Opel Astra, Zafira

since 1998 of release

Repair and car operation



Opel Astra
+ Opel Astra and Zafira Cars
+ Operation manual
+ Routine maintenance
+ Engine
+ Systems of cooling, heating
- Power supply system and release
   - Power supply system
      Sbrasyvaniye of pressure in a power supply system of petrol engines
      Check of a condition and replacement of fuel lines and their shtutserny connections
      Air removal from a fuel path of the diesel engine
      Removal of pollution from a power supply system of the diesel engine
      Removal and installation of components of an inlet air path
      Removal, installation and adjustment of a cable of gas - petrol models
      Removal and installation of a pedal of an accelerator
      Removal and installation of the fuel pump - petrol models
      Removal and installation of the sensor of a stock of fuel
      Removal and installation of a fuel tank
      Removal and installation of the case of a throttle - petrol models
   + 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
+ engine Electric equipment
+ Manual transmission
+ Automatic transmission
+ Coupling and power shafts
+ Brake system
+ Suspension bracket and steering
+ Body
+ Onboard electric equipment




Power supply system

General information and precautionary measures

Petrol models

The power supply system consists of the car of the fuel tank placed in it of an electric gasoline pump established in a back part, the fuel filter, injectors of injection, a regulator of pressure of fuel, assembly of an air purifier, the throttle case, and also laid under the bottom of the car and connecting a fuel tank with the fuel highway of lines of giving and fuel return. All models are equipped with electronic system of injection of the fuel, functioning under control of ECM (see. System of injection of fuel of petrol engines).

Accumulating in a tank and gasoline pipe lines during car parking fuel evaporations accumulate in the adsorber filled with absorbent carbon, from where then are deduced to the inlet highway and burned process of normal functioning of the engine.

Information on fuel consumption is deduced on the car dashboard.

Essential influence on fuel consumption renders style of driving. Some councils on reasonable use of a pedal of an accelerator on equipped with system of injection of fuel cars below are given:

  1. In any weather (even in a frost) begin movement right after start implementation двигателяю
  2. At a car stop for a while more than 40 with, suppress двигателью
  3. Try to move always on the highest transfer
  4. On distant trips try to support constant speed of movement. Avoid movement on excessively high speeds. Operate the car circumspectly, avoid causeless торможенийю
  5. Transport the car excessive cargo, in the absence of need remove from a roof top багажникю
  6. Regularly check pressure of a rating of tires — try not to allow its excessive decrease.

Diesel models

The fuel system consists of the car of the fuel tank equipped with the built-in moisture separator of the warmed-up fuel filter established in a back part, the fuel pump of a high pressure (TNVD), nozzles and connecting components of system of toplivoprovodny lines.

TNVD takes away fuel from a tank and banishes it via the fuel filter where there is a catching of extraneous particles and moisture. Unspent excess of fuel is used by the engine for greasing of internal components of the pump then comes back back to a fuel tank.

The drive of TNVD is carried out from a cranked shaft by means of belt (engines of 1.7 l) or chain (engines of 2.0 l) transfers. Working turns of the pump make exactly a half from turns of a cranked shaft. The high pressure necessary for opening of nozzles and fuel injection in forkamery/it is direct in cylinders, it is provided at the expense of use of the radial plunzherny pump.

TNVD has electronic control thanks to what the engine completely meets constantly toughened international requirements for decrease in toxicity of an exhaust. Basic elements of a control system are the electronic module of the engine management (ECM) which has been built in pump assembly the TNVD control unit and a set of information sensors (see. Systems of injection and turbo-supercharging of the diesel engine).

Four fuel nozzles inject the sprayed fuel in forkamer of cylinders (engines of 1.7 l of SOHC), or is direct in combustion chambers (engines of 1.7 l of DOHC and 2.0 l). Optimization of process of combustion of a mix is provided at the expense of thin calibration of nozzles. Needles of nozzles are greased with the fuel accumulated in spring chambers, unclaimed surplus of fuel on separate lines comes back to TNVD.

On models of 2.0 l the inlet pipeline is equipped with the petal valve providing increase of efficiency of return of the engine on small turns. In the pipeline it is organized on two inlet channels on each of cylinders. One of channels is equipped with means of an electromagnet operated on the ECM teams and a vacuum diaphragm the petal valve. At turns of the engine the valve is lower 1500 in a minute remains closed and air in the cylinder moves only on one of channels. Increase of turns leads to opening of valves and, according to increase in weight of combustion of air submitted to chambers.

On engines of 1.7 l of DOHC the inlet pipeline consists of two sections divided by a metal partition. In the top section of the pipeline the EGR valve and the sensor of pressure of pressurization are established.

For the purpose of increase of efficiency of return the engine is equipped high-pressure head (Y20DTH engine) or low-pressure head (other engines) a turbokompressor providing redundancy of pressure in the inlet pipeline rather atmospheric that the mass consumption of air submitted to cylinders allows to increase — supply of fuel also in proportion increases. Established between a final collector and a reception pipe of system of production of the fulfilled gases, working from pressure of the fulfilled gases the turbokompressor makes an air fence from an air purifier, at the corresponding complete set (except Y20DTL engines) banishes it through mounted at the left on a radiator of system of cooling the heat exchanger of an intermediate cooler (interkuler) and under a pressure submits to the inlet pipeline. A problem of an interkuler is cooling heated up at a szhimaniye in the supercharger of air submitted to the engine. As the cooled air has big density, decrease in its temperature allows to lift efficiency of return of the engine even more.

Excessive increase of pressure in the inlet pipeline is prevented at the expense of application of the special safety valve providing removal of fulfilled gases from a turbokompressor by means of pressure sensitive to change of the actuation mechanism. Operation of the valve occurs at the command of ECM. Sensitive to pressure change the sensor switch provides operation of the control lamp built in in an instrument guard warning the driver about excess of admissible pressure of pressurization.

Greasing of a turbokompressor is made arriving on a special tube from the block of cylinders by impellent oil — the turbine shaft literally "floats" in oil — from the supercharger oil of the returnable line arrives back in the case pallet. Turbokompressor is equipped with the built-in safety valve and the vacuum diaphragm, providing adjustment of pressure of pressurization in the inlet pipeline. Internal components of a turbokompressor rotate with high speed and are very sensitive to quality of oil. Hit on rotating shovels of the turbine of extraneous particles can have the most serious consequences. In view of the compressor told before removal it is necessary to clear carefully its external surfaces, and also surfaces of the knots located in the neighbourhood. Removed components put in densely closed container. All openings in the compressor at once stick with an adhesive tape, for rubbing of details use only неворсящуюся rags.

At all do not start the turbirovanny engine at the removed inlet air line — depth of depression on an entrance of the compressor can increase in steps that increases risk of absorption in the turbine of extraneous subjects and their subsequent ejection with a high speed!

It should be noted that on diesel models there is no accelerator cable — instead of it on a pedal the sensor of its situation is established.

Also special locking valve of an otsechka of fuel is provided at ignition switching off.

The fuel system of diesel engines is extremely reliable. Under condition of use of pure fuel and a regularity of performance of procedures of service it should function regularly before the termination of service life of the car. At high run the TNVD internal components and nozzles can wear out, and demand carrying out regenerative repair — in view of complexity of a design of components it is necessary to charge performance of repair to specialists of car-care center.

Security measures and rules of observance of purity at work with fuel system

General rules

Do not come nearer to a venue of works with open fire or the lit cigaret. Always keep in readiness the fire extinguisher.

Fuel pairs are poisonous — watch ensuring normal ventilation of a workplace.

The fuel system is under pressure. When opening system fuel can escape from it under pressure — before an otpuskaniye of shtutserny sockets turn them rags. Use goggles.

At work with components of a power supply system of the diesel engine observe special precautionary measures. In a special measure this statement belongs to procedures of service of nozzles. Remember that pressure of fuel on an exit makes about 1100 atmospheres of nozzles — do not substitute under a stream of a hand and other parts of a body.

Collars of tape and tightening type are applied to fastening of shlangovy connections. After a detachment of hoses it is necessary to replace tightening collars tape or worm. Fixing of locks of some collars demands use of special adaptations — consult with experts firm HUNDRED Opel.

Before undocking of shtutserny sockets carefully wipe them outside in order to avoid dirt hit in a path.

Removed components stack on a pure lining and turn in polyethylene or paper — avoid application for rubbing and a reversing of components ворсящейся rags.

If repair demands time, track, that all open openings in knots and components of a power supply system were carefully muffled.

Establish into place only pure details. Spare parts take out from packing only directly ahead of installation. Do not apply details which were stored unpacked (for example, in a tool box).

Avoid application of the compressed air at an open fuel path. Whenever possible try not to move the car.

Do not apply some hermetics containing silicone. The particles which have got to the engine of silicone do not burn down and damage a lambda probe can be at the bottom.

Security measures at removal of a fuel tank

Before removal of a tank merge from it fuel or pump out it pump specially provided for this purpose.

The fuel tank acts in film from the bottom party of the car. Before an otpuskaniye of assembly tapes, prop up a tank from below a telezhechny jack — lay between a tank and a jack head wooden whetstone.

The empty tank is explosive and before utilization should be cut on a part — try not to allow when cutting a tank of an iskroobrazovaniye. It will be most correct to hand over a tank in special place of acceptance.

After installation of a tank start the engine and check tightness of all connections.