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
   - 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 Multec fuel
      Removal and installation of components of systems of the distributed injection of Multec-S and Simtec-70 fuel
      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 components of systems of the distributed injection of Multec-S and Simtec-70 fuel

See the prevention at the beginning of Sbrasyvaniye of pressure in a power supply system of petrol enginesthe section .

System of injection of Multec-S

Before finally affirming as opinion on an exit of injectors out of operation, try to add in fuel any of the automobile engines of additives approved by producers. Make sure also that the fuel tank is not polluted.


 PERFORMANCE ORDER

  1. Dump pressure in a power supply system (see Sbrasyvaniye pressure in a power supply system of petrol engines), then disconnect a negative wire from the battery.
  2. Uncover a maslozalivny mouth, turn out fixing screws and remove a protective casing of the engine.
  3. Disconnect electroconducting from the sensor of temperature of soaked-up air (IAT), disconnect an inlet air line from an air purifier and the throttle case. On the Zafira models remove a sealing strip of an impellent compartment and a cover of the fairing established under bottom edge of a windscreen. For the purpose of ensuring access to an inlet air line give fixing nuts/bolts and remove the top cover of the panel of a front.
  4. Disconnect hoses of ventilation of a case from a cover of the gas-distributing mechanism.
  5. Disconnect all electroconducting laid in a plastic route trench, going along the fuel highway, - try to remember an order of laying of plaits. The following components are subject to a detachment:
  • Valve of a purge of a coal adsorber;
  • Sensor of provision of a cranked shaft (CKP);
  • Sensor of emergency pressure of oil;
  • Step-by-step electromotor of system of stabilization of turns of idling;
  • The sensor of temperature of cooling liquid (ECT);
  • Sensor of provision of a butterfly valve (TPS);
  • Sensor of provision of a camshaft (CMP);
  • The sensor of absolute pressure in the inlet pipeline (MAP);
  • EGR valve;
  • Ignition module;
  • Lambda probe;
  • Top ECM socket;
  • Sensor of a detonation (KS);
  • Interference suppressor on the ignition module;
  • Two tires of grounding of the pipeline;
  • The gray socket of the assembly block of the relay in a forward part of an impellent compartment.
  1. Disconnect a vacuum hose of a regulator of pressure of fuel in the left part of the fuel highway.
  2. Disconnect from the fuel highway топливопроводы, - pay attention to a difference in the amount of shtutserny connections.
  1. Turn out two fixing bolts and remove the fuel highway together with injectors and a plastic trench of electroconducting.
  1. In case of need injectors can be removed from the fuel highway, - release the corresponding clamps. Sealing rings of injectors at installation of the last are subject to replacement without fail.
  2. Installation is made upside-down. Pay attention to the next moments:
    1. Before installation grease new sealing rings with a small amount of impellent oil.
    2. When filling injectors to the highway try not to allow shifts of sealing rings. Track reliability of fixing of injectors.
    3. At installation of the fuel highway try not to damage nozzles. All fixture tighten with demanded effort.
    4. In end start the engine and check the highway on existence of signs of development of leaks.

Regulator of pressure of fuel

 PERFORMANCE ORDER

  1. Uncover a maslozalivny mouth, turn out fixing screws and remove a protective casing of the engine. Dump pressure in system (see Sbrasyvaniye pressure in a power supply system of petrol engines) and disconnect a negative wire from the battery.
  2. Disconnect from a regulator a vacuum hose.
  1. Turn out the fixing screw and remove an assembly collar of a regulator.
  1. Accurately liberate a regulator from the fuel highway together with sealing elements.
  2. Installation is made upside-down. Do not forget to replace sealing elements. In summary start the engine and check the highway on existence of signs of development of leaks.

Step-by-step electromotor of system of stabilization of turns of idling

 PERFORMANCE ORDER

  1. Uncover a maslozalivny mouth, turn out fixing screws and remove a protective casing of the engine.
  2. Disconnect electroconducting from the sensor of temperature of soaked-up air (IAT), disconnect an inlet air line from an air purifier and the throttle case. On the Zafira models remove a sealing strip of an impellent compartment and a cover of the fairing established under bottom edge of a windscreen. For the purpose of ensuring access to an inlet air line give fixing nuts / bolts and remove the top cover of the panel of a front.
  3. Disconnect electroconducting from the step-by-step electric motor.
  1. Turn out two fixing screws and remove the electromotor from the throttle case.
  1. Installation is made upside-down. For check of serviceability of functioning of system of stabilization of turns of idling measure size of a vystupaniye of a plunzher (And) from the electric motor, - the result of measurement should make no more than 33 mm, - in case of need correct the provision of a plunzher. A carving part of fixing screws before installation grease with anaerobny hermetic.

Sensor of provision of a butterfly valve (TPS)

 PERFORMANCE ORDER

  1. Uncover a maslozalivny mouth, turn out fixing screws and remove a protective casing of the engine.
  2. Disconnect electroconducting from the sensor of temperature of soaked-up air (IAT), disconnect an inlet air line from an air purifier and the throttle case. On the Zafira models remove a sealing strip of an impellent compartment and a cover of the fairing established under bottom edge of a windscreen. For the purpose of ensuring access to an inlet air line give fixing nuts / bolts and remove the top cover of the panel of a front.
  3. Make sure that ignition is switched off, then disconnect electroconducting from the throttle of the TPS sensor established on the case.
  1. Turn out fixing bolts and remove the sensor.
  1. Installation is made upside-down. Track correctness of input of a potentiometer in gearing with a butterfly valve axis. Before a vvorachivaniye of fixing bolts grease their carving part with anaerobny hermetic. Having tightened bolts with demanded effort, connect to the sensor electroconducting.
  1. Check serviceability of functioning of a zaslonka, then connect electroconducting and establish to the place of an inlet air line.

The sensor of temperature of cooling liquid (ECT)

The sensor of temperature of cooling liquid will screw in the thermostat case. The description of procedures of removal and sensor installation – see. Check of serviceability of functioning, removal and installation of electric components of a chain of management of system of cooling of the engine.

The sensor of temperature of soaked-up air (IAT)

The sensor is established in the inlet air line connecting the case of an air purifier to the inlet pipeline.

 PERFORMANCE ORDER

  1. Make sure that ignition is switched off and disconnect from the sensor electroconducting.
  2. Operating extremely carefully, accurately take the sensor block, - try not to damage an air line. Remove a sealing element of the sensor subject to obligatory replacement.
  3. Installation is made upside-down. Track, that the sensor flange correctly was combined with an opening in an inlet air line.

The sensor of absolute pressure in the pipeline (MAP)

The MAP sensor is fixed on a partition of an impellent compartment, to the left of the inlet pipeline.

 PERFORMANCE ORDER

  1. Switch off ignition, disconnect from the sensor electroconducting and a vacuum hose. The sensor can be removed now from an arm.
  2. Installation is made upside-down.

Sensor of provision of a cranked shaft (CKP)

 PERFORMANCE ORDER

  1. The sensor is established on the right in a back part of the block of cylinders and access to it is possible from under the car. Cock the parking brake, поддомкратьте a front of the car and establish it on props. At the corresponding complete set remove protection of a case.
  2. Walk on electroconducting from the sensor, liberating a plait from intermediate clamps and remembering a route of its laying. Disunite the contact socket, - the sensor acts in film together with a part of a plait.
  1. Turn out a fixing bolt and remove the sensor.
  1. Installation is made upside-down. Track, that the fixture was tightened with demanded effort. Make sure of correctness of laying and reliability of fixing of a plait.
  2. In end measure distance between the sensor and teeths of a rotor of the sensor on a pulley of a cranked shaft, - if the result exceeds 1.0  ± 0.7 mm, replace a basic arm of fastening of the sensor.

Sensor of provision of a camshaft (CMP)

 PERFORMANCE ORDER

  1. Remove the top cover of a drive of GRM (see. Head Engine).
  2. Walk on electroconducting from the sensor, liberating a plait from intermediate clamps and remembering a route of its laying. Disunite the contact socket.
  3. Turn out fixing bolts and remove the sensor assembled with electroconducting from a head of cylinders.
  4. Installation is made upside-down. Before a vvorachivaniye grease a carving part of fixing bolts with anaerobny hermetic. Tighten bolts with demanded effort. Track correctness of laying and reliability of fixing of electroconducting.

Sensor of a detonation (KS)

The sensor of a detonation is established on a back wall of the block of cylinders.

 PERFORMANCE ORDER

  1. For the purpose of ensuring access cock the parking brake, поддомкратьте the car and establish it on props. The sensor can be removed from below the car.
  2. Make sure of that ignition is switched off, then walk on electroconducting from the sensor, liberating a plait from intermediate clamps and remembering a route of its laying. Disunite the contact socket.
  3. Turn out a fixing bolt and remove the sensor.
  4. Installation is made upside-down. Before installation make sure of absoluteness of purity and dryness of interfaced surfaces. Tighten fixture with demanded effort. Track correctness of laying of electroconducting.

Electronic module of engine management (ECM)

 PERFORMANCE ORDER

  1. Disconnect a negative wire from the battery and open a cover of the assembly block of the relay located in an impellent compartment.
  2. Turn out two fixing screws, uncover a maslozalivny mouth and a protective casing of the engine.
  3. Release clamps and disconnect from ECM electroconducting. Turn out three fixing bolts and remove the module.
  4. Installation is made upside-down. Track correctness of connection of electroconducting.

At replacement of the block make its adaptable coding to the engine of your car in the conditions of a workshop of car-care center of Opel.

Relay of system of injection

The relay of system of injection is in the assembly block located in an impellent compartment.

 PERFORMANCE ORDER

  1. Remove from the assembly block a cover. The relay of system is painted in purple color. Make sure that ignition is switched off, then liberate the relay from a block.

  1. Installation is made upside-down.

Central air sensor switch

The sensor switch of system of the conditioner will screw in one of lines of a refrigerator path and it can not be removed without a preliminary discharge of system (see. Head of System of cooling, heating). In view of the sensor switch told replacement it is necessary to make in the conditions of a car-care center workshop.

System of injection of Simtec-70

The fuel highway with injection injectors

Before finally affirming as opinion on an exit of injectors out of operation, try to add in fuel any of the automobile engines of additives approved by producers. Make sure also that the fuel tank is not polluted.


 PERFORMANCE ORDER

  1. Dump pressure in a power supply system (see Sbrasyvaniye pressure in a power supply system of petrol engines), then disconnect a negative wire from the battery.
  2. Uncover a maslozalivny mouth, turn out fixing screws and remove a protective casing of the engine.
  3. Disconnect electroconducting from the sensor of measurement of weight of air (MAF), disconnect an inlet air line from an air purifier and the throttle case. On the Zafira models remove a sealing strip of an impellent compartment and a cover of the fairing established under bottom edge of a windscreen. For the purpose of ensuring access to an inlet air line give fixing nuts / bolts and remove the top cover of the panel of a front.
  4. Disconnect hoses of ventilation of a case from a cover of the gas-distributing mechanism and the throttle case.
  5. Disconnect all electroconducting laid in a plastic route trench, going along the fuel highway, - try to remember an order of laying of plaits. Liberate a plait from a trench.
  1. Turn out fixing bolts and disconnect grounding tires from an electroconducting trench to the right of the inlet pipeline and ECM to the left of the pipeline.
  1. Turn out a bolt of fastening of a trench.
  1. Disconnect from the fuel highway топливопроводы, - pay attention to a difference in the amount of shtutserny connections.
  1. Turn out two fixing bolts and remove the fuel highway together with injectors and a plastic trench of electroconducting. Remove and will throw out the bottom sealing rings - at assembly they is subject to replacement without fail.
  1. Release clamps and accurately remove an electroconducting trench from injectors, - contact sockets are built in the trench and to replacement in an individual order are not subject.
  1. Release the corresponding clamps and remove from the fuel highway injectors. Remove the top sealing rings, at installation of a ring is subject to replacement without fail.
  1. Installation is made upside-down. Pay attention to the next moments:

    1. Before installation grease new sealing rings with a small amount of impellent oil.
    2. When filling injectors to the highway try not to allow shifts of sealing rings. Track reliability of fixing of injectors.
    3. At installation of the fuel highway try not to damage nozzles. All fixture tighten with demanded effort.
    1. At installation of a trench track correctness of connection of contact sockets of injectors.
    1. In end start the engine and check the highway on existence of signs of development of leaks.

Regulator of pressure of fuel

 PERFORMANCE ORDER

  1. On models of 1.8 l adjustment of pressure of fuel is carried out by the module of the gasoline pump placed in a fuel tank, - the regulator is established under a pump cover, in an individual order on the markets of spare parts is not delivered and in default all pump assembly (the description of procedures of removal and installation of pump assembly – is subject to replacement see. Removal and installation of the fuel pump - petrol models). Disconnect from a regulator fuel lines, disconnect electroconducting disconnect got under a pump cover electroconducting. On engines of 2.0 l remove a protective casing of the engine. Dump pressure in a power supply system (see Sbrasyvaniye pressure in a power supply system of petrol engines) and disconnect a negative wire from the battery.
  1. Disconnect from a regulator a vacuum hose (1).
  2. Turn out the fixing screw and remove an assembly collar (2) regulators.
  1. Accurately liberate a regulator from the fuel highway together with sealing elements.
  2. Installation is made upside-down. Do not forget to replace sealing elements. In summary start the engine and check the highway on existence of signs of development of leaks.

Butterfly valve regulator - models of 1.8 l

On models of 1.8 l turns of the engine are supervised by ECM by means of a butterfly valve regulator. The sensor of situation (potentiometer) of a butterfly valve (TPS) is built in a regulator being an integral part of the case of a throttle. In case of violation of serviceability of functioning of any of elements, the case of a throttle is subject to replacement in collecting (see. Removal and installation of the case of a throttle - petrol models).

The step-by-step electromotor of system of stabilization of turns of idling - models of 2.0 l

 PERFORMANCE ORDER

  1. Disconnect electroconducting from the sensor of measurement of weight of air (MAF). Release a collar and disconnect a hose of ventilation of a case from a back part of a cover of the gas-distributing mechanism, then disconnect an inlet air line. On the Zafira models remove a sealing strip of an impellent compartment and a cover of the fairing established under bottom edge of a windscreen. For the purpose of ensuring access to an inlet air line give fixing nuts / bolts and remove the top cover of the panel of a front.
  2. Disconnect electroconducting from the step-by-step electric motor.
  1. Turn out two fixing screws and remove the electromotor from the throttle case, - sealing laying is subject to replacement without fail.

    A — the Detachment of the contact socket of electroconducting of the step-by-step electromotor
    B — Screws of fastening of the step-by-step electromotor

A.

B.
  1. Installation is made upside-down. Do not forget to replace laying. All fixture tighten with demanded effort.

Sensor of situation (potentiometer) of a butterfly valve (TPS)

 PERFORMANCE ORDER

  1. On engines of 1.8 l the sensor is built in a butterfly valve regulator. On engines of 2.0 l remove the throttle case (see. Removal and installation of the case of a throttle - petrol models).
  2. Turn out fixing bolts and remove the sensor from the throttle case.
  3. Installation is made upside-down. Track correctness of input of a potentiometer in gearing with a butterfly valve axis.

The sensor of temperature of cooling liquid (ECT)

The sensor of temperature of cooling liquid will screw in a back part of the inlet pipeline. The description of procedures of removal and sensor installation – see. Check of serviceability of functioning, removal and installation of electric components of a chain of management of system of cooling of the engine.

The sensor of temperature of soaked-up air (IAT)

Functions of the IAT sensor are carried out by the sensor of measurement of a tel of weight of air (MAF), - see below.

Sensor of measurement of a tel of weight of air (MAF)

 PERFORMANCE ORDER

  1. Switch off ignition and disconnect from the sensor electroconducting.
  1. Release fixing collars, disconnect inlet air lines and remove the sensor from the engine. On the Zafira models remove a sealing strip of an impellent compartment and a cover of the fairing established under bottom edge of a windscreen. For the purpose of ensuring access to an inlet air line give fixing nuts / bolts and remove the top cover of the panel of a front.
  2. Installation is made upside-down. Track correctness of connection of air lines.

The sensor of provision of a cranked shaft (CKP) - models of 1.8 l

 PERFORMANCE ORDER

  1. The sensor is established on an arm on the right in a back part of the block of cylinders, access to it is possible from under the car. For the purpose of ensuring access, cock the parking brake, поддомкратьте a front of the car and establish it on props and remove protection of a case.
  2. Walk from the sensor on an electroconducting plait, liberating it from intermediate clamps. Disunite the contact socket, - the sensor acts in film together with the piece of conducting built in in it.
  1. Turn out a fixing bolt and remove the sensor from the block of cylinders.

  1. Installation is made upside-down. Tighten a bolt of fastening of the sensor with demanded effort. Track correctness of laying and reliability of fixing of electroconducting.

The sensor of provision of a cranked shaft (CKP) - models of 2.0 l

 PERFORMANCE ORDER

  1. Remove an air purifier (see. Removal and installation of components of an inlet air path).
  2. On equipped In models turn out a fixing bolt and remove directing tube щупа measurements of level of oil from a forward part of the block of cylinders.
  3. Walk from the sensor on an electroconducting plait, liberating it from intermediate clamps. Disunite the contact socket, - the sensor acts in film together with the piece of conducting built in in it.
  4. Turn out a fixing bolt and remove the sensor from the block of cylinders, - the sealing ring is subject to replacement without fail.
  5. Installation is made upside-down. Do not forget to replace a sealing ring, tighten a bolt of fastening of the sensor with demanded effort. Track correctness of laying and reliability of fixing of electroconducting.

Sensor of provision of a camshaft (CMP)

 PERFORMANCE ORDER

  1. On engines of 1.8 l uncover a maslozalivny mouth, turn out fixing screws and remove a protective casing of the engine. On engines of 2.0 l turn out fixing screws and uncover spark plugs the top part of a head of cylinders.
  2. Switch off ignition and disconnect from the sensor electroconducting.
  3. Remove the top cover of a drive of GRM (see. Head Engine).
  1. Turn out fixing bolts and remove the sensor from a head of cylinders.
  1. Installation is made upside-down. Before a vvorachivaniye grease a carving part of fixing bolts with anaerobny hermetic. Tighten bolts with demanded effort.

Sensor of a detonation (KS)

 PERFORMANCE ORDER

  1. The sensor of a detonation is established on a back wall of the block of cylinders. For the purpose of ensuring access cock the parking brake, поддомкратьте the car and establish it on props. The sensor can be removed from below the car.
  2. On engines of 2.0 l remove a starter (see. Head engine Electric equipment).
  3. Make sure that ignition is switched off, then walk on electroconducting from the sensor, liberating a plait from intermediate clamps and remembering a route of its laying. Disunite the contact socket.
  1. Turn out a fixing bolt and remove the sensor.
  1. Installation is made upside-down. Before installation make sure of absoluteness of purity and dryness of interfaced surfaces. Tighten fixture with demanded effort. Track correctness of laying of electroconducting. On engines of 2.0 l establish into place a starter (see. Head engine Electric equipment).

Electronic module of engine management (ECM)


ECM fastening on models of 2.0 l

1 — the grounding Tyre
2 — the Module of management (ECM)

3 — the Contact socket of electroconducting
4 — the Contact socket of electroconducting


 PERFORMANCE ORDER

  1. Disconnect a negative wire from the battery. Open a cover of the assembly block of the relay located in an impellent compartment.
  2. On engines of 1.8 l of ECM приболчен to the left side of the inlet pipeline. On engines of 2.0 l the module fastens behind the storage battery.
  3. Release clamps and disconnect from ECM electroconducting. Disconnect the grounding tire from a module frame. On engines of 1.8 l, without disuniting, liberate the contact socket of electroconducting from a basic arm on ECM frame.
  1. Turn out three fixing bolts and remove ECM about cars, - pay attention that the bottom bolt of fastening of the module is used also for fastening of a basic arm of the contact socket of electroconducting (see an illustration ECM Fastening on models of 2.0 l).

  1. Installation is made upside-down. Track correctness of connection of electroconducting.

At replacement of the block make its adaptable coding to the engine of your car in the conditions of a workshop of car-care center of Opel.

Relay of system of injection

The relay of system of injection is in the assembly block located in an impellent compartment.

 PERFORMANCE ORDER

  1. Remove from the assembly block a cover. The relay of system is painted in purple color. Make sure that ignition is switched off, then liberate the relay from a block.

  1. Installation is made upside-down.

Central air sensor switch

The sensor switch of system of the conditioner will screw in one of lines of a refrigerator path, and it can not be removed, without a preliminary discharge of system (see. Head of System of cooling, heating). In view of the sensor switch told replacement it is necessary to make in the conditions of a car-care center workshop.

Electromagnet of management of functioning valve of switching of the inlet pipeline

The electromagnet of management is established by functioning of the valve of switching of the pipeline in the left part of the last.


 PERFORMANCE ORDER

  1. Switch off ignition and disconnect from the valve electroconducting.
  2. Disconnect both vacuum hoses, turn out the fixing screw and remove an electromagnet.
  3. Installation is made upside-down.

Diafragmenny knot of management of functioning of the valve of switching of an inlet collector

The Diafragmenny knot is established in the left part of the inlet pipeline.

 PERFORMANCE ORDER

  1. On engines of 1.8 l remove ECM (see above). On engines of 2.0 l remove the inlet pipeline (see. Removal and installation of the inlet pipeline).
  2. On engines of 1.8 l disconnect a vacuum hose, disconnect from the hinge a diaphragm rod, turn out fixing bolts and remove diafragmenny knot from the pipeline. On engines of 2.0 l turn out a nut of fastening of a rod of a diaphragm to the valve lever, take a pin of fastening of the case of a diaphragm to the inlet pipeline and disconnect a vacuum hose.
  3. Installation is made upside-down.