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
   - 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 a power supply system
      Signals and tension on conclusions of the module of management
      Removal and TNVD installation
      Removal and installation of fuel nozzles
      Removal and turbokompressor installation
      Removal and installation of an intermediate cooler (interkuler)
      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

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Removal and installation of electric components of a power supply system

Models of 1.7 l of SOHC

Sensor of measurement of weight of air (MAF)

The sensor of temperature of soaked-up air (IAT) is built in the MAF sensor.


 PERFORMANCE ORDER

  1. Switch off ignition and disconnect from the sensor electroconducting.
  1. Release clamps, disconnect from the sensor electroconducting and remove the sensor from the car.
  2. Installation is made upside-down. Track reliability of fixing of the sensor and air lines.

Sensor of provision of a pedal of an accelerator

 PERFORMANCE ORDER

  1. At the moment of drawing up of the real Management pedal assembly was issued in monolithic knot and in case of violation of serviceability of functioning was subject to replacement assembled.
  2. In salon of the car turn out fixture and for the purpose of ensuring access to pedal assembly remove the left bottom section of furnish of the dashboard (see. Head Body).
  1. Give fixing nuts and remove assembly of a pedal of an accelerator from a partition of an impellent compartment.
  1. Release a clamp and disconnect from the sensor electroconducting.
  2. Installation is made upside-down. Track correctness of connection of electroconducting and reliability of a tightening of fixture with demanded effort.
  3. Do not forget to establish finishing section of the dashboard.

Sensor of provision of a cranked shaft (CKP)

 PERFORMANCE ORDER

  1. The sensor is established in a forward part of the block of cylinders, - disconnect electroconducting, try to remember an order of its laying.
  2. Turn out a fixing bolt and remove the sensor.
  3. Installation is made upside-down. Track, that the fixture was tightened with demanded effort.

The sensor of temperature of cooling liquid (ECT)

 PERFORMANCE ORDER

  1. The sensor of temperature of cooling liquid is established in the thermostat case on the right side of a head of cylinders, - disconnect electroconducting.
  1. Empty cooling system (see. Head Routine maintenance), prepare for collecting spilled cooling liquid.
  2. Turn out the sensor from the thermostat case, - previously open a cover of a broad tank, for dumping of superfluous pressure in a path, then establish a cover on a place and densely tighten. Having turned out the sensor at once закупорьте an opening under its installation by a rubber cap for the purpose of minimization of losses of cooling liquid.
  3. Before installation grease a carving part of the sensor with hermetic. Screw the sensor in a landing nest and tighten it with demanded effort.
  4. Connect to the sensor electroconducting.
  5. Fill cooling system (see. Head Routine maintenance).

Sensor of pressure of pressurization

 PERFORMANCE ORDER

  1. The sensor of pressure of pressurization is established on the right in the inlet pipeline, - disconnect electroconducting.

  1. Turn out the fixing screw and remove the sensor from the pipeline.
  2. Installation is made upside-down. Track, that the fixture was tightened with demanded effort.

Sensor of emergency pressure of oil

The sensor will screw in a back part of the case of the oil pump. Signals developed by the sensor are used by ECM at management of functioning of the control lamp located on the dashboard.

1 — the contact socket of electroconducting
2 — the sensor of emergency pressure of oil


 PERFORMANCE ORDER

  1. 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. Disconnect from the sensor electroconducting.
  3. Turn out the sensor, - prepare for collecting spilled oil, at once закупорьте an opening under sensor installation by a suitable cap.
  4. Installation is made upside-down. At the corresponding complete set do not forget to replace a sealing element, track, that the sensor was tightened with demanded effort.

Electronic module of engine management (ECM)

Before removal of ECM make its decoding in the conditions of a car-care center workshop.


 PERFORMANCE ORDER

  1. ECM is established under a loker of protection of an arch of the left forward wheel. Cock the parking brake, поддомкратьте a front of the car and establish it on props, remove a wheel.
  2. Turn out fixing screws and remove a loker.
  1. Disconnect electroconducting and remove ECM from a basic arm.
  1. Installation is made upside-down. Track correctness of connection and reliability of fixing of electroconducting.

Electronic module of management of TNVD

The module of management of TNVD is built in pump assembly. Originators of the real Management do not recommend to make attempt of dismantle of the module.

Sensor of temperature of fuel

The sensor is built in pump assembly. Originators of the real Management do not recommend to make attempt of dismantle of the sensor.

Sensor of provision of a shaft of TNVD

The sensor is built in pump assembly. Originators of the real Management do not recommend to make attempt of dismantle of the sensor.

Sensor of the moment of the beginning of injection

The sensor is built in pump assembly. Originators of the real Management do not recommend to make attempt of dismantle of the sensor.

Locking electromagnetic valve

The sensor is built in pump assembly. Originators of the real Management do not recommend to make attempt of dismantle of the sensor.

Models of 1.7 l of DOHC

Sensor of measurement of weight of air (MAF)

The sensor of temperature of soaked-up air (IAT) is built in the MAF sensor.

See above Models of 1.7 l of SOHC, corresponding subsection.

Sensor of provision of a pedal of an accelerator

See above Models of 1.7 l of SOHC, corresponding subsection.

Sensor of provision of a cranked shaft (CKP)

 PERFORMANCE ORDER

  1. Cock the parking brake, поддомкратьте the car and establish it on props, at the corresponding complete set remove protection of a case.

  2. The sensor is established in a back part of the block of cylinders, under a starter. Be appropriated for the car and disconnect from the sensor electroconducting, - try to remember an order of its laying.
  1. Turn out a fixing bolt and remove the sensor, - the sealing ring is subject to replacement without fail.
  1. Installation is made upside-down. Do not forget to replace a sealing ring, track, that the fixture was tightened with demanded effort.

The sensor of temperature of cooling liquid (ECT)

See above Models of 1.7 l of SOHC, corresponding subsection.

Sensor of pressure of pressurization

 PERFORMANCE ORDER

  1. Remove established in a back part of an impellent compartment an air purifier air line (see. Removal and installation of components of an inlet air path).
  2. Remove from the inlet pipeline the EGR valve (see. Systems of release and decrease in toxicity of the fulfilled gases).
  3. Disconnect conducting from the sensor fixed on the right on the inlet pipeline.
  1. Turn out fixing bolts and remove the sensor.
  1. Installation is made upside-down. Track, that the fixture was tightened with demanded effort.

Sensor of emergency pressure of oil

 PERFORMANCE ORDER

  1. Signals developed by the sensor are used by ECM at management of functioning of the control lamp located on the dashboard.
  2. Remove the storage battery with a basic arm (see. Head engine Electric equipment).
  3. The sensor is located at the left on the block of cylinders, disconnect from it electroconducting.
  1. Turn out the sensor from the block, - prepare for collecting spilled oil.
  1. Slightly grease a carving part of the sensor with hermetic. Screw the sensor and tighten it with demanded effort.
  2. Attach electroconducting, then establish into place the battery with a basic arm.
  3. Start the engine and check it on existence of signs of development of leaks.

Electronic module of engine management (ECM)

Before removal of ECM make its decoding in the conditions of a car-care center workshop.


 PERFORMANCE ORDER

  1. ECM is located in the top part of the engine, over the EGR valve.
  2. Disconnect a negative wire from the battery.
  1. Release spring clamps and disunite two contact sockets of electroconducting of ECM, - try not to damage sockets.
  1. Turn out fixing bolts / nuts and remove ECM.
  2. Installation is made upside-down. Track correctness of connection and reliability of fixing of electroconducting. Sockets differ from each other on a design, the plait is connected to a back nest, going of the left part of an impellent compartment.

Electronic module of management of TNVD

The module of management of TNVD is located in a back part of pump assembly.

 PERFORMANCE ORDER

  1. 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. Be appropriated for the car and disconnect electroconducting from the management module.
  1. Turn out fixing bolts and remove the management module.
  1. Installation is made upside-down.

Safety electromagnetic valve of system of a turbo-supercharging

 PERFORMANCE ORDER

  1. 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. Operating according to the instructions stated above (see. The electronic module of management of TNVD), remove the module of management of TNVD.
  3. Disconnect from the valve a vacuum tube and electroconducting.
  4. Turn out two fixing bolts and remove the electromagnetic valve.
  5. Installation is made upside-down. Track reliability of a tightening of fixing bolts. Pay attention to a difference of thickness of vacuum tubes, - smaller it is connected to the entrance union.

Sensor of atmospheric pressure (BARO)

The sensor is established in a back part of the block of cylinders, between TNVD and a starter.

 PERFORMANCE ORDER

  1. 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. Disconnect from the sensor electroconducting.
  1. Lift the sensor up and liberate it from a basic arm.
  1. Installation is made upside-down.

Sensor of temperature of fuel


TNVD components (model of 1.7 l of DOHC)

1 — the Drain gate
2 — the Line of return of fuel
3 — the Sensor of temperature of fuel
4 — the Line of supply of fuel

5 — the Programmed block of memory
6 — the Electromagnetic valve of management the moment of injection (PROM)
7 — the Sensor of provision of a shaft of TNVD

The sensor is established on the right at the top of TNVD assembly (see an illustration TNVD Components (model of 1.7 l of DOHC)).

 PERFORMANCE ORDER

  1. Disconnect electroconducting and turn out the sensor from pump assembly.
  1. Having replaced a sealing element, screw the sensor in TNVD and reliably tighten a nut.
  1. Restore initial connection of electroconducting.

Sensor of provision of a shaft of TNVD

The sensor is located sideways on TNVD assembly (see an illustration TNVD Components (model of 1.7 l of DOHC)) and in an individual order on the market of spare parts is not delivered, in case of need address for consultations to experts firm HUNDRED Opel.

Sensor of the moment of the beginning of injection

The sensor is under TNVD, is closer to a flywheel / to a driving disk and in an individual order on the market of spare parts is not delivered, in case of need address for consultations to experts firm HUNDRED Opel.

Electromagnetic locking valve

The valve is established in the top part of TNVD, is closer to a flywheel / to a driving disk and in an individual order on the market of spare parts is not delivered, in case of need address for consultations to experts firm HUNDRED Opel.

Models of 2.0 liters

Sensor of measurement of weight of air (MAF)

The sensor of temperature of soaked-up air (IAT) is built in the MAF sensor.

See above Models of 1.7 l of SOHC, corresponding subsection.

Sensor of provision of a pedal of an accelerator

See above Models of 1.7 l of SOHC, corresponding subsection.

Sensor of provision of a cranked shaft (CKP)

 PERFORMANCE ORDER

  1. Turn out fixing screws and remove a plastic protective casing from the top part of a head of cylinders a plastic cover from above heads of cylinders.
  2. For the purpose of ensuring adequate access to the sensor 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.
  1. Walk on an electroconducting plait from the sensor to the contact socket of electroconducting. Liberate the socket from a basic arm and disunite it.
  1. Wipe an engine surface round the sensor, then turn out a fixing bolt and remove the sensor from a forward part of the block of cylinders, remove a sealing ring.
  1. Installation is made upside-down. Do not forget to replace a sealing ring, track, that the fixing bolt was tightened with demanded effort.

The sensor of temperature of cooling liquid (ECT)

The sensor will screw on the right in a forward part of a head of cylinders, 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.

Sensor of pressure of pressurization

 PERFORMANCE ORDER

  1. Turn out fixing screws and remove a plastic protective casing of the engine.

  1. Turn out screws of fastening of a route trench of electroconducting to the top part of the inlet pipeline and disconnect from the sensor electroconducting.
  1. Turn out a fixing bolt and remove the sensor from the top part of the inlet pipeline, - pay attention to the sealing ring planted on a shaft.
  2. Installation is made upside-down. Do not forget to replace a sealing ring, track, that the fixing bolt was tightened with demanded effort.

Sensor of temperature of oil

 PERFORMANCE ORDER

  1. 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. Merge impellent oil (see. Head Routine maintenance), - on termination of procedure do not forget to screw into place a drain stopper of the pallet with a new sealing washer and to tighten it with demanded effort.
  1. Disconnect electroconducting and turn out the sensor from a forward part of the pallet of a case.
  1. Installation is made upside-down.
  2. In summary fill in in the engine fresh oil (see. Head Routine maintenance).

Electronic module of engine management (ECM)

Before removal of ECM make its decoding in the conditions of a car-care center workshop.

See above Models of 1.7 l of SOHC, Sensor of emergency pressure of oil.

Electronic module of management of TNVD

The module of management of TNVD is built in pump assembly. Originators of the real Management do not recommend to make attempt of dismantle of the module.

Electromagnetic valve of switching of the inlet pipeline


The scheme of laying of vacuum lines on models of 2.0 l with a high-pressure head turbo-supercharging

1 — the Electromagnetic valve of control of pressure of pressurization
2 — the Actuation mechanism of management of pressure of pressurization
3 — the Vacuum pump
4 — the EGR Valve

5 — the Electromagnet of management of functioning of the valve of switching of the inlet pipeline
6 — the Valve of switching of the inlet pipeline
7 — the EGR Valve

On the engine two valves are established: valve of a retsirkulyatsiya of exhaust gases (EGR) and valve of switching of the inlet pipeline. The last is established closer to a forward part of the car (see an illustration the Scheme of laying of vacuum lines on models of 2.0 l with a high-pressure head turbo-supercharging).

 PERFORMANCE ORDER

  1. Disconnect from the valve electroconducting and vacuum hoses, turn out fixing screws and remove the valve from a basic arm.
  2. Installation is made upside-down.

Electromagnetic safety valve of system of a turbo-supercharging

The electromagnetic valve is established in the right back corner of an impellent compartment.

 PERFORMANCE ORDER

  1. For the purpose of ensuring access to the valve of receiving access to the valve remove an inlet air line (assembled with the MAF sensor), conducting from an air purifier to a turbokompressor.
  2. Disconnect from the valve electroconducting and vacuum hoses, turn out fixing screws and remove the valve from a basic arm.
  3. Installation is made upside-down.