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
   - Systems of injection and turbo-supercharging of the diesel engine
      Check and adjustment of the maximum turns of the engine
      Check and adjustment of installations of the moments of injection of fuel
      Removal and installation of electric components of the power supply system
      Signals and pressure on conclusions of the module of management
      Removal and installation ТНВД
      Removal and installation of fuel atomizers
      Removal and installation турбокомпрессора
      Removal and installation of an intermediate cooler (интеркулера)
      Removal and installation of the inlet pipeline
      Removal and installation of a final collector
   + 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 electric components of the power supply system

Models 1.7 of l SOHC

The gauge of measurement of weight of air (MAF)

The gauge of temperature of soaked up air (IAT) is built in gauge MAF.


 PERFORMANCE ORDER

  1. Switch off ignition and disconnect from the gauge electroconducting.
  1. Release clamps, disconnect from the gauge electroconducting and remove the gauge from the car.
  2. Installation is made upside-down. Track reliability of fixing of the gauge and air lines.

The gauge of position of a pedal of an accelerator

 PERFORMANCE ORDER

  1. At the moment of drawing up of the present Management pedal assemblage was issued by monolithic knot and in case of infringement of serviceability of functioning was subject to replacement in gathering.
  2. In car salon turn out fixture and for the purpose of providing of access to pedal assemblage remove the left bottom section of furnish of the panel of devices (the Body see the Head).
  1. Give fixing nuts and remove assemblage of a pedal of an accelerator from a partition of an impellent compartment.
  1. Release a clamp and disconnect from the gauge electroconducting.
  2. Installation is made upside-down. Track correctness of connection of electroconducting and reliability of a tightening of fixture with demanded effort.
  3. Do not forget to establish finishing section of the panel of devices.

The gauge of position of a cranked shaft (CKP)

 PERFORMANCE ORDER

  1. The gauge is established in a forward part of the block of cylinders, - disconnect electroconducting, try to remember an order of its lining.
  2. Turn out a fixing bolt and remove the gauge.
  3. Installation is made upside-down. Track, that the fixture has been tightened with demanded effort.

The gauge of temperature of a cooling liquid (ECT)

 PERFORMANCE ORDER

  1. The gauge of temperature of a cooling liquid is established in the case of the thermostat on the right side of a head of cylinders, - disconnect electroconducting.
  1. Empty cooling system (Routine maintenance see the Head), prepare for gathering of a spilt cooling liquid.
  2. Turn out the gauge from the thermostat case, - preliminary open a cover of a broad tank, for dump of superfluous pressure in a path, then establish a cover into place and densely tighten. Having turned out the gauge at once закупорьте an aperture under its installation rubber заглушкой for the purpose of minimisation of losses of a cooling liquid.
  3. Before installation grease a carving part of the gauge with hermetic. Screw the gauge in a landing nest and tighten it with demanded effort.
  4. Connect to the gauge electroconducting.
  5. Fill cooling system (Routine maintenance see the Head).

The gauge of pressure of pressurisation

 PERFORMANCE ORDER

  1. The gauge of pressure of pressurisation is established on the right in the inlet pipeline, - disconnect electroconducting.

  1. Turn out the fixing screw and remove the gauge from the pipeline.
  2. Installation is made upside-down. Track, that the fixture has been tightened with demanded effort.

The gauge of emergency pressure of oil

The gauge will screw in a back part of the case of the oil pump. Signals developed by the gauge are used ECM at management of functioning located on the panel of devices of a control lamp.

1 — a contact socket of electroconducting
2 — the gauge of emergency pressure of oil


 PERFORMANCE ORDER

  1. Cock a lay brake, поддомкратьте redock of the car and establish it on props, at a corresponding complete set remove protection картера.
  2. Disconnect from the gauge electroconducting.
  3. Turn out the gauge, - prepare for gathering of spilt oil, at once закупорьте an aperture under installation of the gauge approaching заглушкой.
  4. Installation is made upside-down. At a corresponding complete set do not forget to replace a sealing element, track, that the gauge has been tightened with demanded effort.

The electronic module of engine management (ECM)

Before removal ECM make its decoding in the conditions of a car-care centre workshop.


 PERFORMANCE ORDER

  1. ECM it is established under локером protection of an arch of the left forward wheel. Cock a lay brake, поддомкратьте redock of the car and establish it on props, remove a wheel.
  2. Turn out fixing screws and remove локер.
  1. Disconnect electroconducting and remove ECM from a basic arm.
  1. Installation is made upside-down. Track correctness of connection and reliability of fixing of electroconducting.

The electronic module of management ТНВД

The module of management ТНВД is built in pump assemblage. Composers of the present Management do not recommend to make attempt of dismantle of the module.

The gauge of temperature of fuel

The gauge is built in pump assemblage. Composers of the present Management do not recommend to make attempt of dismantle of the gauge.

The gauge of position of shaft ТНВД

The gauge is built in pump assemblage. Composers of the present Management do not recommend to make attempt of dismantle of the gauge.

The gauge of the moment of the beginning of injection

The gauge is built in pump assemblage. Composers of the present Management do not recommend to make attempt of dismantle of the gauge.

Запорный the electromagnetic valve

The gauge is built in pump assemblage. Composers of the present Management do not recommend to make attempt of dismantle of the gauge.

Models 1.7 of l DOHC

The gauge of measurement of weight of air (MAF)

The gauge of temperature of soaked up air (IAT) is built in gauge MAF.

The corresponding subsection see above Model 1.7 of l SOHC.

The gauge of position of a pedal of an accelerator

The corresponding subsection see above Model 1.7 of l SOHC.

The gauge of position of a cranked shaft (CKP)

 PERFORMANCE ORDER

  1. Cock a lay brake, поддомкратьте the car and establish it on props, at a corresponding complete set remove protection картера.

  2. The gauge is established in a back part of the block of cylinders, under a starter. Get under the car and disconnect from the gauge electroconducting, - try to remember an order of its lining.
  1. Turn out a fixing bolt and remove the gauge, - the sealing ring is subject to replacement without fail.
  1. Installation is made upside-down. Do not forget to replace a sealing ring, track, that the fixture has been tightened with demanded effort.

The gauge of temperature of a cooling liquid (ECT)

The corresponding subsection see above Model 1.7 of l SOHC.

The gauge of pressure of pressurisation

 PERFORMANCE ORDER

  1. Remove established in a back part of an impellent compartment an air cleaner air line (Removal and installation of components of an inlet air path see).
  2. Remove from the inlet pipeline valve EGR (Systems of release and decrease in toxicity of the fulfilled gases see).
  3. Disconnect conducting from the gauge fixed on the right on the inlet pipeline.
  1. Turn out fixing bolts and remove the gauge.
  1. Installation is made upside-down. Track, that the fixture has been tightened with demanded effort.

The gauge of emergency pressure of oil

 PERFORMANCE ORDER

  1. Signals developed by the gauge are used ECM at management of functioning located on the panel of devices of a control lamp.
  2. Remove the storage battery with a basic arm (the engine Electric equipment see the Head).
  3. The gauge is located at the left on the block of cylinders, disconnect from it electroconducting.
  1. Turn out the gauge from the block, - prepare for gathering of spilt oil.
  1. Slightly grease a carving part of the gauge with hermetic. Screw the gauge and tighten it with demanded effort.
  2. Attach electroconducting, then establish into place the battery with a basic arm.
  3. Start the engine and check up it on presence of signs of development of leaks.

The electronic module of engine management (ECM)

Before removal ECM make its decoding in the conditions of a car-care centre workshop.


 PERFORMANCE ORDER

  1. ECM is located in the top part of the engine, over valve EGR.
  2. Disconnect a negative wire from the battery.
  1. Release spring clamps and disunite two contact sockets of electroconducting ECM, - try not to damage sockets.
  1. Turn out fixing bolts / of a nut and remove ECM.
  2. Installation is made upside-down. Track correctness of connection and reliability of fixing of electroconducting. Sockets differ from each other on a design, the plait is connected to a back nest, going of the left part of an impellent compartment.

The electronic module of management ТНВД

The module of management ТНВД is located in a back part of pump assemblage.

 PERFORMANCE ORDER

  1. Cock a lay brake, поддомкратьте redock of the car and establish it on props, at a corresponding complete set remove protection картера.
  2. Get under the car and disconnect electroconducting from the management module.
  1. Turn out fixing bolts and remove the management module.
  1. Installation is made upside-down.

The safety electromagnetic valve of system of a turbo-supercharging

 PERFORMANCE ORDER

  1. Cock a lay brake, поддомкратьте redock of the car and establish it on props, at a corresponding complete set remove protection картера.
  2. Operating according to the instructions stated above (the Electronic module of management ТНВД see), remove the module of management ТНВД.
  3. Disconnect from the valve a vacuum tube and electroconducting.
  4. Turn out two fixing bolts and remove the electromagnetic valve.
  5. Installation is made upside-down. Track reliability of a tightening of fixing bolts. Pay attention to a difference of thickness of vacuum tubes, - smaller it is connected to the entrance union.

The gauge of atmospheric pressure (BARO)

The gauge is established in a back part of the block of cylinders, between ТНВД and a starter.

 PERFORMANCE ORDER

  1. Cock a lay brake, поддомкратьте redock of the car and establish it on props, at a corresponding complete set remove protection картера.
  2. Disconnect from the gauge electroconducting.
  1. Lift the gauge upwards and liberate it from a basic arm.
  1. Installation is made upside-down.

The gauge of temperature of fuel


Components ТНВД (model 1.7 of l DOHC)

1 — the Drain gate
2 — the Line of return of fuel
3 — the Gauge of temperature of fuel
4 — the Line of giving of fuel

5 — the Programmed block of memory
6 — the Electromagnetic valve of management of the injection moment (PROM)
7 — the Gauge of position of shaft ТНВД

The gauge is established on the right at the top of assemblage ТНВД (Components ТНВД (model 1.7 of l DOHC) see an illustration).

 PERFORMANCE ORDER

  1. Disconnect electroconducting and turn out the gauge from pump assemblage.
  1. Having replaced a sealing element, screw the gauge in ТНВД and reliably tighten a nut.
  1. Restore initial connection of electroconducting.

The gauge of position of shaft ТНВД

The gauge is located sideways on assemblage ТНВД (Components ТНВД (model 1.7 of l DOHC) see an illustration) and in an individual order on the market of spare parts is not delivered, in case of need address for consultations to experts firm HUNDRED Opel.

The gauge of the moment of the beginning of injection

The gauge is under ТНВД, is closer to a flywheel / приводному to a disk and in an individual order on the market of spare parts is not delivered, in case of need address for consultations to experts firm HUNDRED Opel.

Electromagnetic запорный the valve

The valve is established in the top part ТНВД, is closer to a flywheel/privodnomu to a disk and in an individual order on the market of spare parts is not delivered, in case of need address for consultations to experts firm HUNDRED Opel.

Litre models 2.0

The gauge of measurement of weight of air (MAF)

The gauge of temperature of soaked up air (IAT) is built in gauge MAF.

The corresponding subsection see above Model 1.7 of l SOHC.

The gauge of position of a pedal of an accelerator

The corresponding subsection see above Model 1.7 of l SOHC.

The gauge of position of a cranked shaft (CKP)

 PERFORMANCE ORDER

  1. Turn out fixing screws and remove a plastic protective casing from the top part of a head of cylinders a plastic cover from above heads of cylinders.
  2. For the purpose of maintenance of adequate access to the gauge cock a lay brake, поддомкратьте redock of the car and establish it on props, at a corresponding complete set remove protection картера.
  1. Walk on a plait of electroconducting from the gauge to a contact socket of electroconducting. Liberate a socket from a basic arm and disunite it.
  1. Wipe a surface of the engine round the gauge, then turn out a fixing bolt and remove the gauge from a forward part of the block of cylinders, remove a sealing ring.
  1. Installation is made upside-down. Do not forget to replace a sealing ring, track, that the fixing bolt has been tightened with demanded effort.

The gauge of temperature of a cooling liquid (ECT)

The gauge will screw on the right in a forward part of a head of cylinders, the description of procedures of removal and gauge installation – Check of serviceability of functioning, removal and installation of electric components of a chain of management of system of cooling of the engine see.

The gauge of pressure of pressurisation

 PERFORMANCE ORDER

  1. Turn out fixing screws and remove a plastic protective casing of the engine.

  1. Turn out screws of fastening of a routeing trench of electroconducting to the top part of the inlet pipeline and disconnect from the gauge electroconducting.
  1. Turn out a fixing bolt and remove the gauge from the top part of the inlet pipeline, - pay attention to the sealing ring planted on a shaft.
  2. Installation is made upside-down. Do not forget to replace a sealing ring, track, that the fixing bolt has been tightened with demanded effort.

The gauge of temperature of oil

 PERFORMANCE ORDER

  1. Cock a lay brake, поддомкратьте redock of the car and establish it on props, at a corresponding complete set remove protection картера.
  2. Merge impellent oil (Routine maintenance see the Head), - on termination of procedure do not forget to screw into place a drain stopper of the pallet with a new sealing washer and to tighten it with demanded effort.
  1. Disconnect electroconducting and turn out the gauge from a forward part поддана картера.
  1. Installation is made upside-down.
  2. In summary fill in in the engine fresh oil (Routine maintenance see the Head).

The electronic module of engine management (ECM)

Before removal ECM make its decoding in the conditions of a car-care centre workshop.

The Gauge of emergency pressure of oil see above Model 1.7 of l SOHC.

The electronic module of management ТНВД

The module of management ТНВД is built in pump assemblage. Composers of the present Management do not recommend to make attempt of dismantle of the module.

The electromagnetic valve of switching of the inlet pipeline


The scheme of a lining of vacuum lines on models 2.0 of l with высоконапорным a turbo-supercharging

1 — the Electromagnetic valve of the control of pressure of pressurisation
2 — the Actuation mechanism of management of pressure of pressurisation
3 — the Vacuum pump
4 — Valve EGR

5 — the Electromagnet of management of functioning of the valve of switching of the inlet pipeline
6 — the Valve of switching of the inlet pipeline
7 — Valve EGR

On the engine it is established two valves: the valve рециркуляции exhaust gases (EGR) and the valve of switching of the inlet pipeline. Last is established more close to a forward part of the car (the Scheme of a lining of vacuum lines see models 2.0 of l with высоконапорным a turbo-supercharging an illustration).

 PERFORMANCE ORDER

  1. Disconnect from the valve electroconducting and vacuum hoses, turn out fixing screws and remove the valve from a basic arm.
  2. Installation is made upside-down.

Electromagnetic safety valve of system of a turbo-supercharging

The electromagnetic valve is established in the right back corner of an impellent compartment.

 PERFORMANCE ORDER

  1. For the purpose of providing of access to the valve of reception of access to the valve remove an inlet air line (in gathering with gauge MAF), the leader from an air cleaner to турбокомпрессору.
  2. Disconnect from the valve electroconducting and vacuum hoses, turn out fixing screws and remove the valve from a basic arm.
  3. Installation is made upside-down.