagnet of management is established by functioning of the valve of switching of the pipeline in the left part of the last.


 PERFORMANCE ORDER

  1. Switch off ignition and disconnect from the valve electroconducting.
  2. Disconnect both vacuum hoses, turn out the fixing screw and remove an electromagnet.
  3. Installation is made upside-down.

Diafragmennyj knot of management of functioning of the valve of switching of an inlet collector

The diafragmennyj knot is established in the left part of the inlet pipeline.

 PERFORMANCE ORDER

  1. On engines of 1.8 l remove ECM (see above). On engines of 2.0 l remove the inlet pipeline (Removal and installation of the inlet pipeline see).
  2. On engines of 1.8 l disconnect a vacuum hose, disconnect from the hinge a diaphragm rod, turn out fixing bolts and remove диафрагменный knot from the pipeline. On engines of 2.0 l turn out a nut of fastening of a rod of a diaphragm to the valve lever, take a pin of fastening of the case of a diaphragm to the inlet pipeline and disconnect a vacuum hose.
  3. Installation is made upside-down.