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Vauxhall Workshop Service and Repair Manuals

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MTA Manual Transmission from/to Engine Detach and Attach (Engine Removed) > < MTA-Manual Transmission, Remove from Engine and Install

Astra H

Repair engine using a short block

  Remove

1.   Remove engine
2.  
  • Remove manual transmission from engine LUREF_1.gif
  • Remove MTA-manual transmission from engine LUREF_1.gif
3.   Drain engine oil
•   Place collecting pan underneath.
•   Remove oil drain bolt
•   Detach oil filter housing cover
•   Take out oil filter element
4.   Detach thrust plate and clutch disk LUREF_1.gif
5.   Remove flywheel (1)
Note:   KM-6263 remains attached to the engine. To provide a clearer illustration, KM-6263 is not shown here
•   Lock with KM-652 (2)
•   Unscrew 6x bolts (3)
Object Number: 3446116 Size: DEFAULT


6.   7. Detach right hand engine bracket (1)
•   Unscrew 3 bolts
Object Number: 2411044 Size: DEFAULT


7.   8. Tighten oil drain bolt 10 Nm
•   Replace sealing ring
•   Remove collecting pan
8.   Remove ribbed V-belt
•   Mark direction of rotation
•   Apply tension to ribbed V-belt tensioner (arrow) clockwise with KM-6131
•   Insert KM-955-2 (1)
•   Relieve tension on ribbed V-belt tensioner
Object Number: 2410376 Size: DEFAULT


9.   Remove ribbed V-belt tensioner
•   Apply tension to ribbed V-belt tensioner in the direction of the arrow with KM-6131
•   Remove KM-955-2 (1)
•   Release ribbed V-belt tensioner
•   Unscrew 2x bolts (arrows)
•   Take out ribbed V-belt tensioner
Object Number: 2410378 Size: DEFAULT


10.   Detach engine wiring harness
•   Unscrew alternator wiring harness (1)
– Unscrew 2x nuts
•   Unscrew starter wiring harness
– Unscrew 2x nuts
Object Number: 2410438 Size: DEFAULT


11.   Detach alternator
•   Remove 2x screwed connections
12.   Disconnect cable connections (2) from starter (1)
•   Slacken 3x nut
13.   Unscrew 2x bolts
14.   Remove starter
Object Number: 3446313 Size: DEFAULT


15.   Detach engine management wiring harness
•   Remove cover - injectors
– Unscrew 2x bolts
•   Disconnect 11x wiring harness plugs
– Oil pressure switch (6), coolant temperature sensor (8), camshaft sensor (9), throttle valve module (2), engine control unit (12), exhaust gas recirculation valve (4), ignition module (3), oxygen sensor, mixture control (5), knock sensor (10), crankshaft sensor (11), injectors (1)
•   Detach earth cable, engine control unit (13)
– Unscrew bolt
•   Unclip wiring trough (7)
•   Unclip 4x wiring harness from brackets (14)
Object Number: 2411040 Size: DEFAULT


16.   Remove coolant hose from exhaust gas recirculation valve
•   Release clamp
17.   Remove dipstick guide tube
•   Unscrew bolt
18.   Detach coolant pump (1)
Note:   Note guide sleeves when removing
•   Place collecting pan underneath.
•   Unscrew 9x bolts
Note:   Note differing bolt lengths (arrows = short bolts)
Object Number: 2410459 Size: DEFAULT


19.   Release heat shield
•   Unscrew 2x bolts
20.   Remove oil dipstick guide tube (1)
•   Detach from exhaust manifold (3)
– Unscrew bolt (2)
•   Remove from cylinder block
Object Number: 3446266 Size: DEFAULT


21.   Detach exhaust manifold (2)
•   Unscrew 9x nuts (1)
Object Number: 3446296 Size: DEFAULT


22.   Remove engine vent hoses (2) from cylinder head cover
•   Undo 2 clamps
23.   Remove ignition module
•   Disconnect cooling module wiring harness plug (4)
•   Pull the cover of the ignition module (1) away from the cylinder head cover in the direction of the arrow
•   Unscrew 2x bolts (6)
Important:   Do not tilt
•   Remove ignition module (5) from spark plugs with KM-6009 (3)
24.   Detach cylinder head cover (7) from cylinder head
•   Unscrew 13x bolts
Object Number: 3446273 Size: DEFAULT


25.   Slacken bolt, crankshaft hub (1)
Note:   2.people
•   Attach KM-956-1/-2 (2)
Object Number: 2410469 Size: DEFAULT


26.   Adjust the camshafts
•   Turn crankshaft evenly in direction of engine rotation with KM-956-1/-2 until KM-953 (1) engages in the camshaft groove as far as the stop
27.   Detach crankshaft hub
Note:   Observe correct fitting position
•   Unscrew bolt
•   Remove KM-956-1/-2
28.   Remove oil pan
•   Turn engine (180°)
•   Unscrew 16x bolts
•   Remove oil pan gasket
Object Number: 2410671 Size: DEFAULT


29.   Remove timing case
Note:   Do not damage camshaft sensor (1)
•   Turn engine (90°)
•   Unscrew 15x bolts (arrows)
Note:   Note bolt lengths
Object Number: 2410461 Size: DEFAULT


30.   Detach chain drive
•   Slacken 2x bolts, camshaft sprocket
– Counterhold the camshafts on the hexagon
•   Lock chain tensioner (1)
– Insert KM-955-1 (2)
•   Detach sliding rail (3), guide rail (5), tension rail (7), camshaft sprockets
•   Take out timing chain (4) with drive gear (6)
•   Take out timing case gasket
Object Number: 2398446 Size: DEFAULT


31.   Remove cylinder head
•   Turn engine (90°)
•   Remove KM-953
•   Unscrew 12x cylinder head bolt
Note:   Comply with sequence illustrated
– Slacken 12x bolts (90°)
– Slacken 12x bolts 180°)
•   Place cylinder head on wooden blocks
•   Remove cylinder head gasket
Object Number: 2399430 Size: DEFAULT


32.   Detach oil filter housing
•   Unscrew 3 bolts
33.   Remove knock sensor
•   Unscrew bolt
34.   If present: detach oil baffle plate
•   Turn engine (180°)
•   Unscrew 8x bolts
35.   Remove crankshaft sensor
•   Unscrew bolt
36.   Detach cylinder block from KM-412
•   Attach KM-2358
•   Attach cylinder block to workshop crane.
•   Detach 8x bolted connections
•   Detach from cylinder block KM-412-18
– Unscrew 4x bolts

  Install

37.   Attach cylinder block to KM-412
•   Transfer KM-2358
•   Attach KM-412-18 to cylinder block
– Tighten 4x bolts
•   Remove KM-2358
38.   Emboss engine number
39.   Tap 6x guide sleeves into cylinder block
•   using KM-427
40.   Clean sealing surfaces.
•   Cylinder block, cylinder head, cylinder head cover, oil filter housing, crankshaft bearing bridge, timing case, oil pan, coolant pump. exhaust manifold
41.   Visually check components
•   Cylinder block, cylinder head, cylinder head cover, oil filter housing, crankshaft bearing bridge, chain drive, timing case, oil pan, coolant pump, exhaust manifold
42.   If the cylinder head is to be checked and overhauled: Detach all external attaching parts from cylinder head LUREF_1.gif
43.   Check flatness of cylinder head
•   With straight edge and feeler gauge
Object Number: 2410435 Size: DEFAULT


44.   Lock crankshaft
•   Unscrew closure bolt (1)
•   Insert KM-952 (2)
– Turn crankshaft evenly until KM-952 engages
Object Number: 2410470 Size: DEFAULT


45.   If present: attach oil baffle plate
•   Tighten 8x bolt 8 Nm
46.   Attach oil filter housing
•   Turn engine (180°)
•   Replace gasket
•   Tighten 3x bolt 20 Nm
•   Oil Filter Element, Replace
•   Attach oil filter housing cover
– Replace sealing ring
– Tighten cover 25 Nm
47.   Adjust the camshafts
•   Insert KM-953 (1)
– Turn the camshafts by the hexagon (arrows)
•   Remove KM-953
Object Number: 2399432 Size: DEFAULT


48.   Install cylinder head
•   Replace gasket
Note:   Marking TOP/OBEN must point upwards
•   Replace cylinder head bolts
•   Tighten 12x cylinder head bolt 25 Nm + 60° + 60° + 60 °
Note:   Note correct tightening sequence
Object Number: 2410464 Size: DEFAULT


49.   Attach timing chain
•   Attach KM-953
•   Replace timing case gasket
Note:   Note correct seating (arrows)
•   Renew bolts
•   Push on drive gear (5)
•   Position exhaust camshaft sprocket
– Screw in bolt
•   Place timing chain in position (3)
•   Insert intake camshaft sprocket in timing chain with phase sensor disc
– Screw in bolt
Note:   It must be possible to turn the phase sensor disc by hand
Object Number: 2410447 Size: DEFAULT


50.   Attach timing chain tension rail (6)
Note:   Ensure timing chain is seated correctly
•   Tighten bolt 20 Nm
51.   Attach timing chain guide rail (4)
Note:   Ensure timing chain is seated correctly
•   Tighten bolt 8 Nm
52.   Attach timing chain sliding rail (2)
•   Tighten 2x bolt 8 Nm
53.   Relieve tension on chain tensioner
•   Remove KM-955-1
Object Number: 2410447 Size: DEFAULT


54.   Attach coolant pump
•   Replace gasket (1)
•   Attach with short bolts (2)
Note:   Ensure guide sleeves are correctly seated (arrows)
– Tighten 3x bolt 8 Nm
Object Number: 2398448 Size: DEFAULT


55.   Attach timing case.
•   Screw in all bolts
Note:   Note correct tightening sequence
•   Tighten 5x bolt M6 (1) 8 Nm
•   Tighten 14x bolt M6 (2) 8 Nm
•   Tighten 2x bolt M10 (3) 35 Nm
Object Number: 2410471 Size: DEFAULT


56.   Replace front crankshaft seal ring (1)
•   Smear sealing lips with silicone grease
•   Push on to KM-960 (2)
•   Drive in flush using KM-960
57.   Remove KM-952 and KM-953
Note:   Locking tools may not be used for counterholding
Object Number: 2398447 Size: DEFAULT


58.   Attach crankshaft hub (1)
Note:   Marking must point upwards
•   Replace bolt
•   Counterhold with KM-956-1/-2 (2)
Note:   Use a second person
•   Tighten bolt 150 Nm + 45° + 15°
•   Remove KM-956-1/-2
59.   Attach crankshaft ribbed V-belt pulley
•   Tighten 6x bolt 8 Nm
– Counterhold against bolt, crankshaft hub
•   Insert KM-952
60.   Insert KM-953
Object Number: 2410469 Size: DEFAULT


61.   Attach KM-954 (1)
•   Turn phase sensor disc (2) until KM-954 can be attached to timing case
Object Number: 2410436 Size: DEFAULT


62.   Fasten camshaft sprockets
Note:   First of all tighten bolt of intake camshaft sprocket
•   Tighten 2x bolt (2) 10 Nm
Note:   Tightening torque 10 Nm serves to fix the camshaft sprockets and the phase sensor disc
– Counterhold the camshafts on the hexagon (1)
63.   Take out locking tools KM-952 , KM-953 , KM-954
64.   Tighten camshaft sprockets
Note:   First of all tighten bolt of intake camshaft sprocket
•   Tighten 2x bolt 50 Nm + 60°
– Use a second person
Object Number: 2399406 Size: DEFAULT


65.   64. Timing, Check
•   Turn crankshaft (720°)
•   Insert KM-952
•   Insert KM-953
•   attach KM-954
66.   Take out locking tools KM-952 , KM-953 , KM-954
67.   67. Install oil pan
•   Turn engine (180°)
•   Replace gasket
•   Tighten 16x bolt 10 Nm
68.   Tighten closure bolt crankshaft bearing bridge 50 Nm
•   Replace gasket
69.   Attach knock sensor
•   Tighten bolt 20 Nm
70.   Attach crankshaft sensor
•   Replace gasket
•   Tighten bolt 8 Nm
71.   Attach cylinder head cover (1)
•   Turn engine (180°)
•   Replace gasket and seal rings (2)
•   Apply sealant (dimension I = 2 mm)
– Complete assembly work within 10 minutes
•   Tighten bolts 8 Nm
•   Attach 2x engine vent hose
– Attach 2x clamps
Object Number: 2410670 Size: DEFAULT


72.   Connect ignition module to spark plugs and attach to cylinder head
•   Tighten 2x bolt 8 Nm
73.   Attach ignition module cover to cylinder head cover
74.   Insert exhaust manifold gasket
75.   Install exhaust manifold
•   Tighten 9x nut 15 Nm (2 passes)
76.   Install heat shield
•   Screw in 2x bolts
77.   Install dipstick guide tube
•   Use new seal rings
– 2 off
•   Tighten bolt
78.   Fasten heat shield
•   Tighten 2x bolts
79.   Attach engine transport shackle
•   Tighten 2x bolt 20 Nm
80.   Attach coolant hoses to coolant pump and exhaust gas recirculation valve
•   Attach 3x clamps
81.   Attach engine management wiring harness
•   Lay wiring harness
•   Connect 14x wiring harness plugs
•   Attach earth cable, engine control unit
– Tighten bolt
•   Clip on wiring trough
•   Attach wiring harness
•   Attach cover - injectors
– Tighten 2x bolts
82.   Attach starter to cylinder block
•   Tighten 2x bolt 25 Nm
83.   Attach starter wiring harness
•   Tighten 3x nuts
84.   Install alternator
•   Insert alternator into bracket
•   Tighten 2x screwed joint 35 Nm
•   Attach alternator wiring harness
– Tighten 2x nuts
85.   Attach ribbed V-belt tensioner -
•   Tighten bolt M8 20 Nm
•   Tighten bolt M10 55 Nm
•   Apply tension to ribbed V-belt tensioner in the direction of the arrow with KM-6131 (2)
– Insert KM-6130 (1)
Object Number: 2410376 Size: DEFAULT


86.   Attach ribbed V-belt pulley, coolant pump
•   Tighten 3x bolt 20 Nm
87.   Insert ribbed V-belt
•   Position ribbed V-belt
– Ensure correct running direction and installation position
•   Apply tension to ribbed V-belt tensioner with KM-6131
•   Remove KM-955-2
•   Relieve tension on ribbed V-belt tensioner
88.   Attach right hand engine bracket
•   Tighten 3x bolt 60 Nm
89.   Fit flywheel
Note:   Use new bolts
•   Clean 6x thread in crankshaft
•   Tighten 6x bolt 35 Nm + 60° + 15°
– Apply screw locking compound
– Lock with KM-652
90.   Attach thrust plate and clutch disk LUREF_1.gif
91.   Top up engine oil.
•   Observe specified engine oil quantity
92.  
  • Attach manual transmission to engine LUREF_1.gif
  • Attach MTA manual transmission to engine LUREF_1.gif
93.   Install engine

MTA Manual Transmission from/to Engine Detach and Attach (Engine Removed) > < MTA-Manual Transmission, Remove from Engine and Install