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 the inlet pipeline

Models of 1.7 l of SOHC

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

 PERFORMANCE ORDER

  1. Disconnect a negative wire from the battery.
  2. In case of need remove the case of an air purifier and inlet air lines with the MAF sensor (see. Removal and installation of components of an inlet air path).
  3. On models with a right-hand steering remove the generator (see. Head engine Electric equipment).
  4. Remove a final collector (see. Removal and installation of a final collector).
  1. Disconnect electroconducting from the sensor of pressure of pressurization established on the inlet pipeline.
  1. Give fixing nuts and remove the inlet pipeline from a head of cylinders together with sealing laying.
  2. Make sure of absoluteness of purity and dryness of interfaced surfaces of a head of cylinders and the inlet pipeline and plant on pipeline hairpins new laying.
  3. Establish the pipeline on regular and screw nuts of its fastening. In a diagonal order in stages evenly tighten nuts with demanded effort.
  4. Connect electroconducting to the pressurization sensor.
  5. Make sure of absoluteness of purity and dryness of interfaced surfaces of a final collector and a head. Establish a collector (see. Removal and installation of a final collector).
  6. On models with a right-hand steering establish into place the generator (see. Head engine Electric equipment).
  7. Establish inlet air lines and the air purifier case with the MAF sensor (see. Removal and installation of components of an inlet air path).
  8. Connect a negative wire to the battery.

Models of 1.7 l of DOHC

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

 PERFORMANCE ORDER

  1. Disconnect a negative wire from the battery.
  1. Lift up lock rychazhka of clamps and disunite two contact sockets of electroconducting of ECM.
  1. Give fixing nuts / bolts and remove ECM.
  2. Release fixture and disconnect an inlet air line from a tube connecting the MAF sensor to a turbokompressor.
  3. Turn out bolts of fastening of a basic arm of a tube of pressurization to the left side of the case of the gas-distributing mechanism and the EGR valve.
  4. Turn out bolts of fastening of a tube of EGR to a final collector and the left side of the GRM case. Release the socket of big shtutserny connection on the EGR valve and lift the receiver.
  5. Give shtutserny nuts and remove fuel tubes of nozzles. Originators of the real Management insist on a bolt and shift otdavaniye to the right cases of a maslookhladitel (see. Head the Engine) for the purpose of ensuring adequate access to the back party of the fuel pump, - prepare for collecting spilled fuel.

At all do not bend a tube, - internal pressure in them is very high!

  1. Disconnect electroconducting and vacuum hoses from the electromagnetic EGR valve (see. Systems of release and decrease in toxicity of the fulfilled gases)
  2. Disconnect the socket of conducting of the sensor of pressure of pressurization.
  3. Liberate an electroconducting plait from intermediate clamps on the inlet pipeline, - try to remember a route of laying of a plait.
  4. Disconnect a tube of return of fuel from the top part of the inlet pipeline and TNVD.
  5. Turn out two fixing bolts and remove from the inlet pipeline the EGR valve.
  1. Turn out fixing bolts and nuts and remove back (and in case of need and a lobby) section of the inlet pipeline.


  1. Carefully smooth out interfaced surfaces of a head and the pipeline and establish new laying.
  2. Further installation is made as it should be, the return to an order of dismantle of components. Track, that all fixture was tightened evenly and with demanded effort.
  3. Make sure of reliability of a tightening of shtutserny sockets (see. A power supply system and release, Specifications), in summary check them on existence of signs of development of leaks.

Models of 2.0 l

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

 PERFORMANCE ORDER

  1. Disconnect a negative wire from the battery.
  2. On engines with a low-pressure head turbo-supercharging (X20DTL/Y20DTL) remove a metal tube and an air line connecting the inlet pipeline to a turbokompressor. On engines with high-pressure head pressurization (Y20DTH) remove an air line connecting the pipeline to an interkuler.
  1. Turn out screws of fastening of a route trench of electroconducting to the top part of the inlet pipeline. Release clamps of sockets and disconnect electroconducting from sensors of temperature, TNVD, the CKP sensor and the sensor of pressure of pressurization.
  1. Take a trench aside from the pipeline.
  1. Disconnect a vacuum tube from the EGR valve on the top part of the inlet pipeline.
  1. Carefully wipe shtutserny sockets and disconnect fuel tubes from nozzles and TNVD, - at an otpuskaniye of nuts hold reciprocal parts of TNVD sockets with the second rozhkovy key. For the purpose of minimization of losses of fuel and in order to avoid hit in a dirt power supply system at once закупорьте the open ends of fuel lines and shtutserny sockets.

    A — Otpuskaniye of a shtutserny nut of fastening of a fuel tube to a nozzle and TNVD
    C — Removal топливопроводов

A.

B.
  1. Gradually and having evenly weakened, turn out fixing bolts and carefully remove the top part of the pipeline, - sealing laying is subject to replacement without fail.
  1. For removal of the bottom section of the pipeline, disconnect a vacuum tube from diafragmenny assembly of the valve of switching of the pipeline.
  1. Turn out fastening bolts to the pipeline of a basic arm of the socket of electroconducting.
  1. Evenly and having gradually weakened, give fixing nuts and remove the bottom section of the pipeline from a head of cylinders, - sealing laying is subject to replacement without fail.
  1. Make sure of absoluteness of purity and dryness of interfaced surfaces.
  1. Lay new laying on a head of cylinders, then establish the bottom section of the pipeline. Screw new fixing nuts and in a diagonal order in stages evenly tighten them with demanded effort. Attach a hose of the valve switch establish a basic arm of electroconducting.
  1. Lay new laying on the top cut of the bottom section, and establish the top section the pipeline. Tighten with demanded effort fixing bolts.
  2. Establish fuel tubes, - track, that nuts of shtutserny sockets were tightened with demanded effort.
  3. Establish on the pipeline a route trench of electroconducting, reliably tighten fixing bolts and restore initial connection of electroconducting. Connect a vacuum tube to the EGR valve.
  4. Establish inlet an air line / tube (see. Removal and installation of components of an inlet air path). Establish on a head of cylinders a plastic protective casing.
  5. Connect a negative wire to the battery.