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 the inlet pipeline

Models 1.7 of l SOHC

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

 PERFORMANCE ORDER

  1. Disconnect a negative wire from the battery.
  2. In case of need remove the case of an air cleaner and inlet air lines with gauge MAF (Removal and installation of components of an inlet air path see).
  3. On models with a right-hand steering remove the generator (the engine Electric equipment see the Head).
  4. Remove a final collector (Removal and installation of a final collector see).
  1. Disconnect electroconducting from the gauge of pressure of pressurisation established on the inlet pipeline.
  1. Give fixing nuts and remove the inlet pipeline from a head of cylinders together with a sealing lining.
  2. Make sure of absoluteness of cleanliness and dryness of interfaced surfaces of a head of cylinders and the inlet pipeline and plant on pipeline hairpins a new lining.
  3. Establish the pipeline on regular and screw nuts of its fastening. In a diagonal order in stages in regular intervals tighten nuts with demanded effort.
  4. Connect electroconducting to the pressurisation gauge.
  5. Make sure of absoluteness of cleanliness and dryness of interfaced surfaces of a final collector and a head. Establish a collector (Removal and installation of a final collector see).
  6. On models with a right-hand steering establish into place the generator (the engine Electric equipment see the Head).
  7. Establish inlet air lines and the case of an air cleaner with gauge MAF (Removal and installation of components of an inlet air path see).
  8. Connect a negative wire to the battery.

Models 1.7 of l DOHC

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

 PERFORMANCE ORDER

  1. Disconnect a negative wire from the battery.
  1. Lift upwards lock рычажки clamps and disunite two contact sockets of electroconducting ECM.
  1. Give fixing nuts / bolts and remove ECM.
  2. Release fixture and disconnect an inlet air line from a tube connecting gauge MAF with турбокомпрессором.
  3. Turn out bolts of fastening of a basic arm of a tube of pressurisation to a case left-hand side газораспределительного the mechanism and to valve EGR.
  4. Turn out bolts of fastening of tube EGR to a final collector and case GRM left-hand side. Release a socket big штуцерного connections on valve EGR and lift the receiver.
  5. Give штуцерные nuts and remove fuel tubes of atomizers. Composers of the present Management draw on отдавании a bolt and displacement to the right cases маслоохладителя (the Engine) for the purpose of maintenance of adequate access to the back party of the fuel pump see the Head, - prepare for gathering of spilt fuel.

At all do not bend a tube, - internal pressure in them is very high!

  1. Disconnect electroconducting and vacuum hoses from electromagnetic valve EGR (Systems of release and decrease in toxicity of the fulfilled gases see)
  2. Disconnect a socket of conducting of the gauge of pressure of pressurisation.
  3. Liberate burn down electroconductings from intermediate clamps on the inlet pipeline, - try to remember a route of a lining of a plait.
  4. Disconnect a tube of return of fuel from the top part of the inlet pipeline and ТНВД.
  5. Turn out two fixing bolts and remove from the inlet pipeline valve EGR.
  1. Turn out fixing bolts and nuts and remove back (and in case of need and a lobby) section of the inlet pipeline.


  1. Carefully smooth out interfaced surfaces of a head and the pipeline and establish a new lining.
  2. The further installation is made in an order, the return to an order of dismantle of components. Track, that all fixture has been tightened in regular intervals and with demanded effort.
  3. Make sure of reliability of a tightening штуцерных sockets (see the Power supply system and release, the Specification), in summary check up them on presence of signs of development of leaks.

L models 2.0

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

 PERFORMANCE ORDER

  1. Disconnect a negative wire from the battery.
  2. On engines with низконапорным a turbo-supercharging (X20DTL/Y20DTL) remove a metal tube and an air line connecting the inlet pipeline with турбокомпрессором. On engines with высоконапорным pressurisation (Y20DTH) remove an air line connecting the pipeline with интеркулером.
  1. Turn out screws of fastening of a routeing trench of electroconducting to the top part of the inlet pipeline. Release clamps of sockets and disconnect electroconducting from temperature gauges, ТНВД, gauge CKP and the gauge of pressure of pressurisation.
  1. Take a trench aside from the pipeline.
  1. Disconnect a vacuum tube from valve EGR on the top part of the inlet pipeline.
  1. Carefully wipe штуцерные sockets and disconnect fuel tubes from atomizers and ТНВД, - at отпускании nuts hold reciprocal parts of sockets ТНВД with the second рожковым a key. For the purpose of minimisation of losses of fuel and in order to avoid hit in the dirt power supply system at once закупорьте the open ends of fuel lines and штуцерных sockets.

    A — Otpuskanie штуцерной nuts of fastening of a fuel tube to an atomizer and ТНВД
    C — Removal топливопроводов

A.

B.
  1. Gradually and in regular intervals having weakened, turn out fixing bolts and cautiously remove the top part of the pipeline, - the sealing lining is subject to replacement without fail.
  1. For removal of the bottom section of the pipeline, disconnect a vacuum tube from диафрагменной assemblages of the valve of switching of the pipeline.
  1. Turn out fastening bolts to the pipeline of a basic arm of a socket of electroconducting.
  1. In regular intervals and gradually having weakened, give fixing nuts and remove the bottom section of the pipeline from a head of cylinders, - the sealing lining is subject to replacement without fail.
  1. Make sure of absoluteness of cleanliness and dryness of interfaced surfaces.
  1. Lay a new lining on a head of cylinders, then establish the bottom section of the pipeline. Screw new fixing nuts and in a diagonal order in stages in regular intervals tighten them with demanded effort. Attach a valve-switch hose establish a basic arm of electroconducting.
  1. Lay a new lining on the top cut of the bottom section, and establish the top section the pipeline. Tighten with demanded effort fixing bolts.
  2. Establish fuel tubes, - track, that nuts штуцерных sockets have been tightened with demanded effort.
  3. Establish on the pipeline a routeing trench of electroconducting, reliably tighten fixing bolts and restore initial connection of electroconducting. Connect a vacuum tube to valve EGR.
  4. Establish an inlet air line / a tube (Removal and installation of components of an inlet air path see). Establish on a head of cylinders a plastic protective casing.
  5. Connect a negative wire to the battery.