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 the inlet pipeline

SOHC engines

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


 PERFORMANCE ORDER

  1. Dump pressure in a power supply system (see Sbrasyvaniye pressure in a power supply system of petrol engines). Disconnect a negative wire from the battery.
  2. Remove a belt of a drive of auxiliary units and empty cooling system (see. Head Routine maintenance).
  3. Remove an air purifier and inlet air lines (see. Removal and installation of components of an inlet air path).
  4. Disconnect from a cover of the case of a throttle vacuum hoses and hoses of ventilation of a case, turn out fixing screws and remove from the throttle case a cover with a sealing ring.
  5. Disconnect electroconducting from the TPS sensor, the step-by-step electromotor of system of stabilization of turns of idling, an injector of injection of fuel, the ECT sensor, the EGR valve, the valve of ventilation of a fuel tank and the MAP sensor. Liberate electroconducting plaits from intermediate clamps, - try to remember an order of their laying. Remove a route trench of electroconducting from a cover of the gas-distributing mechanism and take him aside from the inlet pipeline.
  6. Turn out bolts of fastening of an arm of fastening of the generator to the inlet pipeline. Liberate the generator from an eye and reject it back.
  7. Give shtutserny nuts and disconnect from the throttle case fuel hoses, - at an otpuskaniye of nuts hold the socket from a provorachivaniye by means of the second rozhkovy key.
  1. Disconnect driving draft from a butterfly valve axis, turn out two fixing bolts and remove from the pipeline a basic arm together with the cover of a cable fixed in it.
  1. Disconnect from the throttle case vacuum hoses and hoses of ventilation of a case, try to remember the adjusting provision of components. Disconnect a vacuum hose from the valve of ventilation of a fuel tank.
  2. Weaken a fixing collar and disconnect a hose of an okhladitelny path from a back part of the inlet pipeline.
  1. Release a clamp and remove from the pipeline a hose of the servo-driver of the vacuum amplifier of brakes.
  1. Make sure that all lines of communication are disconnected and nothing disturbs pipeline removal. Turn out nuts of fastening of the pipeline.
  2. Remove the pipeline from the engine and remove from it sealing laying, - try to remember the adjusting provision of laying.
  3. Installation is made upside-down. Pay attention to the next moments:
    1. Before installation check a condition of fixing hairpins of the pipeline, - defective hairpins replace. Use new nuts of fastening of the pipeline;
    2. Before installation make sure of absoluteness of purity and dryness of interfaced surfaces of the pipeline and the block, do not forget to replace sealing laying. A tightening of fixing nuts with demanded effort make in stages, - try to provide full uniformity;
    3. Track correctness of connection and reliability of fixing of all lines of communication;
    4. Track, that shtutserny nuts of fuel lines and a hose of the vacuum amplifier of brakes were tightened with demanded effort.
  4. In summary establish a belt of a drive of auxiliary units and make filling of system of cooling (see. Head Routine maintenance).

Engines 1.4 and 1.6 of l of DOHC

If only back part of the pipeline is subject to removal, execute procedures of paragraphs with 1 on 15.


 PERFORMANCE ORDER

  1. Uncover a maslozalivny mouth, turn out fixing screws and remove a protective casing of the engine. Screw on a place a cover of a maslozalivny mouth. Empty cooling system (see. Head Routine maintenance).
  2. Remove an air purifier with an inlet air line (see. Removal and installation of components of an inlet air path).
  3. Overcoming resistance of a spring, develop a natyazhitel for the central bolt and remove from pulleys a belt of a drive of auxiliary units.
  4. Turn out fixing bolts and remove a basic arm of the generator on the right side of the pipeline.
  1. Weaken the bottom bolt of fastening of the generator and reject the generator back.
  1. Remove established between the inlet pipeline and the block of cylinders a basic arm.
  1. Disconnect from a cover of the gas-distributing mechanism a hose of ventilation of a case.
  2. Remove the fuel highway with injection injectors (see. Removal and installation of components of systems of the distributed injection of Multec-S and Simtec-70 fuel).
  3. Disconnect a gas cable from the case of a throttle and liberate it from a basic arm (see. Removal, installation and adjustment of a cable of gas - petrol models).
  4. Disconnect electroconducting from the step-by-step electromotor of system of stabilization of turns of idling and the TPS sensor.
  5. Weaken a fixing collar and disconnect from the pipeline a hose of the servo-driver of the vacuum amplifier of brakes.
  6. Disconnect a vacuum hose from the MAP sensor.
  1. Disconnect from the throttle case a hose of ventilation of a fuel tank.
  1. Weaken collars and disconnect from the throttle case hoses of an okhladitelny path.
  1. Turn out fixing bolts and remove the pipeline from a landing flange. To assort the pipeline it is not recommended.
  1. For removal of a landing flange, disconnect from its left part a hose of an okhladitelny path.
  1. Turn out fixing nuts and remove a flange from a head of cylinders, - for removal of a flange from hairpins it is necessary to wring out a little down a hose of an okhladitelny path.
  2. Installation is made upside-down. Pay attention to the next moments:
    1. Before installation check a condition of fixing hairpins of the pipeline, - the damaged elements replace;
    2. Before installation make sure of absoluteness of purity and dryness of interfaced surfaces, do not forget to replace sealing laying. If removed a flange, track, that nuts of its fastening were tightened evenly and with demanded effort;
    3. Establish a back part of a collector, do not forget to replace laying. Track, that fixing bolts were tightened with demanded effort;
    4. Restore initial connection of all lines of communication, - track correctness of their connection and reliability of fixing;
    5. Track, that nuts of shtutserny connections were tightened with demanded effort;
  3. In summary make filling of system of cooling (see. Head Routine maintenance) and adjustment of a cable of gas (see. Removal, installation and adjustment of a cable of gas - petrol models).

 L engines 1.8 and 2.0

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


 PERFORMANCE ORDER

  1. Remove a belt of a drive of auxiliary units and empty cooling system (see. Head Routine maintenance).
  2. Dump pressure in a power supply system (see Sbrasyvaniye pressure in a power supply system of petrol engines). Disconnect a negative wire from the battery.
  3. Uncover a maslozalivny mouth, turn out fixing screws and remove a protective casing of the engine.
  4. Disconnect electroconducting from the MAF sensor.
  5. Release fixing collars, disconnect an inlet air line assembled with the MAF sensor. 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.
  1. Release a clamp and disconnect from the hinge a gas cable, liberate a cable from a basic arm.

On the models equipped with a control system of the engine, remove a driving cable темпостата, - the cable fastens to the hinge a spring bracket.

  1. Weaken collars and disconnect hoses of ventilation of a case from a cover of the gas-distributing mechanism and the throttle case.
  1. Disconnect from the throttle case hoses of an okhladitelny path. Disconnect a tube of system of cooling from a cover of the gas-distributing mechanism and the left edge of the inlet pipeline and take her aside.
  1. Disconnect from the throttle case a hose of ventilation of a fuel tank.
  2. On engines of 2.0 l disconnect electroconducting from the TPS sensor and the valve of system of stabilization of turns of idling. On engines of 1.8 l disconnect electroconducting from a butterfly valve regulator.
  3. Disconnect from the throttle case all remained hoses, - try to remember the adjusting provision of components.
  1. On engines of 1.8 l weaken the bottom bolt of fastening of the generator and turn out the top fixing bolt. Turn out fixing bolts and separate a basic arm of the generator from the inlet pipeline and a head of cylinders. On engines of 2.0 l remove from the inlet pipeline a basic arm of the generator, also remove an arm of fastening of the generator to a system flange cooling and to the inlet pipeline. Reject the generator back.
  1. Turn out fixing bolts and remove a basic arm from the pipeline basis.
  1. On engines of 1.8 l weaken a shtutserny nut and disconnect a gasoline pipe line from the fuel highway, - at an otpuskaniye of a shtutserny nut hold the socket from a provorachivaniye the second key. On engines of 2.0 l disconnect a returnable gasoline pipe line from a pressure regulator, the line of supply of fuel disconnect from the fuel highway.
  2. Disconnect electroconducting from the sensor of provision of a cranked shaft (CKP) and the electromagnetic valve switching of the inlet pipeline, also disunite contact sockets of all plaits laid in established over injectors of injection a route trench. Turn out the left bolt of fastening of a trench. On engines of 2.0 l uncover spark plugs and disconnect electroconducting from the sensor of provision of a camshaft (CMP).
  1. Turn out bolts of fastening of the fuel highway to the inlet pipeline, remove the highway assembled with injectors and an electroconducting trench.
  1. Disconnect from the inlet pipeline a hose of the servo-driver of the vacuum amplifier of brakes. Disconnect from the pipeline all remained vacuum / air hoses, - try to remember the adjusting provision of components.
  1. Disconnect from the inlet pipeline a heater hose.
  1. Turn out fixing bolts and remove a back eye of transportation of the engine from a head of cylinders.
  1. Give screws with a TORX type head (engines of 1.8 l) and nuts (engines of 2.0 l), and remove from the inlet pipeline the throttle case.
  2. On equipped RKPP models of 2.0 l release the socket and disconnect a tube from the hydraulic cylinder of a drive of coupling. On engines of 1.8 l disconnect the remained electroconducting, turn out three fixing bolts and remove from the inlet ECM pipeline.
  1. Turn out fixing bolts / nuts and remove the pipeline from the engine.
  1. Remove and will throw out sealing laying.

Do not undertake attempts of dismantling of the inlet pipeline, - in an individual order on the market of spare parts it is delivered only diafragmenny and electromagnetic klapanny knots.

  1. Installation is made upside-down.
    1. Before installation check a condition of fixing hairpins of the pipeline, - the damaged elements replace;
    2. Before installation make sure of absoluteness of purity and dryness of interfaced surfaces, do not forget to replace sealing laying. Track, that fixing bolts were tightened with demanded effort;
    3. Restore initial connection of all lines of communication, - track correctness of their connection and reliability of fixing;
    4. On models from RKPP check serviceability of functioning of coupling, in case of need pump over a hydraulic path (see. Head Coupling and power shafts).
    5. Track, that nuts of shtutserny connections were tightened with demanded effort.
  2. In summary establish a belt of a drive of auxiliary units, make filling of system of cooling (see. Head Routine maintenance) and adjustment of a cable of gas (see. Removal, installation and adjustment of a cable of gas - petrol models).