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

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Check of serviceability of functioning and replacement of components of systems of decrease in toxicity of the fulfilled gases

System of ventilation of a case (PCV)

All models

Components of system do not need special service over usual checks of a condition of hoses and their shtutserny connections according to the Schedule of routine maintenance of the car (see. Head Routine maintenance).

System of catching of fuel evaporations (EVAP) - petrol models

Check

First of all always check a condition of vacuum hoses, passableness violation, a detachment or which damage more often and it appears a system cause of failure (be verified with the scheme of laying of hoses provided on a label of VECI of your car). In case of need replace the damaged hoses. Complete diagnostics of system is possible only with use of the specialized equipment connected to the DLC socket (see. Principle of functioning of systems of injection of fuel). In default the valve of a purge and/or a coal adsorber are subject to replacement.

Replacement

Coal adsorber

The coal adsorber is established under the right forward wing of the car.

 PERFORMANCE ORDER

  1. For the purpose of ensuring adequate access to an adsorber cock the parking brake, then поддомкратьте a front of the car and establish it on props. Remove the right forward wheel.
  2. Turn out fixing screws, release clamps and remove a loker of protection of a wheel arch.
  3. Disconnect electroconducting and remove assembly of the lateral repeater of the index of the right turn (see. Head Onboard electric equipment).
  1. Give a nut of fastening of an adsorber. In an impellent compartment disconnect from an adsorber hoses, previously them having marked. Remove an adsorber from the car.
  1. Installation is made upside-down. Track correctness of connection of hoses and reliability of a tightening of fixture.

Valve of a purge of an adsorber

The valve of a purge is established in the right part of an impellent compartment, behind an air purifier.


 PERFORMANCE ORDER

  1. Switch off ignition, wring out on a clamp and disunite the contact socket of electroconducting of the valve.
  2. Disconnect from the valve hoses (try to remember an order from connection), Release clamps, separate the valve from the case of an air purifier and remove it from the car.
  3. Installation is made upside-down.

Control of composition of the fulfilled gases

Check

Catalytic converter

The diagnostic equipment for check of serviceability of a condition of the catalytic converter is expensive and the extremely difficult in operation. At emergence of suspicions on failure of the converter, drive away the car for check on car repair shop.

Each time when the car for any reason rises over the earth, examine the converter on existence of signs of mechanical damages, traces of leaks and corrosion development. Check a condition of welded seams and reliability of a tightening of flange bolts of fastening of the device to sections of system of production of the fulfilled gases. The defective catalytic converter is subject to replacement.

Despite reliability of a design of the converter, there is rather high probability of its obstruction. The simplest way of check of passableness of the converter is check with use of the vacuum gage.

 PERFORMANCE ORDER

  1. Connect the vacuum gage to a source of depression of the inlet pipeline (see. Procedures of repair of diesel engines of 1.7 l and 2.0 l without their extraction from the car).
  2. Warm up the engine to normal working temperature, transfer the selector lever to the situation "R" (models from AT), or include neutral transfer (models with RKPP) and cock the parking brake.
  3. Consider vacuum gage indications at single turns of the engine.
  4. Quickly open a butterfly valve almost against the stop, then at once release, having dumped turns to the single. Consider and write down vacuum gage indications.
  5. Repeat the described check still three times, each time writing down result.
  6. If the result of the fourth measurement appears more than on 2.54 mm of mercury. below the instrument read at single turns, therefore, there is a probability of violation of passableness of the converter, or the exhaust silencer.

Lambda probe (the oxygen sensor)

 PERFORMANCE ORDER

  1. Find the electric socket of the sensor. From a reverse side of the socket enter the unbent writing paper clip into a nest of contact of an alarm wire (the plug No. 1 [+]), the second paper clip enter into a nest of the No. plug 2 (weight). Connect to the first paper clip positive щуп the voltmeter, negative connect to a paper clip entered into the grounding plug. Cock the parking brake, transfer the AT selector lever to the situation "R", on models from RKPP choose neutral transfer. To Poddomkratta a car front also establish it on props.
  1. Start the engine and start to trace changes of alarm tension a lambda probe.

Try not to touch to warmed up with surfaces of system of production of the fulfilled gases!

  1. At the initial stage the cold sensor should develop a constant signal amplitude 0.1 — 0.2 In (a mode of the opened contour). About two minutes later the engine will reach normal working temperature and the indication of the sensor will start to hesitate in limits from 0.1 to 0.9 In (a mode of the closed contour). If the system does not pass to a mode of the closed contour, or passes with is inadmissible a big delay (the lazy sensor), replace the sensor.
  2. Check also serviceability of functioning of a heater a lambda probe. Disunite the socket of electroconducting of a probe and connect an ohmmeter between plugs of a heater (No. No. 3 and 4 plug). Nominal resistance makes 10 — 40 Ohm.
  3. Check serviceability of giving of a food on a heater. Disunite the electric socket and measure tension on it from a plait between the plug No. 4 and weight. At the included ignition (do not start the engine) the voltmeter should fix tension of the battery. If a food is absent, check an electroconducting condition on a chain site between the main relay, ECM and a lambda probe.
  4. At negative results listed above checks, replace the faulty sensor.

Replacement

Catalytic converter

The catalytic converter is among components not needing service, however, there are some moments to which the owner of as appropriate equipped car should pay attention.

  • Do not fill equipped with the catalytic converter of the car with unleaded fuel, - lead containing in it is postponed on the surfaces of the catalyst covered with rare-earth metals that in an essential measure reduces efficiency of functioning of the converter and finally can lead to a full exit it out of operation;
  • Watch serviceability of a condition of components of system of production of the fulfilled gases, regularly make necessary checks according to the Schedule of routine maintenance of the car (see. Head Routine maintenance);
  • At emergence of admissions of ignition, it is necessary to refuse using a vehicle till malfunction elimination, - not burned down fuel getting to the converter can then ignite and be at the bottom of a catalyst exit out of operation;
  • For the same reason it is necessary to refuse engine start by towage or car pushing;
  • Do not switch off ignition at high turns of the engine;
  • Do not use any additives to fuel and impellent oil, - they can contain, components harmful to the catalytic converter.
  • At emergence on an exit of system of production of the fulfilled gases of the gray loop which is a consequence of burning out of impellent oil originators of the real Management also recommend to refuse car operation (see point c);
  • Remember that the catalytic converter functions at very high working temperatures, - do not park the car on covered to a dry grass or last year's foliage platforms;
  • Remember that the catalytic converter can be easily damaged at blows, - be careful, performing any works near it;
  • Emergence of a smell of hydrogen sulfide (rotten eggs) in the first days of operation of the new car is a consequence of normal functioning of the catalytic converter, - the smell should disappear after the first several thousand kilometers of run;
  • At the serviceable car service life of the catalytic converter makes to 150 000 km. In case of decrease in efficiency of functioning the catalytic converter is subject to replacement.

The description of procedures of removal and installation of the catalytic converter – see. Removal and installation of a final collector.

Lambda probe (the oxygen sensor)

At service a lambda probe it is necessary to observe some special precautionary measures:

  • Lambda probe it is equipped tightly built in in it and the equipped contact tip with a piece of the electroconducting which attempts of a detachment can lead to an irreversible exit of the sensor out of operation;
  • Try not to allow hits in a jalousie of the sensor or its electric socket of dirt and greasing;
  • Do not use for cleaning a lambda probe any solvents;
  • Address with the sensor extremely carefully, - do not drop it and try not to shake;
  • The silicone protective cover should be put on the sensor strictly definitely not to be melted and not to break serviceability of functioning of a probe.

Models with l engines 1.4 and 1.6

 PERFORMANCE ORDER

  1. Warm up the engine to normal working temperature, muffle and disconnect a negative wire from the battery.
  1. Walk on electroconducting from the final collector of the sensor screwed in the left part to the contact socket of its electroconducting. Liberate conducting from clamps and disunite the socket.
  1. Turn out the sensor and remove it from a collector.

Try not to touch the warmed-up elements of system of production of the fulfilled gases!

  1. Installation is made upside-down. Before a vvorachivaniye grease a carving part of the sensor with heat-resistant greasing of the Opel No. 1948602/90295397 type. Tighten the sensor with demanded effort and track correctness of laying of electroconducting, - the plait should not concern warmed-up surfaces of system of release.

Models with l engines 1.8 and 2.0

 PERFORMANCE ORDER

  1. Cock the parking brake, then поддомкратьте a front of the car and establish it on props. Disconnect a negative wire from the battery.
  1. Walk on electroconducting from screwed in reception section of system of release of the sensor to the contact socket of its electroconducting at the left on a head of cylinders. Liberate conducting from clamps and disunite the socket.
  1. Turn out the sensor and remove it from the car, - the sealing ring is subject to replacement without fail.
  2. Installation is made upside-down. Before a vvorachivaniye grease a carving part of the sensor with heat-resistant greasing of the Opel No. 1948602/90295397 type. Tighten the sensor with demanded effort and track correctness of laying of electroconducting, - the plait should not concern warmed-up surfaces of system of release.

System of a retsirkulyatsiya of the fulfilled gases (EGR)

Check

All models

Exhaustive check of system can be executed only with use of the specialized equipment connected to the diagnostic DLC socket (see. Principle of functioning of systems of injection of fuel). The failed EGR valves are subject to replacement.

Replacement

EGR valve

Petrol models

 PERFORMANCE ORDER

  1. Switch off ignition, disconnect from the valve electroconducting. On the models equipped with the SOHC engine, the valve is established in an average part of the inlet pipeline, on models with DOHC engines - in its left part.
  2. Turn out fixing screws and remove the valve assembled with sealing laying.
  3. Installation is made upside-down. Do not forget to replace laying, track, that the valve was tightened with demanded effort.

Diesel models

Models with engines of 1.7 l of SOHC

 PERFORMANCE ORDER

  1. Release clamps, turn out bolts of fastening of a basic arm and lift the receiver the pressurization, connecting a turbokompressor with an interkuler.
  1. Disconnect from the EGR valve a vacuum hose, take a lock ring and remove the EGR valve from the left part of the inlet pipeline.
  1. Installation is made upside-down.

Models with engines of 1.7 l of DOHC

 PERFORMANCE ORDER

  1. Remove ECM (see. Principle of functioning of systems of injection of fuel). Turn out fixing bolts and remove the basic arm of ECM located over the EGR valve.
  2. Disconnect from the EGR valve a vacuum tube.
  3. Turn out fixing bolts and disconnect an inlet tube from the top part of the EGR valve.
  1. Rozhkov a key release the shtutserny socket of a tube of EGR on the valve.

    EGR valve (engine of 1.7 l of DOHC)
    1 — the Inlet pipeline
    2 — the EGR Valve
    3 — the Lock ring

  1. Give bolts of fastening of the EGR valve to the inlet pipeline, - try to remember the adjusting provision of basic arms fixed by the same nuts.
  1. The failed valve is subject to replacement.
  2. Installation is made upside-down.

Models with engines of 2.0 l

The valve in an individual order on the market of spare parts is not delivered and in default is replaced assembled with the top section of the inlet pipeline (see. Removal and installation of the inlet pipeline).

The electromagnetic valve of management of EGR valve functioning - diesel models

Models with engines of 1.7 l of SOHC

 PERFORMANCE ORDER

  1. Disconnect from klapanny assembly electroconducting and vacuum hoses behind on the inlet pipeline, - try to remember laying and an order of connection of lines.
  1. Turn out two fixing bolts and remove the electromagnetic valve.
  2. Installation is made upside-down.

Models with engines of 1.7 l of DOHC

 PERFORMANCE ORDER

  1. In case of need remove an air purifier and an inlet air line in the right part of an impellent compartment (see. Removal and installation of components of an inlet air path).
  1. The valve is established in the right part of the inlet pipeline. Disconnect from the valve vacuum hoses, - pay attention to a difference in their diameters.
  2. Disconnect from the valve electroconducting.
  1. Turn out two fixing bolts and remove the valve.
  1. Installation is made upside-down.

Models with engines of 2.0 l

The valve is established in a forward left part of an impellent compartment, in the neighbourhood with the valve of switching of the pipeline. And the EGR valve is back of two and can be identified on black color of electroconducting.

 PERFORMANCE ORDER

  1. Disconnect from the valve electroconducting and vacuum hoses. Turn out fixing screws and remove the valve from a basic arm, - try to remember the adjusting provision of components.
  2. Installation is made upside-down.