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
   - Systems of release and decrease in toxicity of the fulfilled gases
      System of release of the fulfilled gases - the general information, removal and installation
      Systems of decrease in toxicity of the fulfilled gases - the general information
      Check of serviceability of functioning and replacement of components of systems of 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



Check of serviceability of functioning and replacement of components of systems of decrease in toxicity of the fulfilled gases

Ventilation system картера (PCV)

All models

System components do not require special service over usual checks of a condition of hoses and them штуцерных connections according to the Schedule of routine maintenance of the car (Routine maintenance see the Head).

System of catching of fuel evaporations (EVAP) - petrol models

Check

First of all always check a condition of vacuum hoses, passableness infringement, a detachment or which damage more often and it appears a system cause of a failure (be verified with the scheme of a lining of hoses resulted on label VECI of your car). In case of need replace the damaged hoses. Full diagnostics of system is possible only with application of the specialised equipment connected to socket DLC (the Principle of functioning of systems of injection of fuel see). In default the valve of a purge and-or a coal adsorber are subject to replacement.

Replacement

Coal adsorber

The coal adsorber is established under the right forward wing of the car.

 PERFORMANCE ORDER

  1. For the purpose of maintenance of adequate access to an adsorber cock a lay brake, then поддомкратьте redock of the car and establish it on props. Remove the right forward wheel.
  2. Turn out fixing screws, release clamps and remove локер protection of a wheel arch.
  3. Disconnect electroconducting and remove assemblage of the lateral repeater of the index of the right turn (the Onboard electric equipment see the Head).
  1. Give a nut of fastening of an adsorber. In an impellent compartment disconnect from an adsorber hoses, preliminary them having marked. Remove an adsorber from the car.
  1. Installation is made upside-down. Track correctness of connection of hoses and reliability of a tightening of fixture.

The valve of a purge of an adsorber

The purge valve is established in the right part of an impellent compartment, behind an air cleaner.


 PERFORMANCE ORDER

  1. Switch off ignition, wring out on a clamp and disunite a contact socket of electroconducting of the valve.
  2. Disconnect from the valve hoses (try to remember an order from connection), Release clamps, separate the valve from the case of an air cleaner and remove it from the car.
  3. Installation is made upside-down.

The control of structure of the fulfilled gases

Check

The Katalitichesky converter

The diagnostic equipment for check of serviceability of a condition каталитического the converter is expensive and the extremely difficult in operation. At occurrence of suspicions on converter refusal, drive away the car for check on a car repair shop.

Each time when the car for any reason rises over the earth, examine the converter on presence of signs of mechanical damages, traces of leaks and corrosion development. Check a condition of welded seams and reliability of a tightening фланцевых bolts of fastening of the device to sections of system of release of the fulfilled gases. Defective каталитический the converter is subject to replacement.

Despite reliability of a design of the converter, there is high enough probability of its corking. The elementary way of check of passableness of the converter is check with vacuum gauge application.

 PERFORMANCE ORDER

  1. Connect the vacuum gauge to a source of depression of the inlet pipeline (Procedures of repair of diesel engines of 1.7 l and 2.0 l without their extraction from the car see).
  2. Warm up the engine to normal working temperature, translate the selector lever in position Р (models with АТ), or include neutral transfer (models with РКПП) and cock a lay brake.
  3. Consider vacuum gauge indications at single turns of the engine.
  4. Quickly open throttle заслонку almost against the stop, then at once release, having dumped turns to the single. Consider and write down vacuum gauge indications.
  5. Repeat the described check still three times, each time writing down result.
  6. If the result of the fourth measurement appears more than on 2.54 mm hg below the instrument read at single turns, hence, there is a probability of infringement of passableness of the converter, or the muffler.

Ljambda-probe (the oxygen gauge)

 PERFORMANCE ORDER

  1. Find an electric socket of the gauge. From a socket underside enter the unbent writing paper clip into a nest of contact of an alarm wire (the plug № 1 [+]), the second paper clip enter into a plug nest № 2 (weight). Connect to the first paper clip positive щуп the voltmeter, negative connect to a paper clip entered into the grounding plug. Cock a lay brake, translate selector AT lever in position Р, on models with РКПП choose neutral transfer. Поддомкратьте redock of the car also establish it on props.
  1. Start the engine and start to trace changes of alarm pressure of a ljambda-probe.

Try not to touch to разогретым with surfaces of system of release of the fulfilled gases!

  1. At the initial stage the cold gauge should develop a constant signal amplitude 0.1—0.2 In (a mode of the opened contour). After nearby two minutes the engine will reach normal working temperature and the gauge indication will start to fluctuate in limits from 0.1 to 0.9 In (a mode of the closed contour). If the system does not pass in a mode of the closed contour, or passes with is inadmissible the big delay (the lazy gauge), replace the gauge.
  2. Check up also serviceability of functioning of a heater of a ljambda-probe. Disunite a socket of electroconducting of a probe and connect an ohmmeter between heater plugs (plugs №№ 3 and 4). Nominal resistance makes 10—40 Ohm.
  3. Check up serviceability of giving of a food on a heater. Disunite an electric socket and measure pressure on it from outside a plait between the plug № 4 and weight. At the included ignition (do not start the engine) the voltmeter should fix pressure of the battery. If a food is absent, check up an electroconducting condition on a chain site between the main relay, ECM and a ljambda-probe.
  4. At negative results listed above checks, replace the faulty gauge.

Replacement

The Katalitichesky converter

The Katalitichesky converter is among components not requiring service, however, there are some moments to which the owner appropriate amount of the equipped car should pay attention.

  • Do not fill equipped каталитическим with the car converter неэтилированным fuel, - lead containing in it is postponed on the surfaces of the catalyst covered with rare-earth metals that in an essential measure reduces efficiency of functioning of the converter and finally can lead to its full exit out of operation;
  • Watch serviceability of a condition of components of system of release of the fulfilled gases, regularly make necessary checks according to the Schedule of routine maintenance of the car (Routine maintenance see the Head);
  • At occurrence of admissions of ignition, it is necessary to refuse using a vehicle till the moment of elimination of malfunction, - not burnt down fuel getting to the converter can then ignite and be at the bottom of a catalyst exit out of operation;
  • For the same reason it is necessary to refuse start of the engine by towage or car pushing;
  • Do not switch off ignition at high turns of the engine;
  • Do not use any additives to fuel and impellent oil, - they can contain, harmful for каталитического the converter components.
  • At occurrence on an exit of system of release of the fulfilled gases of the grey loop which is a consequence of burning out of impellent oil composers of the present Management also recommend to refuse car operation (the point see);
  • Remember that каталитический the converter functions at very high working temperatures, - do not park the car on covered to a dry grass or last year's foliage platforms;
  • Remember that каталитический the converter can be easily damaged at blows, - be careful, performing any works near to it;
  • Occurrence of a smell of hydrogen sulphide (rotten eggs) in the first days of operation of the new car is a consequence of normal functioning каталитического the converter, - the smell should disappear after first several thousand kilometres of run;
  • At the serviceable car service life каталитического the converter makes to 150 000 km. In case of decrease in efficiency of functioning каталитический the converter is subject to replacement.

The description of procedures of removal and installation каталитического the converter – see Removal and installation of a final collector.

Ljambda-probe (the oxygen gauge)

At ljambda-probe service it is necessary to observe some special safety measures:

  • The ljambda-probe is equipped tightly built in in it and the equipped contact tip by a piece of the electroconducting which attempts of a detachment can lead to an irreversible exit of the gauge out of operation;
  • Try not to suppose hit in jalousie of the gauge or its electric socket of a dirt and greasing;
  • Do not use for ljambda-probe clearing any solvents;
  • Address with the gauge extremely carefully, - do not drop it and try not to shake;
  • The silicone protective cover should be put on the gauge strictly definitely not to be fused and not to break serviceability of functioning of a probe.

Models with engines of 1.4 and 1.6 l

 PERFORMANCE ORDER

  1. Warm up the engine to normal working temperature, muffle and disconnect a negative wire from the battery.
  1. Walk on electroconducting from the final collector of the gauge screwed in the left part to a contact socket of its electroconducting. Liberate conducting from clamps and disunite a socket.
  1. Turn out the gauge and remove it from a collector.

Try not to touch to разогретым to elements of system of release of the fulfilled gases!

  1. Installation is made upside-down. Before вворачиванием grease a carving part of the gauge with heat-resistant greasing of type Opel №1948602/90295397. Tighten the gauge with demanded effort and track correctness of a lining of electroconducting, - the plait should not concern warmed up surfaces of system of release.

Models with engines of 1.8 and 2.0 l

 PERFORMANCE ORDER

  1. Cock a lay brake, then поддомкратьте redock of the car and establish it on props. Disconnect a negative wire from the battery.
  1. Walk on electroconducting from screwed in reception section of system of release of the gauge to a contact socket of its electroconducting at the left on a head of cylinders. Liberate conducting from clamps and disunite a socket.
  1. Turn out the gauge and remove it from the car, - the sealing ring is subject to replacement without fail.
  2. Installation is made upside-down. Before вворачиванием grease a carving part of the gauge with heat-resistant greasing of type Opel №1948602/90295397. Tighten the gauge with demanded effort and track correctness of a lining of electroconducting, - the plait should not concern warmed up surfaces of system of release.

System рециркуляции the fulfilled gases (EGR)

Check

All models

Exhaustive check of system can be executed only with application of the specialised equipment connected to diagnostic socket DLC (the Principle of functioning of systems of injection of fuel see). Failed valves EGR are subject to replacement.

Replacement

Valve EGR

Petrol models

 PERFORMANCE ORDER

  1. Switch off ignition, disconnect from the valve electroconducting. On the models equipped with engine SOHC, the valve is established in an average part of the inlet pipeline, on models with engines DOHC - in its left part.
  2. Turn out fixing screws and remove the valve in gathering with a sealing lining.
  3. Installation is made upside-down. Do not forget to replace a lining, track, that the valve has been tightened with demanded effort.

Diesel models

Models with engines of 1.7 l SOHC

 PERFORMANCE ORDER

  1. Release clamps, turn out bolts of fastening of a basic arm and lift the receiver the pressurisation, connecting турбокомпрессор with интеркулером.
  1. Disconnect from valve EGR a vacuum hose, take a lock ring and remove valve EGR from the left part of the inlet pipeline.
  1. Installation is made upside-down.

Models with engines of 1.7 l DOHC

 PERFORMANCE ORDER

  1. Remove ECM (the Principle of functioning of systems of injection of fuel see). Turn out fixing bolts and remove basic arm ECM located over valve EGR.
  2. Disconnect from valve EGR a vacuum tube.
  3. Turn out fixing bolts and disconnect an inlet tube from the top part of valve EGR.
  1. Rozhkovym key release штуцерный a socket of tube EGR on the valve.

    Valve EGR (the engine of 1.7 l DOHC)
    1 — the Inlet pipeline
    2 — Valve EGR
    3 — the Lock ring

  1. Give bolts of fastening of valve EGR to the inlet pipeline, - try to remember adjusting position of basic arms fixed by the same nuts.
  1. The failed valve is subject to replacement.
  2. Installation is made upside-down.

Models with engines of 2.0 l

The valve in an individual order on the market of spare parts is not delivered and in default is replaced in gathering with the top section of the inlet pipeline (Removal and installation of the inlet pipeline see).

The electromagnetic valve of management of valve EGR functioning - diesel models

Models with engines of 1.7 l SOHC

 PERFORMANCE ORDER

  1. Disconnect from клапанной assemblages electroconducting and vacuum hoses behind on the inlet pipeline, - try to remember a lining and an order of connection of lines.
  1. Turn out two fixing bolts and remove the electromagnetic valve.
  2. Installation is made upside-down.

Models with engines of 1.7 l DOHC

 PERFORMANCE ORDER

  1. In case of need remove an air cleaner and an inlet air line in the right part of an impellent compartment (Removal and installation of components of an inlet air path see).
  1. The valve is established in the right part of the inlet pipeline. Disconnect from the valve vacuum hoses, - pay attention to a difference in their diameters.
  2. Disconnect from the valve electroconducting.
  1. Turn out two fixing bolts and remove the valve.
  1. Installation is made upside-down.

Models with engines of 2.0 l

The valve is established in a forward left part of an impellent compartment, in the neighbourhood with the valve of switching of the pipeline. And valve EGR is back of two and can be identified on black colour of electroconducting.

 PERFORMANCE ORDER

  1. Disconnect from the valve electroconducting and vacuum hoses. Turn out fixing screws and remove the valve from a basic arm, - try to remember adjusting position of components.
  2. Installation is made upside-down.