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 the inlet pipeline

Engines SOHC

At installation new nuts of fastening of the pipeline are required.


 PERFORMANCE ORDER

  1. Dump pressure in the power supply system (Sbrasyvanie of pressure in the power supply system of petrol engines see). Disconnect a negative wire from the battery.
  2. Remove a belt of a drive of auxiliary units and empty cooling system (Routine maintenance see the Head).
  3. Remove an air cleaner and inlet air lines (Removal and installation of components of an inlet air path see).
  4. Disconnect from a cover of the case of a throttle vacuum hoses and ventilation hoses картера, turn out fixing screws and remove from the case of a throttle a cover with a sealing ring.
  5. Disconnect electroconducting from gauge TPS, the step-by-step electromotor of system of stabilisation of turns of idling, an injector of injection of fuel, gauge ECT, valve EGR, the valve of ventilation of a fuel tank and gauge MAP. Liberate plaits of electroconducting from intermediate clamps, - try to remember an order of their packing. Remove a routeing trench of electroconducting from a cover газораспределительного the mechanism and take him aside from the inlet pipeline.
  6. Turn out bolts of fastening of an arm of fastening of the generator to the inlet pipeline. Liberate the generator from an eye and reject it back.
  7. Give штуцерные nuts and disconnect from the throttle case fuel hoses, - at отпускании nuts hold a socket from проворачивания by means of the second рожкового a key.
  1. Disconnect приводную draught from an axis throttle заслонки, turn out two fixing bolts and remove from the pipeline a basic arm together with the cover of a cable fixed in it.
  1. Disconnect from the throttle case vacuum hoses and ventilation hoses картера, try to remember adjusting position of components. Disconnect a vacuum hose from the valve of ventilation of a fuel tank.
  2. Ослабьте a fixing collar also disconnect a hose охладительного a path from a back part of the inlet pipeline.
  1. Release a clamp and remove from the pipeline a hose of the servo-driver of the vacuum amplifier of brakes.
  1. Make sure that all lines of communication are disconnected also disturbs nothing to pipeline removal. Turn out nuts of fastening of the pipeline.
  2. Remove the pipeline from the engine and remove from it a sealing lining, - try to remember adjusting position of a lining.
  3. Installation is made upside-down. Pay attention to following moments:
    1. Before installation check up a condition of fixing hairpins of the pipeline, - defective hairpins replace. Use new nuts of fastening of the pipeline;
    2. Before installation make sure of absoluteness of cleanliness and dryness of interfaced surfaces of the pipeline and the block, do not forget to replace a sealing lining. A tightening of fixing nuts with demanded effort make in stages, - try to provide full uniformity;
    3. Track correctness of connection and reliability of fixing of all lines of communication;
    4. Track, that штуцерные nuts of fuel lines and a hose of the vacuum amplifier of brakes have been tightened with demanded effort.
  4. In summary establish a belt of a drive of auxiliary units and make refuelling of system of cooling (Routine maintenance see the Head).

Engines of 1.4 and 1.6 l DOHC

If only back part of the pipeline is subject to removal, execute procedures of paragraphs with 1 on 15.


 PERFORMANCE ORDER

  1. Uncover маслозаливной mouths, turn out fixing screws and remove a protective casing of the engine. Screw on a place a cover маслозаливной mouths. Empty cooling system (Routine maintenance see the Head).
  2. Remove an air cleaner with an inlet air line (Removal and installation of components of an inlet air path see).
  3. Overcoming resistance of a spring, develop натяжитель for the central bolt and remove from pulleys a belt of a drive of auxiliary units.
  4. Turn out fixing bolts and remove a basic arm of the generator on the right side of the pipeline.
  1. Ослабьте the bottom bolt of fastening of the generator also reject the generator back.
  1. Remove established between the inlet pipeline and the block of cylinders a basic arm.
  1. Disconnect from a cover газораспределительного the mechanism a ventilation hose картера.
  2. Remove a fuel highway with injection injectors (Removal and installation of components of systems of the distributed injection of fuel Multec-S and Simtec-70 see).
  3. Disconnect a cable of gas from the case of a throttle and liberate it from a basic arm (Removal, installation and adjustment of a cable of gas - petrol models see).
  4. Disconnect electroconducting from the step-by-step electromotor of system of stabilisation of turns of idling and gauge TPS.
  5. Ослабьте a fixing collar also disconnect from the pipeline a hose of the servo-driver of the vacuum amplifier of brakes.
  6. Disconnect a vacuum hose from gauge MAP.
  1. Disconnect from the case of a throttle a hose of ventilation of a fuel tank.
  1. Ослабьте collars also disconnect from the case of a throttle hoses охладительного a path.
  1. Turn out fixing bolts and remove the pipeline from a landing flange. To assort the pipeline it is not recommended.
  1. For removal of a landing flange, disconnect from its left part a hose охладительного a path.
  1. Turn out fixing nuts and remove a flange from a head of cylinders, - for removal of a flange from hairpins it is necessary to wring out a little downwards a hose охладительного a path.
  2. Installation is made upside-down. Pay attention to following moments:
    1. Before installation check up a condition of fixing hairpins of the pipeline, - the damaged elements replace;
    2. Before installation make sure of absoluteness of cleanliness and dryness of interfaced surfaces, do not forget to replace a sealing lining. If removed a flange, track, that nuts of its fastening have been tightened in regular intervals and with demanded effort;
    3. Establish a back part of a collector, do not forget to replace a lining. Track, that fixing bolts have been tightened with demanded effort;
    4. Restore initial connection of all lines of communication, - track correctness of their connection and reliability of fixing;
    5. Track, that nuts штуцерных connections have been tightened with demanded effort;
  3. In summary make refuelling of system of cooling (Routine maintenance see the Head) and adjustment of a cable of gas (Removal, installation and adjustment of a cable of gas - petrol models see).

Engines of 1.8 and 2.0 l

At installation new nuts of fastening of the pipeline are required.


 PERFORMANCE ORDER

  1. Remove a belt of a drive of auxiliary units and empty cooling system (Routine maintenance see the Head).
  2. Dump pressure in the power supply system (Sbrasyvanie of pressure in the power supply system of petrol engines see). Disconnect a negative wire from the battery.
  3. Uncover маслозаливной mouths, turn out fixing screws and remove a protective casing of the engine.
  4. Disconnect electroconducting from gauge MAF.
  5. Release fixing collars, disconnect an inlet air line in gathering with gauge MAF. 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.
  1. Release a clamp and disconnect from the hinge a gas cable, liberate a cable from a basic arm.

On the models equipped with a control system by the engine, remove приводной a cable темпостата, - the cable fastens to the hinge a spring bracket.

  1. Ослабьте collars also disconnect ventilation hoses картера from a cover газораспределительного the mechanism and the throttle case.
  1. Disconnect from the case of a throttle hoses охладительного a path. Disconnect a tube of system of cooling from a cover газораспределительного the mechanism and a left edge of the inlet pipeline and take her aside.
  1. Disconnect from the case of a throttle a hose of ventilation of a fuel tank.
  2. On engines of 2.0 l disconnect electroconducting from gauge TPS and the valve of system of stabilisation of turns of idling. On engines of 1.8 l disconnect electroconducting from a regulator throttle заслонки.
  3. Disconnect from the throttle case all remained hoses, - try to remember adjusting position of components.
  1. On engines of 1.8 l ослабьте the bottom bolt of fastening of the generator also turn out the top fixing bolt. Turn out fixing bolts and separate a basic arm of the generator from the inlet pipeline and a head of cylinders. On engines of 2.0 l remove from the inlet pipeline a basic arm of the generator, also remove an arm of fastening of the generator to a flange of system cooling and to the inlet pipeline. Reject the generator back.
  1. Turn out fixing bolts and remove a basic arm from the pipeline basis.
  1. On engines of 1.8 l ослабьте штуцерную a nut also disconnect a gasoline pipe line from a fuel highway, - at отпускании штуцерной nuts keep a socket from проворачивания the second key. On engines of 2.0 l disconnect a returnable gasoline pipe line from a pressure regulator, a line of giving of fuel disconnect from a fuel highway.
  2. Disconnect electroconducting from the gauge of position of a cranked shaft (CKP) and the electromagnetic valve-switching of the inlet pipeline, also disunite contact sockets of all plaits laid in established over injectors of injection a routeing trench. Turn out the left bolt of fastening of a trench. On engines of 2.0 l uncover spark plugs and disconnect electroconducting from the gauge of position of a camshaft (CMP).
  1. Turn out bolts of fastening of a fuel highway to the inlet pipeline, remove a highway in gathering with injectors and an electroconducting trench.
  1. Disconnect from the inlet pipeline a hose of the servo-driver of the vacuum amplifier of brakes. Disconnect from the pipeline all remained vacuum / air hoses, - try to remember adjusting position of components.
  1. Disconnect from the inlet pipeline a heater hose.
  1. Turn out fixing bolts and remove a back eye of transportation of the engine from a head of cylinders.
  1. Give screws with a head of type TORX (engines 1.8 ) and nuts (engines 2.0 ), and remove from the inlet pipeline the throttle case.
  2. On equipped РКПП l models 2.0  release a socket and disconnect a tube from the hydraulic cylinder of a drive of coupling. On engines of 1.8 l disconnect the remained electroconducting, turn out three fixing bolts and remove from inlet pipeline ECM.
  1. Turn out fixing bolts / of a nut and remove the pipeline from the engine.
  1. Remove and will throw out a sealing lining.

Do not undertake attempts of dismantling of the inlet pipeline, - in an individual order on the market of spare parts it is delivered only диафрагменный and electromagnetic клапанный knots.

  1. Installation is made upside-down.
    1. Before installation check up a condition of fixing hairpins of the pipeline, - the damaged elements replace;
    2. Before installation make sure of absoluteness of cleanliness and dryness of interfaced surfaces, do not forget to replace a sealing lining. Track, that fixing bolts have been tightened with demanded effort;
    3. Restore initial connection of all lines of communication, - track correctness of their connection and reliability of fixing;
    4. On models with РКПП check up serviceability of functioning of coupling, in case of need pump over a hydraulic path (Coupling and power shafts see the Head).
    5. Track, that nuts штуцерных connections have been tightened with demanded effort.
  2. In summary establish a belt of a drive of auxiliary units, make refuelling of system of cooling (Routine maintenance see the Head) and adjustment of a cable of gas (Removal, installation and adjustment of a cable of gas - petrol models see).