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Engine Flywheel Removal - 1.4L LUH, LUJ and LUV > < Camshaft Timing Chain Replacement

Astra J

Engine Replacement (1.4L LDD)

Special Tools

•  CH-904   Underframe
•  CH-49289   Centering Frame
•  CH-49290   Engine Support Tool
•  EN-6015   Closure Plugs
•  EN-34730-91   Pressure Tester

For equivalent regional tools, refer to Special Tools .

Removal Procedure

1. Remove the lower intermediate steering shaft bolt. Refer to Intermediate Steering Shaft Replacement .
2. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .
3. Remove the battery tray. Refer to Battery Tray Replacement .

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4. Remove the windshield washer solvent container filler tube (1).

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5. Remove the front compartment fuse block cover (1).

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6. Loosen the 3 front compartment fuse block bolts (1).
7. Unclip the 4 front compartment fuse block retainer clips (2) and (3) and lift the front compartment fuse block slightly up.

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Note:  The wiring harness plugs should remain in the lower part (4) of the front compartment fuse block.
8. Entirely loosen the 3 front compartment fuse block bolts (1) while lifting the front compartment fuse block until it can be removed from the 3 wiring harness plugs (3), (5) and (6).

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9. Remove the ECM wiring harness plug (1) from the lower part of the front compartment fuse block.
10. Disconnect the ECM wiring harness plug (2) and unclip it from retainer clip (3).

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11. Remove the 3 ground cable nuts (1) and put the 3 ground cables (2) aside.
12. Unclip the ECM wiring harness from body.
13. Unclip the back up lamp switch wiring harness from body.
14. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement .
15. Remove the front bumper fascia. Refer to Front Bumper Fascia Replacement .
16. Remove the front tire and wheel assembly. Refer to Tire and Wheel Removal and Installation .
17. Drain the cooling system. Refer to Cooling System Draining and Filling .
18. Disconnect the coolant level indicator module wiring harness plug. Refer to Engine Coolant Level Indicator Module Replacement .
19. Unclip the radiator surge tank. Refer to Radiator Surge Tank Replacement .
20. Put the radiator surge tank aside.
21. Remove the manual transmission shift lever and selector lever cable from the transmission. Refer to Manual Transmission Shift Lever and Selector Lever Cable Replacement .
22. Remove the heater inlet and outlet hose from the bulkhead. Refer to Heater Inlet Hose Replacement and Heater Outlet Hose Replacement .

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23. Disconnect the booster vacuum pipe (1) from the intake manifold.
24. Disconnect backup lamp switch wiring harness electrical connector and unclip from retainer clip.
25. Place collecting basin underneath the vehicle.
26. Disconnect the clutch actuator cylinder front pipe. Refer to Clutch Actuator Cylinder Front Pipe Replacement .

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Warning: Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby.


27. Remove fuel injector rail cap (1).

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28. Relieve fuel pressure. Use EN-34730-91   pressure tester (1).

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29. Remove fuel feed pipe (2) from fuel injector rail.
30. Unclip fuel feed pipe from retainer clip (1).
31. Remove fuel ventilation pipe (4) from evaporative emission canister purge solenoid valve.
32. Unclip fuel ventilation pipe from retainer clip (3).
33. Close the vents with the EN-6015   closure plugs .

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34. Remove the lower condenser hose nut (3).
35. Remove the lower condenser hose (1) and the seal ring (2).

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36. Remove the A/C compressor and condenser hose nut (1) from air conditioning evaporator hose.
37. Remove the A/C compressor and condenser hose (2) and the seal ring (3) from air conditioning evaporator hose.
38. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
39. Remove the front compartment splash shield. Refer to Front Compartment Splash Shield Replacement .
40. Remove the upper stabilizer shaft link from the absorber on both sides. Refer to Stabilizer Shaft Link Replacement .
41. Remove steering linkage outer tie rod from the steering knuckle on both sides. Refer to Steering Linkage Outer Tie Rod Replacement .
42. Remove the front lower control arm from the steering knuckle. Refer to Lower Control Arm Replacement .
43. Remove the front wheel shafts from the wheel hubs. Refer to Front Wheel Drive Shaft Replacement - Right Side and Front Wheel Drive Shaft Replacement - Left Side .
44. Disconnect the wheel speed sensors on both sides and unclip from suspension frame.
45. Remove the wheel speed sensor wiring harness retainers from the frame.

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46. Disconnect the engine coolant fan wiring harness plug (1) an unclip from suspension frame (2).
47. Disconnect the EPS wiring harness plug (3).
48. Disconnect the EPS main wiring harness plug from EPS unit.
49. Remove the exhaust front pipe. Refer to Exhaust Front Pipe Replacement .

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Note:  The SPX installation manual is supplied with the special tool and is also available online from SPX directly. Go to www.spxtools-shop.com.
50. Assemble the CH-49290   engine support tool (1) according to the details provided in the SPX installation manual.
51. Support the CH-904   base frame on a jack.
52. Support the CH-49290   engine support tool on the CH-904   base frame .

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Note:  The SPX installation manual is supplied with the special tool and is also available online from SPX directly. Go to www.spxtools-shop.com.
53. Install the CH-49290   engine support tool (1) according to the details provided in the SPX installation manual.

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54. Remove the 3 engine mount bolts (2) from the engine mount (1) and the engine mount bracket (3).

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55. Remove the 3 transmission mount bolts (2) from the transmission mount (3) and the transmission mount bracket (1).

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Note:  The SPX installation manual is supplied with the special tool and is also available online from SPX directly. Go to www.spxtools-shop.com.
56. Assemble the CH-49289   centering frame (1) according to the details provided in the SPX installation manual.
57. Support the CH-904   base frame on a jack.
58. Support the CH-49289   centring frame on the CH-904   base frame .

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Note:  The SPX installation manual is supplied with the special tool and is also available online from SPX directly. Go to www.spxtools-shop.com.
59. Install the CH-49289   centering frame (1) according to the details provided in the SPX installation manual.

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Note:  Simplified graphic. Engine/transmission unit is fixed with engine support tool to suspension frame. Suspension frame is supported by centering adapter and underframe.
60. Remove the frame front bolts (1).
61. Remove the frame rear bolts (2).
62. Remove the frame reinforcements (3).
63. Lower suspension frame (4) carefully with the engine transmission unit off the vehicle with hydraulic jack about 7 cm (2.75 in) .
64. Remove the 2 wiring harness bracket bolts from EPS unit.
65. Remove the 2 wiring harness bracket from EPS unit.
66. Remove suspension frame carefully with the engine transmission unit from the vehicle with hydraulic jack.
67. Remove the right wheel drive shaft from the transmission. Refer to Front Wheel Drive Shaft Seal Replacement - Right Side .
68. Remove the left wheel drive shaft from the transmission. Refer to Front Wheel Drive Shaft Seal Replacement - Left Side .

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69. Remove the engine coolant air bleed hose (2) from water outlet.
70. Remove the radiator surge tank (1) in compound with the engine coolant air bleed hose.
71. Remove the A/C compressor and condenser hose nut (5) from condenser.
72. Remove the A/C compressor and condenser hose (6) from condenser.
73. Unlock the radiator coolant feed hose quick connector (8) and remove the radiator coolant feed hose (7) from engine coolant thermostat housing.
74. Remove the radiator coolant return hose clamp (3).
75. Remove the radiator coolant return hose (4) from water outlet.
76. Remove the complete radiator and condenser assembly from suspension frame.
77. Install suitable cable at the 3 engine lift brackets.
78. Install a suitable engine lifting device to the cable.
79. Extend the engine lifting device until the steel cable are slightly tensioned.

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80. Remove the front transmission mount through bolt (1).

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81. Remove the transmission bracket mount to mount through bolt (1).
82. Lower and remove the frame.
83. Put the engine transmission unit down on a wooden pallet.
84. Loosen the 8 transmission bolts and remove 6 of them. Refer to Transmission Replacement .

Note:  Second technician required.
85. Remove the last 2 transmission bolts and the transmission.
86. Install the engine to suitable engine stand.
87. Transfer parts as needed.

Installation Procedure

1. Remove the engine from the engine stand.
2. Put the engine down on a wooden pallet.

Note:  Second technician required.
3. Install the transmission and 2 transmission bolts.
4. Install the 6 transmission bolts.

Caution: Refer to Fastener Caution .
5. Tighten the 8 transmission bolts. Refer to Transmission Replacement .
6. Install suitable cable at the 3 engine lift brackets. Install a suitable engine lifting device to the cable. Raise the engine transmission unit and extend the engine lifting device until the steel cable are slightly tensioned.
7. Raise the CH-904   base frame and CH-49289   centring frame with the hydraulic jack until it contacts the frame.
8. Place the engine transmission unit into the front frame.

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9. Install the rear transmission bracket mount to mount through bolt (1) and tighten to 100 N·m (74 lb ft) .

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10. Install the front transmission mount through bolt (1) and tighten to 100 N·m (74 lb ft) .
11. Remove the cable from the 3 engine lift brackets.
12. Install the complete radiator and condenser assembly to the suspension frame.

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13. Install the A/C condenser and compressor hose (6) to condenser.

Caution: Refer to Fastener Caution .
14. Install the A/C condenser and compressor hose nut and tighten to 19 N·m (14 lb ft) .
15. Install the radiator outlet hose (7) to the thermostat housing and lock the quick connector (8).
16. Install the radiator inlet hose (4) to the water outlet.
17. Install the radiator inlet hose clamp (3).
18. Install the engine coolant air bleed hose (2).
19. Lay the radiator surge tank (1) aside.
20. Install the right wheel drive shaft to the transmission. Refer to Front Wheel Drive Shaft Seal Replacement - Right Side .
21. Install the left wheel drive shaft to the transmission. Refer to Front Wheel Drive Shaft Seal Replacement - Left Side .

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Note:  Positioning pins (1) of CH-49289   centring frame MUST be extended in order to guide into underbody holes.
22. Move the frame (1) with the engine transmission unit to the vehicle upward until the wiring harness bracket can be fixed to the EPS unit.
23. Install the wiring harness bracket to the EPS unit.
24. Tighten the 2 wiring harness bracket bolts and tighten to 9 N·m (80 lb in) .

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Note:  Simplified graphic. Engine/transmission unit is fixed with engine support tool to suspension frame. Suspension frame is supported by centering adapter and underframe.
25. Install the frame (4).
26. Install the frame reinforcements (3).
27. Install frame rear bolts (2). Hand tighten ONLY.
28. Install frame front bolts (3). Hand tighten ONLY.
29. Tighten the rear frame bolts (2) and tighten to 160 N·m (118 lb ft) .
30. Tighten the front frame bolts (1) and tighten to 160 N·m (118 lb ft) .

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31. Lower the CH-49289   centring frame (1) with CH-904   base frame and a jack.
32. Remove the CH-49289   centring frame from the CH-904   base frame .

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Note:  The SPX installation manual is supplied with the special tool and is also available online from SPX directly. Go to www.spxtools-shop.com.
33. Disassemble the CH-49289   centering frame (1) according to the details provided in the SPX installation manual.

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34. Install the 3 transmission mount bolts (2) to the transmission mount (3) and the transmission mount bracket (1) and tighten to 62 N·m (46 lb ft) .

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35. Install the 3 engine mount bolts (2) to the engine mount (1) and the engine mount bracket (3) and tighten to 62 N·m (46 lb ft) .

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36. Lower the CH-49290   support tool (1) with CH-904   base frame and a jack.
37. Remove the CH-49290   support tool from the CH-904   base frame .

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Note:  The SPX installation manual is supplied with the special tool and is also available online from SPX directly. Go to www.spxtools-shop.com.
38. Disassemble the CH-49290   support tool (1) according to the details provided in the SPX installation manual.
39. Install the exhaust front pipe. Refer to Exhaust Front Pipe Replacement .

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40. Connect the engine coolant fan wiring harness plug (1) an clip to suspension frame (2).
41. Connect the EPS wiring harness plug (3).
42. Connect EPS main wiring harness to EPS unit.
43. Install the wheel speed sensor wiring harness retainers from the frame.
44. Connect the wheel speed sensor on both sides.
45. Install the front wheel shafts to the wheel hubs. Refer to Front Wheel Drive Shaft Replacement - Right Side .
46. Install the front lower control arm to the steering knuckle. Refer to Lower Control Arm Replacement .
47. Install the steering linkage outer tie rod to the steering knuckle on both sides. Refer to Steering Linkage Outer Tie Rod Replacement .
48. Install the upper stabilizer shaft link to the absorber on both sides. Refer to Stabilizer Shaft Link Replacement .
49. Install the front compartment splash shield. Refer to Front Compartment Splash Shield Replacement .
50. Check the transmission fluid level. Refer to Transmission Fluid Level Inspection .
51. Lower the vehicle.

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Note:  Use a NEW O-ring seal. Refer to Air Conditioning O-Ring Seal Replacement .
52. Install the A/C compressor and condenser hose (2) and the seal ring (3) to air conditioning evaporator hose.
53. Install the A/C compressor and condenser hose nut (1) to air conditioning evaporator hose and tighten to 19 N·m (14 lb ft) .

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Note:  Use a NEW O-ring seal. Refer to Air Conditioning O-Ring Seal Replacement .
54. Install the lower condenser hose (1) and the seal ring (2).
55. Install the lower condenser hose nut (3) and tighten to 19 N·m (14 lb ft) .
56. Remove the EN-6015   closure plugs .

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57. Connect fuel feed pipe (2) to the fuel injector rail.
58. Clip fuel feed pipe to retainer clip (1).
59. Connect fuel ventilation pipe (4) to evaporative emission canister purge solenoid valve.
60. Clip fuel ventilation pipe to retainer clip (3).

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61. Install fuel injector rail cap (1).
62. Connect the clutch actuator cylinder front pipe. Refer to Clutch Actuator Cylinder Front Pipe Replacement .
63. Bleed the hydraulic clutch system. Refer to Hydraulic Clutch System Bleeding .
64. Fill the reservoir with clutch/brake fluid up to the MAX level.
65. Connect backup lamp switch wiring harness electrical connector.

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66. Connect the booster vacuum pipe (1) to the intake manifold.
67. Install the heater inlet and outlet hose to the bulkhead. Refer to Heater Inlet Hose Replacement and Heater Outlet Hose Replacement .
68. Install the manual transmission shift lever and selector lever cable to the transmission. Refer to Manual Transmission Shift Lever and Selector Lever Cable Replacement .
69. Clip in the radiator surge tank. Refer to Radiator Surge Tank Replacement .
70. Connect the coolant level indicator module wiring harness plug. Refer to Engine Coolant Level Indicator Module Replacement .
71. Install the front tire and wheel assembly. Refer to Tire and Wheel Removal and Installation .
72. Install the front bumper fascia. Refer to Front Bumper Fascia Replacement .
73. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement .

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74. Install the ECM wiring harness plug (1) to the lower part of the front compartment fuse block.
75. Connect the ECM wiring harness plug (2) and clip it to retainer clip (3).

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76. Install the 3 wiring harnesses (2).
77. Install the 3 ground nuts (1) and tighten to 9 N·m (80 lb in) .

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Note:  Ensure that the 3 wiring harness plugs (3), (5) and (6) fit clearly to the front compartment fuse block.
78. Install the front compartment fuse block (2) to the lower the lower part (4) and loosely install the bolts (1).

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79. Clip in the front compartment fuse block to the 4 retainer clips (2) and (3).
80. Tighten the 3 front compartment fuse block bolts (1) to 22 N·m (16 lb ft) .

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81. Install the front compartment fuse block cover (1).

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82. Install the windshield washer solvent container filler tube (1).
83. Install the battery tray. Refer to Battery Tray Replacement .
84. Evacuate and charge the refrigerant system. Refer to Refrigerant Recovery and Recharging .
85. Check the oil level and fill NEW engine oil up if necessary.
86. Fill the cooling system. Refer to Cooling System Draining and Filling .
87. Install the lower intermediate steering shaft bolt. Refer to Intermediate Steering Shaft Replacement .

Engine Flywheel Removal - 1.4L LUH, LUJ and LUV > < Camshaft Timing Chain Replacement