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Illustration - Coolant Hoses (Z 20 LEH) > < MTA Manual Transmission from/to Engine Detach and Attach (Engine Removed)

Astra H

Repair Engine Using An Engine Short Block (Z16XEP)

  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 engine control unit with engine control unit bracket from intake manifold
•   Detach earth cable (8)
– Unscrew bolt (9)
•   Wiring harness plugs, engine control unit (1) and (3)
– Unlatch in direction of arrow and disconnect
•   Disconnect wiring harness plug (2)
•   Detach bracket for wiring harness plug
– Unscrew 2x bolts (5)
•   Unscrew 3x fastening bolt (4), (6) and (7)
Object Number: 2412793 Size: DEFAULT


11.   Detach engine wiring harness
•   Disconnect 17x wiring harness plugs
•   Unclip wiring harness from brackets and expose
12.   Remove oil dipstick guide tube (old design) LUREF_1.gif
13.   Remove oil dipstick guide tube (new design) LUREF_1.gif
14.   Detach engine transport shackle, intake side
•   Unscrew bolt
15.   Detach engine transport shackle, exhaust side
•   Unscrew bolt
16.   Detach engine vent pipe (1) from cylinder head cover (3)
•   Unlatch fuse clamp (2)
Object Number: 2412797 Size: DEFAULT


17.   Detach intake manifold (2) from cylinder head
•   Detach coolant hose from coolant flange.
– Release clamp
•   Detach vacuum hose from intake manifold
•   Unscrew 2x bolts (1) and (3)
•   Remove gasket
Object Number: 2412798 Size: DEFAULT


18.   Detach exhaust gas recirculation metal tube (2)
•   Unscrew 4x bolt (1) and (3)
Object Number: 2412804 Size: DEFAULT


19.   Detach intake manifold flange (1)
•   Unscrew 2x nuts (2)
•   Unscrew 8x bolts (3)
– Remove gasket
Object Number: 2412805 Size: DEFAULT


20.   If present: detach wiring harness bracket (1) from cylinder head
•   Unscrew 2x bolts (2)
21.   Detach turbocharger (3) from exhaust manifold
•   Unscrew 3x bolts (4)
Object Number: 2412806 Size: DEFAULT


22.   Detach exhaust manifold (2)
•   Unscrew 11x nuts (1)
•   Detach catalytic converter support from engine block
– Unscrew 2x bolts
•   Remove gasket
Object Number: 2412790 Size: DEFAULT


23.   Remove coolant pipe (1)
•   Unscrew 5x bolts (2), (3) and (4)
Object Number: 2412807 Size: DEFAULT


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


25.   Block the flywheel
•   using KM-652 (1)
26.   Remove ribbed V-belt tensioner (3)
Note:   Ribbed V-belt tensioner remains locked with KM-6130
•   Unscrew bolt (4)
27.   Detach toothed belt cover (top) (1)
•   Unscrew 2x bolts (2)
28.   Detach incremental disc (5)
•   Unscrew bolt (6)
Object Number: 2412809 Size: DEFAULT


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


33.   Detach right engine damping block support
•   Unscrew 3 bolts
34.   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


35.   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)
36.   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


37.   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
38.   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


39.   Remove cylinder head
Note:   Second mechanic
•   Lay cylinder head on suitable base
•   Remove cylinder head gasket
40.   Detach thrust plate and clutch disk LUREF_1.gif
41.   Remove flywheel
•   Unscrew 6x bolts
•   Remove KM-652
42.   Release flywheel lock
•   KM-652
43.   Rotate engine on engine overhaul stands through 180°
44.   Possibility 1: Remove oil pan (old design)
•   Remove 2x rubber plug
•   Unscrew 3x bolt from transmission
•   Unscrew 15x bolts (arrows)
Object Number: 2412814 Size: DEFAULT


45.   Possibility 2: Release oil pan (new design)
•   Remove 3x bolt (arrows) from transmission
•   Remove 15x bolts (arrows) from engine block
Object Number: 8230685 Size: DEFAULT


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


48.   Detach knock sensor (3)
•   Unscrew bolt
49.   Detach oil pressure switch (2)
50.   Remove crankshaft sensor (1)
•   Unscrew bolt
Object Number: 2412816 Size: DEFAULT


  Install

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


52.   Clean sealing surfaces.
53.   Clean 15x threads
54.   Possibility 1 (old design oil pan), apply liquid sealant
Note:   The assembly time including torque check must take no longer than 10 min
•   Apply an approx. 2 mm thick bead of silicone sealing compound to the joints (arrows)
•   Apply a bead of silicone sealing compound approx. 2.5 mm thick (dimension I) and in the area of the rear crankshaft bearing cap a bead approx. 3.5 mm thick (dimension II)
•   In addition, apply a bead of silicone sealing compound approx. 3 mm thick (dimension III) to the oil intake pipe connection and the two oil return lines
Object Number: 2412819 Size: DEFAULT


55.   Possibility 2 (oil pan, new design): Apply a bead of silicone sealant approximately 3.5 mm thick to the joint surfaces (arrows) of the oil pan
Object Number: 8231010 Size: DEFAULT


Object Number: 8231009 Size: DEFAULT

56.   Possibility 2 (oil pan, new design): Apply oil pan sealant to 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

57.   Install oil pan
•   Tighten 15x bolt on cylinder block and pump module 10 Nm
•   Tighten 3x bolt on transmission 40 Nm
•   For old design oil pan: insert 2x rubber plug
58.   Attach crankshaft sensor 8 Nm
59.   Attach knock sensor 20 Nm
60.   Attach oil pressure switch 20 Nm
61.   Install pump module
•   Replace gasket
Note:   Note different screw lengths
•   Tighten 8x bolt 20 Nm
62.   Insert toothed belt guide roller
•   Tighten bolt 20 Nm + 120° + 15°
63.   Fit flywheel
•   Clean 6x threads
•   Insert KM-652
•   Renew bolts
•   Tighten 6x bolt 35 Nm + 30° + 15°
– Apply screw locking compound
64.   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
65.   Check for plane surface
•   Use a straight edge to check the cylinder block and cylinder head lengthwise, widthwise and diagonally for distortion
Object Number: 2417952 Size: DEFAULT


66.   Position cylinder head
•   Install cylinder head gasket
Note:   Second mechanic
Important:   Check installation position
•   Position cylinder head
67.   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


68.   Attach toothed belt tensioner
•   Tighten bolt 20 Nm + 120° + 15°
69.   Set crankshaft to cylinder 1 TDC of combustion stroke
•   Marking on toothed belt drive gear and timing case
70.   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
71.   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


72.   Check valve lash and adjust if necessary LUREF_1.gif
73.   Attach toothed belt cover at the bottom
•   Tighten 4x bolt 6 Nm
74.   Fit torsional vibration damper
Important:   Use new bolt
•   Lock flywheel with KM-911 or KM-6625
•   Tighten bolt 95 Nm + 45° + 15°
75.   Attach ribbed V-belt tensioner
•   Tighten bolt 50 Nm
76.   Attach right engine damping block support
•   Tighten 3x bolt 50 Nm
77.   Attach coolant flange
•   Replace gasket
•   Tighten 4x bolt 8 Nm
78.   Attach wiring harness bracket to coolant flange
•   Tighten 2x bolt 8 Nm
79.   Install coolant pipe
•   Tighten 5x bolt 8 Nm
80.   Attach exhaust manifold
•   Use new gasket
•   Tighten 11x nut 15 Nm
81.   Attach catalytic converter support to catalytic converter
•   Tighten 2x bolt 20 Nm
82.   Attach heat shield to exhaust manifold
•   Tighten 3x bolt 8 Nm m
83.   Install oil dipstick guide tube (old design) LUREF_1.gif
84.   Install oil dipstick guide tube (new design) LUREF_1.gif
85.   Attach intake manifold flange
•   Use new gasket
•   Tighten 8x bolt 20 Nm
•   Tighten 2x nut 20 Nm
•   Connect wiring harness plug, injectors
•   Connect wiring harness plug, PDA system vacuum unit
86.   Attach exhaust gas recirculation metal tube
•   Tighten 4x bolt 8 Nm
87.   Install intake manifold
•   Use new gasket
•   Tighten 5x bolt 8 Nm
•   Attach vacuum hose to vacuum unit of PDA system
•   Attach coolant hose to thermostat module
– Fasten clamp
88.   Install intake manifold support
•   Fasten to cylinder block
– Tighten bolt 8 Nm
•   Attach to intake manifold
– Tighten bolt 8 Nm
89.   Replace gasket, cylinder head cover
•   Insert new gasket (1) in cylinder head cover
Object Number: 2412955 Size: DEFAULT


90.   Remove spark plug, cylinder 1
•   using KM-6363
91.   Install KM-6354
•   Install KM-6354 (1)
– 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
92.   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


93.   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
94.   Install spark plug, cylinder 1
•   using KM-6363
– Tightening torque 25 Nm
95.   Attach DIS-ignition module (1)
•   Replace 4x gasket (2)
•   Tighten 2x bolts
•   Attach DIS ignition module cover
Object Number: 2412945 Size: DEFAULT


96.   Attach engine transport shackle, exhaust side
•   Tighten bolt 25 Nm
97.   Attach engine transport shackle, intake side
•   Tighten bolt 25 Nm
98.   Attach engine wiring loom
•   Attach wiring harness to rear toothed belt cover
– Clip in 7x brackets
•   Attach 9x wiring harness plug for camshaft sensor, cylinder block oil pressure sensor, cylinder head oil pressure sensor, crankshaft pulse pick-up, thermostat heating, coolant temperature sensor, EGR valve, knock sensor, engine oil level sensor
99.   Attach wiring harness bracket to cylinder block
•   Tighten 2x bolts
100.   Fit starter
•   Tighten 2x bolt 25 Nm
101.   Attach alternator
•   Tighten 2x bolt 35 Nm
102.   Attach engine control unit bracket with engine control unit
•   Tighten 3x bolt 8 Nm
•   Connect and lock engine control unit wiring harness plug
103.   Clip engine wiring harness to bracket
104.   Attach earth cable to engine control unit support
•   Tighten bolt 8 Nm
105.   Attach wiring harness bracket to cylinder head
•   Tighten 2x bolts
•   Attach wiring harness
106.   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


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

109.   Install engine
110.   Top up engine oil.
•   Check engine oil level and top up if necessary

Illustration - Coolant Hoses (Z 20 LEH) > < MTA Manual Transmission from/to Engine Detach and Attach (Engine Removed)