vauxhall Workshop Repair Guides

Vauxhall Workshop Service and Repair Manuals

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Check crankshaft end play > < Replace crankshaft seal ring (front)

Astra H

Crankshaft, Remove and Install

  Remove

1.   Detach transmission from engine
•   with manual transmission
•   with automatic transmission LUREF_1.gif
2.   Detach ribbed V-belt
3.   Remove torsional vibration damper (1)
•   Unscrew 4x bolts
Note:   Counterhold toothed belt drive gear at bolt (2)
Object Number: 7360963 Size: DEFAULT


4.   Remove ribbed V-belt guide roller (1)
•   Unscrew bolt
Object Number: 7360964 Size: DEFAULT


5.   Remove toothed belt cover
•   Unscrew 6x bolt (arrows)
•   4x unclip camshaft sensor wiring harness
Object Number: 2408169 Size: DEFAULT


6.   Remove engine damping block adapter (1)
•   Unscrew 5x bolts
Note:   Note different bolt lengths
Object Number: 7360966 Size: DEFAULT


7.   Set cylinder no. 1 to TDC of combustion stroke
Note:   The mark on the camshaft sprocket (1) must align with the mark on the cylinder head cover (2).
Object Number: 2408170 Size: DEFAULT


8.   Remove toothed belt (1)
•   Slacken the toothed belt tension roller
– Loosen bolt (2)
Object Number: 2408566 Size: DEFAULT


9.   Turn engine by 180°
•   With KM-412-A
10.   Vehicles with manual transmission: remove clutch LUREF_1.gif
11.   Remove KM-6263
•   Turn rotating spindle back to initial position
•   Remove centring drift
•   Unscrew 4x bolts
•   Remove KM-6263
12.   Attach EN-46792 (1)
•   Tighten bolt
13.   Vehicles with manual transmission: remove flywheel
•   Unscrew 6x bolt (2)
•   Remove EN-46792
– Unscrew bolt
Object Number: 8125646 Size: DEFAULT


14.   Vehicles with automatic transmission: remove drive disc
•   Unscrew 6x bolts (1)
•   Remove EN-46792 (2)
– Unscrew bolt
Object Number: 9007527 Size: DEFAULT


15.   Place collecting basin underneath.
16.   Drain engine oil
•   Loosen oil drain bolt
Note:   Unscrew the oil drain bolt slowly until the oil drain hole is open
•   Drain engine oil
•   Unscrew oil drain bolt
•   Tighten oil drain bolt
– Replace seal
17.   Disconnect residual oil quantity sensor wiring harness plug (1)
18.   Detach engine vent return hose (2)
•   Release clamp
Object Number: 3446072 Size: DEFAULT


19.   Detach vacuum line (2) from oil dipstick guide tube (1)
•   Unclip 2x clips
20.   Detach oil dipstick guide tube from oil pan
•   Unscrew bolt (arrow)
Object Number: 7360944 Size: DEFAULT


21.   Remove oil pan
•   Unscrew 10x bolts (M8) with EN-46796
•   Unscrew 4x bolt (M6) with EN-46794
22.   Attach EN-46730 (1) in conjunction with KM-956-1 (2) to toothed belt drive gear
•   Tighten 4x bolts
23.   Detach toothed belt drive gear
•   Unscrew bolt
Note:   Left-handed thread
•   Counterhold with EN-47630 in conjunction with KM-956-1
•   Remove toothed belt drive gear with EN-47630
Object Number: 3446076 Size: DEFAULT


24.   Remove ribbed V-belt tensioner (1)
•   Tension ribbed V-belt tensioner with KM-913-A
•   Remove KM-6349
•   Unscrew bolt (2)
Object Number: 2406321 Size: DEFAULT


25.   Remove oil pump
•   Detach oil intake pipe
– Unscrew bolt
•   Unscrew 8x bolt (arrows)
•   Remove crankshaft seal ring (1)
Object Number: 7361608 Size: DEFAULT


26.   Remove bracket for rear crankshaft seal ring (2)
•   Unscrew 5x bolts (1)
Object Number: 7360327 Size: DEFAULT


27.   Detach 4x con-rod bearing cap (2) with con-rod bearing shell
•   Unscrew 8x bolts (1)
Note:   Note identification mark on con-rod bearing cap and con-rod. Apply identification mark if not present
Object Number: 8125502 Size: DEFAULT


28.   Remove 5x crankshaft bearing cap with crankshaft bearing shell
•   Release 10x bolt in the order shown (1 - 10)
Note:   Note marking on crankshaft bearing cap
Object Number: 8125503 Size: DEFAULT


29.   Remove crankshaft
Note:   Place crankshaft on wooden blocks
30.   Remove 5x crankshaft bearing shell from cylinder block
31.   Remove wearing rings
Object Number: 8125504 Size: DEFAULT


32.   Detach crankshaft pulse pick-up disc (1)
•   Unscrew 3x bolts (2)
Object Number: 8125505 Size: DEFAULT


  Install

33.   Clean 3x threads
34.   Install crankshaft pulse pick-up disc
•   Tighten 3x bolts
Note:   Insert bolts with bolt locking compound (red).
35.   Replace 8x con-rod bearing shell
•   4x con-rod bearing cap
•   4x con-rod big end
36.   Replace 10x crankshaft bearing shell
•   5x crankshaft bearing cap
•   5x cylinder block
37.   Insert 2x wear ring
•   Coat with engine oil
•   Oil grooves point outwards
Important:   Check installation position
38.   Insert crankshaft
•   Coat crankshaft journal with engine oil
Note:   Ensure that the bearing shells and wearing rings are correctly seated
Important:   Note installation position. Lug points to intake side
39.   Install 5x crankshaft bearing cap
•   Tighten 10x new bolt in depicted sequence (1 – 10) 25 Nm + 100°
Object Number: 8125506 Size: DEFAULT


40.   Install 4x con-rod bearing cap with con-rod bearing shell
•   Tighten 8x new bolt 25 Nm + 60°
Note:   Note identification on con-rod bearing cap and con-rod.
41.   Clean 5x threads
42.   Install new bracket, rear crankshaft seal ring
•   Tighten 5x bolt 9 Nm
Note:   Clean thread before re-using and insert bolt with locking compound (red). The maximum installation time including torque check is 10 minutes.
43.   Clean 8x threads
Important:   Before fastening, align oil pump housing with sealing surfaces of the oil pan on the cylinder block
44.   Install oil pump
•   Replace crankshaft seal
•   Insert new gasket
•   Tighten 7x bolt (arrows) 9 Nm
Note:   Clean thread before re-using and insert bolt with locking compound (red). The maximum installation time including torque check is 10 minutes.
•   Tighten stud bolt (1) from EN-46788
•   Install oil intake pipe
– Tighten bolt
Object Number: 8125507 Size: DEFAULT


45.   Install oil pump seal ring with EN-46793 (1)
Object Number: 3446078 Size: DEFAULT


46.   Install ribbed V-belt tensioner
•   Tighten bolt 50 Nm
47.   Replace toothed belt drive gear
Note:   Note locking
•   Put on with EN-47630
•   Tighten bolt 340 Nm
Note:   Left-handed thread
•   Counterhold with EN-47630
48.   Detach EN-46730 in conjunction with KM-956-1 from toothed belt drive gear
•   Unscrew 4x bolts
49.   Clean sealing surfaces.
•   Oil pan
50.   Apply sealant
Important:   Complete assembly work within 10 minutes
•   Apply sealant to oil pan sealing surface
51.   Install oil pan
•   Tighten 10x bolt (M10) 25 Nm
•   Tighten 4x bolt (M6) 9 Nm
52.   Attach oil dipstick guide tube to oil pan
•   Replace seal
•   Tighten bolt
53.   Attach engine vent return hose
•   Fasten clamp
54.   Connect residual oil sensor wiring harness plug
55.   Clean 6x threads
56.   Vehicles with manual transmission: install flywheel
Note:   Note guide sleeves
•   Attach EN-46792
•   Tighten 6x new bolt 160 Nm
Note:   Insert bolt with locking compound (red). The maximum installation time including torque check is 10 minutes.
57.   Vehicles with automatic transmission: install drive disc
•   Attach EN-46792
•   Tighten 6x new bolt 160 Nm
58.   Attach KM-6263
Important:   Fasten KM-6263 but only to engine block, not to oil pan
•   Tighten 4x bolts
•   Insert clutch pin KM-6263-30 with KM-6263-22
59.   Install clutch
60.   Turn engine by 180°
•   With KM-412-A
61.   Remove toothed belt tightening roller
•   Unscrew bolt
62.   Clean the thread
63.   Install toothed belt tension roller
•   Insert tension roller in guide
•   Screw in bolt
Note:   Insert bolt with locking compound (red). The maximum installation time including torque check is 10 minutes.
64.   Set cylinder no. 1 to TDC of combustion stroke
Note:   The mark on the camshaft sprocket must align with the mark on the cylinder head cover.
65.   Install toothed belt
•   Observe prescribed direction of rotation
Important:   Tightened end (1) must be taut
•   Position toothed belt
66.   Tension the toothed belt
•   Screw in bolt (6)
•   Tension toothed belt tension roller
Note:   Push adjusting lever in direction of arrow with a screwdriver (5) until pointer (4) of toothed belt tension roller aligns with mark (2).
•   Tighten bolt, toothed belt tension roller (3) 25 Nm
Object Number: 2408567 Size: DEFAULT


67.   Check crankshaft setting with EN-46788
•   Unscrew oil pump bolt (arrow)
•   Tighten stud bolt (1) EN-46788
•   Attach positioning disk (4) EN-46788
– Screw in bolt (3)
– Screw in nut (2)
•   Remove positioning disk EN-46788
Object Number: 3446087 Size: DEFAULT


68.   Timing, Check
•   Turn crankshaft 720° in the direction of rotation of the engine
•   Check camshaft position
– The mark on the camshaft sprocket must align with the mark on the cylinder head cover.
69.   Install engine damping block adapter
Note:   Note differing bolt lengths.
•   Tighten 3x bolt (M10) 50 Nm
•   Tighten 2x bolt (M8) 25 Nm
70.   Install toothed belt cover
•   Tighten 4x bolt 9 Nm
•   Tighten 2x bolt 25 Nm
•   4x clip in camshaft sensor wiring harness
71.   Install ribbed V-belt guide roller
•   Tighten bolt 25 Nm
72.   Install torsional vibration damper
Note:   Observe correct fitting position
•   Tighten 4x bolt 25 Nm
Note:   Counterhold toothed belt drive gear at bolt
73.   Attach ribbed V-belt
74.   Attach transmission to engine
•   with manual transmission
•   with automatic transmission LUREF_1.gif
75.   Replenish and correct engine oil

Check crankshaft end play > < Replace crankshaft seal ring (front)