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
   - Systems of release and decrease in toxicity of the fulfilled gases
      System of production of the fulfilled gases - the general information, removal and installation
      Systems of decrease in toxicity of the fulfilled gases - the general information
      Check of serviceability of functioning and replacement of components of systems of 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




Systems of release and decrease in toxicity of the fulfilled gases

System of production of the fulfilled gases - the general information, removal and installation

General information


Design of system of production of the fulfilled gases of models of 1.2 l

1 — the Catalytic converter
2 — the Flexible insert
3 — the Intermediate exhaust silencer (resonator)
4 — Termozashchitny the screen

5 — Flange connection
6 — the Main exhaust silencer
7 — Termozashchitny the screen
8 — Homutnoye connection


Design of system of production of the fulfilled gases of models 1.4, 1.6 (SOHC) and 1.7 l

1 — the Catalytic converter
2 — the Flexible insert
3 — the Intermediate exhaust silencer (resonator)
4 — Termozashchitny the screen

5 — Flange connection
6 — the Main exhaust silencer
7 — Termozashchitny the screen
8 — Homutnoye connection


Design of system of production of the fulfilled gases of models 1.6 (DOHC), 1.8 and 2.0 l

1 — the Catalytic converter
2 — the Flexible insert
3 — the Intermediate exhaust silencer (resonator)
4 — Termozashchitny the screen

5 — Flange connection
6 — the Main exhaust silencer
7 — Termozashchitny the screen
8 — Homutnoye connection

The system of production of the fulfilled gases of all considered models consists of three sections: reception, average (intermediate) and back. Basic elements of system are: a reception pipe, the catalytic converter, exhaust silencers (intermediate and main), connecting tubular sections, fixing collars, and also basic arms and rubber loops by means of which final assembly is suspended to the car bottom (see illustrations the Design of system of production of the fulfilled gases of models of 1.2 l, the Design of system of production of the fulfilled gases of models 1.4, 1.6 (SOHC) both 1.7 l and the Design of system of production of the fulfilled gases of models 1.6 (DOHC), 1.8 and 2.0 l). Sections of system are interfaced among themselves by means of one homutny connection (forward section with intermediate) and one flange (intermediate section with back). Joint of average and back sections of system подпружинен that allows to compensate arising during car movement люфт, for the purpose of decrease in level of vibrations the reception section of system usually joins a flexible insert. The wrong installation of components and sections of system leads to increase of level of noise and the vibrations transferred to a body of the car.

Regularly examine all system on existence of traces of corrosion, deformations and mechanical damages. Check reliability of a tightening of fixture. Violation of tightness of components and their joints is fraught with hit of the fulfilled gases in car salon. Defective components and sections are subject to replacement.

At strong damage of system by corrosion for undocking of its sections the gas cutting torch (it is alternatively possible to use a hacksaw on metal or a pneumatic chisel - do not forget to put on goggles and gloves) can be demanded.

Repair of system should be made in the following order:

 PERFORMANCE ORDER

  1. At removal of components move along a system path in the direction from an exhaust pipe to the engine.
  2. Fixture subject to an otpuskaniye previously oil the getting.
  3. Beforehand prepare necessary replaceable laying, pendant loops, collars and fixture.
  4. Before installation grease a carving part of fixture with anti-taking hermetic.
  5. At installation of components watch, that between sections of system and nearby elements of a suspension bracket / body there was a sufficient gap. Special attention give to correctness of installation and reliability of fastening of the thermofilter of the catalytic converter.

Removal

Each section of system can be dismantled separately. Also there is a possibility of removal of all final path assembled. Even if only separate section needs replacement, it is simpler for dismantling after preliminary removal of all assembly.

 PERFORMANCE ORDER

  1. To Poddomkratta a car front also establish it on props (at the corresponding equipment of a platform it is possible to tire out the car on a platform or a viewing hole). At the corresponding complete set remove protection of a case.

Reception section

Petrol models

Models with SOHC engines

 PERFORMANCE ORDER

  1. Turn out podpruzhinenny bolts of a flange of fastening of a pipe to a final collector.
  2. Release a collar of fastening of a reception pipe to average section. Remove sealing laying. Separate a pipe from average section and take it from under the car.

Models with engines 1.4 and 1.6 of l of DOHC

 PERFORMANCE ORDER

  1. Turn out bolts of a flange of fastening of a pipe to a final collector.
  1. Give a nut of fastening of a reception pipe to a basic arm, remove a washer, the plug and a rubber support.
  1. Release a fixing collar, separate a reception pipe from intermediate section and take it from under the car. Remove sealing laying of a flange joint with a final collector.

Models with engines 1.8 and 2.0 of l of DOHC

 PERFORMANCE ORDER

  1. Walk on electroconducting from a lambda probe to the socket and disunite the last, - try to remember an order of laying of a plait. Need for removal of the sensor is absent, - the pipe can be removed assembled with it.
  1. Turn out bolts of flange connection of a reception pipe to a final collector.
  1. Give nuts of fastening of a reception pipe to a basic arm and remove an assembly plate.
  2. Release a fixing collar, separate a reception pipe from intermediate section and take it from under the car. Remove sealing laying of a flange joint with a final collector.

Diesel models

The structure of reception section includes the catalytic converter.

 PERFORMANCE ORDER

  1. Release a collar of fastening of a reception pipe to average section of system of release.
  1. Separate a reception pipe from turbokompressor assembly, remove sealing laying.
  1. Separate a reception pipe from average section and take it from under the car.

Average section

All models

 PERFORMANCE ORDER

  1. Release a collar of fastening of average section to a reception pipe and give podpruzhinenny bolts of fastening it to a back part.
  1. Remove average section with rubber подвесов, disconnect it from a reception pipe and back section and take it from under the car.

Back section

All models

 PERFORMANCE ORDER

  1. Turn out podpruzhinenny bolts of flange connection of back section with average.

    A — Flange connection of fastening of average section of system of production of the fulfilled gases to back section
    B — Rubber подвесы basic arms of back section of system of release

A.

B.
  1. Remove back section with rubber подвесов and separate it from intermediate section, - sealing laying is subject to replacement without fail.

Release system assembled

Models with SOHC engines

 PERFORMANCE ORDER

  1. Turn out podpruzhinenny bolts of flange connection of a reception pipe with a final collector.
  2. Remove system with rubber подвесов and take it from under the car, sealing laying of flange connection is subject to replacement without fail.

Models with engines 1.4 and 1.6 of l of DOHC

 PERFORMANCE ORDER

  1. Give nuts of fastening of a reception pipe to a basic arm, remove an assembly plate / washer and a rubber support.
  2. Turn out bolts of fastening of a reception pipe to a collector, remove sealing laying, - at assembly laying is subject to replacement without fail.
  3. Remove system with rubber подвесов, lower and take from under the car.

Models with engines 1.8 and 2.0 of l of DOHC

 PERFORMANCE ORDER

  1. Walk on electroconducting from a lambda probe to the socket and disunite the last, - try to remember an order of laying of a plait. Need for removal of the sensor is absent, - the pipe can be removed assembled with it.
  2. Give nuts of fastening of a reception pipe to a basic arm, remove an assembly plate / washer and a rubber support.
  3. Turn out bolts of flange connection of a reception pipe with a final collector, remove sealing laying, - at assembly laying is subject to replacement without fail.
  4. Remove system with rubber подвесов, lower and take from under the car.

Thermofilters

Screens fasten to the car bottom various nuts and bolts. Removal of screens is made after preliminary dismantle of the corresponding section of system of release. If removal is made for the purpose of ensuring access to located under it an element, it will be rather simple to release fixture and to lower a screen guard down.

Installation

Each section is established as it should be, the return to an order of its dismantle. Pay attention to the next moments:

 PERFORMANCE ORDER

  1. Before installation carefully smooth out interfaced surfaces of sections, prepare replaceable sealing laying.
  2. Check a condition rubber подвесов, defective components replace.
  3. If interface of sections is made without application of sealing laying, miss the mark a joint with special hermetic.
  4. Before a tightening of fixture make sure that the system is fixed in all подвесах, and its components do not adjoin to body elements and details of a suspension bracket of the car.