vauxhall Workshop Repair Guides

Vauxhall Workshop Service and Repair Manuals

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Check engine pressure loss > < Remove and install automatic transmission with torque converter from engine

Astra H

Repair Engine Using An Engine Short Block (Z16XE1)

  Remove

1.   Remove engine
2.   Remove transmission from engine
1. Manual transmission LUREF_1.gif
2. MTA manual transmission LUREF_1.gif

3.   Place collecting basin underneath.
4.   Drain engine oil
•   Open drain bolt
•   Tighten drain bolt 14 Nm
5.   Detach ribbed V-belt (1)
•   Mark direction of rotation
•   Apply tension to ribbed V-belt tensioner (2) in the direction of the arrow and fix with KM-6130 (3)
Object Number: 2412799 Size: DEFAULT


6.   Detach alternator
•   Disconnect alternator from power supply
– Unscrew 2x nuts (1) and (2)
•   Unscrew 2x bolts (3) and (4)
Object Number: 2412800 Size: DEFAULT


7.   Detach starter
•   Detach cable (1) and (2)
– Unscrew 2x nuts
•   Disconnect earth cable (3)
•   Unscrew 2x fastening bolt (4) and (5)
Object Number: 2412801 Size: DEFAULT


8.   Detach intake manifold support
•   Unscrew 2x bolts
9.   Detach wiring harness bracket (1) from cylinder block
•   Unscrew 2x bolts (2) and (3)
Object Number: 2412802 Size: DEFAULT


10.   Detach intake manifold
11.   Detach engine transport shackle, intake side
•   Unscrew bolt
12.   Detach engine transport shackle, exhaust side
•   Unscrew bolt
13.   Detach exhaust gas recirculation metal tube (2)
•   Unscrew 4x bolt (1) and (3)
Object Number: 2412804 Size: DEFAULT


14.   Detach exhaust manifold
15.   Take out oil dipstick guide tube
16.   Remove coolant pipe (1)
•   Unscrew 5x bolts (2), (3) and (4)
Object Number: 2412807 Size: DEFAULT


17.   Detach coolant flange (3)
•   Detach bracket (1)
– Unscrew 2x bolt (2)
•   Unscrew 4x bolts (4) and (5)
Object Number: 2412808 Size: DEFAULT


18.   Block flywheel using KM-652
19.   Remove ribbed V-belt tensioner (3)
Note:   Ribbed V-belt tensioner remains locked with KM-6130
•   Unscrew bolt (4)
20.   Detach toothed belt cover (top) (1)
•   Unscrew 2x bolts (2)
21.   Detach torsional vibration damper (5)
•   Unscrew bolt (6)
Object Number: 2412809 Size: DEFAULT


22.   Detach lower part of toothed belt cover (7)
•   Unscrew 4x bolts (6)
23.   Stop toothed belt tensioner
•   Apply tension in the direction of the arrow with an Allen key (1) and lock with KM-6333 (4)
24.   Remove toothed belt (5)
•   Mark direction of rotation
25.   Detach toothed belt tensioner (2)
•   Unscrew bolt (3)
Object Number: 2412811 Size: DEFAULT


26.   Detach right engine damping block support
•   Unscrew 3 bolts
27.   Remove DIS-ignition module
•   Remove cover of DIS-ignition module in the direction of the arrow
Note:   Note arrow on cover
•   Unscrew 2x bolts
•   Remove from spark plugs using KM-6009 (1)
Object Number: 2412812 Size: DEFAULT


28.   Detach cylinder head cover (1)
•   Unclip wiring trough
•   Unlatch and remove engine vent pipe
•   Slacken 3x bolt (3) pull upwards and fix in this position with adhesive tape
•   Slacken 6x bolts (2)
Note:   Care should be taken that the area of the front camshaft bearing caps (arrows) is clean and free from remains of sealant
Object Number: 2412908 Size: DEFAULT


Important:   Remove cylinder head only when engine is cold (room temperature)
29.   Remove cylinder head
•   Unscrew 10x bolt
Note:   Unfasten bolts in the order shown
– Undo 10x bolts (90°)
– Undo 10x bolts (180°)
Object Number: 2412813 Size: DEFAULT


30.   Remove cylinder head
Note:   Second mechanic
•   Lay cylinder head on suitable base
•   Remove cylinder head gasket
Important:   Remove gasket residue and clean sealing surfaces. Do not use sharp metal tools. Take care not to damage the sealing surfaces of the cylinder head
31.   Check for plane surface
•   Use a straight edge to check the cylinder head and cylinder block lengthwise, widthwise and diagonally for distortion
Object Number: 2417952 Size: DEFAULT


32.   Remove cylinder head
Note:   Second mechanic
•   Lay cylinder head on suitable base
•   Remove cylinder head gasket
33.   Detach thrust plate and clutch disk LUREF_1.gif
34.   Remove flywheel
•   Unscrew 6x bolts
•   Remove KM-652
35.   Release flywheel lock
•   KM-652
36.   Rotate engine on engine overhaul stands through 180°
37.   Loosen oil pan
•   Remove 3x bolt (arrows) from transmission
•   Remove 15x bolts (arrows) from engine block
Object Number: 8230685 Size: DEFAULT


38.   Detach toothed belt guide roller (1)
•   Unscrew bolt (2)
39.   Remove pump module
•   Unscrew 8x bolts (3) and (4)
Note:   Note different screw lengths
•   Remove gasket
Object Number: 2412815 Size: DEFAULT


40.   Detach knock sensor (3)
•   Unscrew bolt
41.   Detach oil pressure switch (2)
42.   Remove crankshaft sensor (1)
•   Unscrew bolt
Object Number: 2412816 Size: DEFAULT


  Install

43.   Emboss engine number
•   Onto flattened area on cylinder block (arrow) with numbers punches
Object Number: 2412818 Size: DEFAULT


44.   Clean sealing surfaces.
45.   Clean 15x threads
46.   Apply an approx. 3.5 mm thick bead of oil pan sealant to the joints (arrows)
Object Number: 8231010 Size: DEFAULT


Object Number: 8231009 Size: DEFAULT

47.   Apply oil pan sealant to the oil pan
Note:   The assembly time including torque check must take no longer than 10 min•
•   Apply an approx. 3.5 mm thick bead of oil pan sealant (1) as illustrated

48.   Install oil pan
•   Tighten 15x bolt on cylinder block and pump module 10 Nm
•   Tighten 3x bolt on transmission 40 Nm
49.   Attach crankshaft sensor 8 Nm
50.   Attach knock sensor 20 Nm
51.   Attach oil pressure switch 20 Nm
52.   Install pump module
•   Replace gasket
Note:   Note different screw lengths
•   Tighten 8x bolt 20 Nm
53.   Insert toothed belt guide roller
•   Tighten bolt 20 Nm + 120° + 15°
54.   Fit flywheel
•   Clean 6x threads
•   Insert KM-652
•   Renew bolts
•   Tighten 6x bolt 35 Nm + 30° + 15°
– Apply screw locking compound
55.   Attach thrust plate and clutch disk LUREF_1.gif
Important:   Remove gasket residue and clean sealing surfaces. Do not use sharp metal tools. Take care not to damage the sealing surfaces of the cylinder head
56.   Check for plane surface
•   Use a straight edge to check the cylinder head and cylinder block lengthwise, widthwise and diagonally for distortion
Object Number: 2417952 Size: DEFAULT


57.   Position cylinder head
Note:   Second mechanic
•   Install cylinder head gasket
Important:   Check installation position
•   Position cylinder head
58.   Install cylinder head
•   Tighten 10x bolt 25 Nm + 90° + 90° + 90° + 45°
Note:   Note correct tightening sequence
– Use new cylinder head bolts
Object Number: 2398342 Size: DEFAULT


59.   Attach toothed belt tensioner
•   Tighten bolt 20 Nm + 120° + 15°
60.   Set crankshaft to cylinder 1 TDC of combustion stroke
•   Marking on toothed belt drive gear and timing case
61.   Position toothed belt
•   Move crankshaft in direction of engine rotation to "cylinder 1 TDC of combustion stroke" (III)
•   Position camshaft sprockets in such a way that the markings (arrows) are opposite each other
•   Attach KM-6340-Left to intake camshaft sprocket (I)
•   Insert KM-6340-Right (II)
•   Lock toothed belt tensioner with KM-6333 (IV)
•   Position toothed belt
– Note direction of travel
•   Remove KM-6333
•   Remove KM-6340
62.   Timing, Check
•   Move crankshaft by two revolutions (720°) in direction of engine rotation to "Cylinder 1 TDC of combustion stroke" mark (III)
•   Markings on the camshaft sprockets must be exactly opposite each other (I)
Object Number: 2412820 Size: DEFAULT


63.   Check valve lash and adjust if necessary LUREF_1.gif
64.   Attach toothed belt cover at the bottom
•   Tighten 4x bolt 6 Nm
65.   Fit torsional vibration damper
Important:   Use new bolt
•   Lock flywheel with KM-911 or KM-6625
•   Tighten bolt 95 Nm + 45° + 15°
66.   Attach ribbed V-belt tensioner
•   Tighten bolt 50 Nm
67.   Attach right engine damping block support
•   Tighten 3x bolt 50 Nm
68.   Attach coolant flange
•   Replace gasket
•   Tighten 4x bolt 8 Nm
69.   Attach wiring harness bracket to coolant flange
•   Tighten 2x bolt 8 Nm
70.   Install coolant pipe
•   Tighten 5x bolt 8 Nm
71.   Attach exhaust manifold
•   Use new gasket
•   Tighten 11x nut 15 Nm
72.   Attach catalytic converter support to catalytic converter
•   Tighten 2x bolt 20 Nm
73.   Install dipstick guide tube
74.   Attach heat shield to exhaust manifold
•   Tighten 3x bolt 8 Nm m
75.   Attach exhaust gas recirculation metal tube
•   Tighten 4x bolt 8 Nm
76.   Install intake manifold
77.   Replace gasket, cylinder head cover
•   Insert new gasket (1) in cylinder head cover
Object Number: 2412955 Size: DEFAULT


78.   Remove spark plug, cylinder 1
•   using KM-6363
79.   Install KM-6354 in spark plug thread, cylinder 1
Object Number: 2412922 Size: DEFAULT


Important:   When assembling the cylinder head cover, care must be taken that the gasket of the cylinder head cover does not become detached. An incorrectly fitted gasket in the cylinder head cover can cause serious damage to the engine
80.   Place cylinder head cover in position
•   Lift cylinder head cover via KM-6354
•   Position cylinder head cover at the rear (i)
•   Press cylinder head cover carefully downwards at the back (II)
•   Remove KM-6354 (1)
Object Number: 2412923 Size: DEFAULT


81.   Attach cylinder head cover
•   Remove adhesive tape from 3 bolts
•   Tighten 12x bolt 8 Nm
•   Attach engine vent pipe and latch
•   Clip in wiring trough
82.   Install spark plug, cylinder 1
•   using KM-6363
– Tightening torque 25 Nm
83.   Attach DIS-ignition module (1)
•   Replace 4x gasket (2)
•   Tighten 2x bolts
•   Attach DIS ignition module cover
Object Number: 2412945 Size: DEFAULT


84.   Attach engine transport shackle, exhaust side
•   Tighten bolt 25 Nm
85.   Attach engine transport shackle, intake side
•   Tighten bolt 25 Nm
86.   Attach wiring harness bracket to cylinder block
•   Tighten 2x bolts
87.   Fit starter
•   Tighten 2x bolt 25 Nm
88.   Attach alternator
•   Tighten 2x bolt 35 Nm
89.   Clip engine wiring harness to bracket
90.   Attach wiring harness bracket to cylinder head
•   Tighten 2x bolts
•   Attach wiring harness
91.   Insert ribbed V-belt
Note:   Observe direction of rotation
•   Apply tension to ribbed V-belt tensioner (2) in the direction of the arrow (anti-clockwise) and place ribbed V-belt in position (1)
– Remove KM-6130 (3)
Object Number: 2412799 Size: DEFAULT


92.   Attach toothed belt cover upper section
•   Tighten 2x bolt 4 Nm
93.   Attach transmission to engine
1. Manual transmission LUREF_1.gif
2. MTA manual transmission LUREF_1.gif

94.   Install engine
95.   Top up engine oil.
•   Check engine oil level and top up if necessary

Check engine pressure loss > < Remove and install automatic transmission with torque converter from engine