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Vauxhall Workshop Service and Repair Manuals

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Pressure Loss Test, Charge Air System > < Manual Transmission, Remove from Engine and Install

Astra H

Repair engine using a short block

  Remove

1.   Detach transmission from engine
•   For vehicles with manual transmission LUREF_1.gif
•   For vehicles with automatic transmission LUREF_1.gif
2.   Vehicles with manual transmission: detach clutch LUREF_1.gif
3.   Vehicles with manual transmission: detach KM-6263
•   Turn rotating spindle back to initial position
•   Remove centring drift
•   Unscrew 4x bolts
•   Remove KM-6263
4.   Vehicles with manual transmission: attach EN-46792 (1)
•   Tighten bolt
5.   Vehicles with manual transmission: remove flywheel
•   Unscrew 6x bolt (2)
•   Remove EN-46792
– Unscrew bolt
Object Number: 8125646 Size: DEFAULT


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


8.   Detach heat shield
•   Unscrew 2x bolts
9.   Detach vacuum reservoir (1) and retaining plate
Note:   If present
•   Detach 2x vacuum hose
•   Unscrew 2x bolts (2)
•   Unscrew bolt (3)
Object Number: 8230702 Size: DEFAULT


10.   Detach EGR cooler (1)
•   Unscrew bolt, nut (arrows)
•   Detach EGR valve metal tube
– Release clamp
•   Detach coolant hose
– Release clamp
Object Number: 3446039 Size: DEFAULT


11.   Remove thermostat housing (1)
•   Disconnect wiring harness connector.
•   Unscrew 2x bolts
•   Remove seal
•   Detach coolant hose
– Release clamp
Object Number: 3446045 Size: DEFAULT


12.   Remove vacuum pump (1)
•   Remove vacuum hose
•   Unscrew 3x bolts (2)
•   Remove seal
Object Number: 2408149 Size: DEFAULT


13.   Remove ribbed V-belt (1)
•   Mark rotational direction of ribbed V-belt
•   Tension ribbed V-belt tensioner in direction of arrow
•   Insert KM-6349 (2)
Object Number: 2408559 Size: DEFAULT


14.   Remove compressor
•   Disconnect wiring harness plug (2)
•   Unscrew 3x bolts (1)
Object Number: 8230756 Size: DEFAULT


15.   Detach compressor support from engine block
Note:   Note guide sleeves
•   Unscrew 4x bolts (1)
Note:   Remove with ribbed V-belt guide roller (2)
Object Number: 8230760 Size: DEFAULT


16.   Detach 2x compressor wiring harness bracket
•   Unscrew 2x bolts
– Set wiring harness aside
17.   Remove coolant pipe assembly (1)
•   Unscrew 6x bolt (2)
•   Remove seal
Object Number: 9008494 Size: DEFAULT


18.   Remove torsional vibration damper (1)
•   Unscrew 4x bolts
Note:   Counterhold toothed belt drive gear at bolt (2)
Object Number: 7360963 Size: DEFAULT


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


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


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


22.   Set cylinder no. 1 to TDC of combustion stroke
•   The mark on the camshaft sprocket (1) must be aligned with the mark on the camshaft housing cover (2)
Object Number: 2408170 Size: DEFAULT


23.   Remove toothed belt (1)
Note:   Mark direction of rotation
•   Slacken the toothed belt tension roller
– Loosen bolt (2)
Object Number: 2408566 Size: DEFAULT


24.   Remove toothed belt tightening roller
•   Unscrew bolt
25.   Remove toothed belt guide roller (2)
•   Unscrew bolt (1)
Object Number: 2408569 Size: DEFAULT


26.   Detach vacuum line
•   Unscrew 2x bolts (arrows)
Object Number: 2408150 Size: DEFAULT


27.   Detach witing harness (1) from engine
•   Detach wiring harness bracket from camshaft housing cover
– Unscrew 2x bolts
•   Unclip 5x wiring harnesses
•   Disconnect 11x wiring harness plugs
– 4x injector
– Throttle valve module
– EGR valve
– Accumulator sensor
– High-pressure pump
– Intake air temperature sensor
– Camshaft sensor
– Pressure regulator
Object Number: 9008495 Size: DEFAULT


28.   Detach 4x oil leak line (2) from injectors
Note:   The oil leak line must not be detached from the fuel return damping case. It if is detached, it must be replaced.
•   Unclip 2x leak oil line (1)
•   Release 4x retaining clamp (3) from injector in direction of arrow
Note:   Seal 4x injectors with suitable blanking plugs
– Pull off oil leak line
Object Number: 8230689 Size: DEFAULT


29.   Remove fuel return damping case (1) with oil leak line
Note:   Open fuel connections must be sealed with appropriate plugs
•   Unscrew 2x bolts
•   Detach 2x hoses
– Undo 2 clamps
Object Number: 2408163 Size: DEFAULT


Important:   After detaching the high pressure lines, seal off injector and pressure chamber openings with protective caps 1)
30.   Detach accumulator high pressure line (1) to high pressure pump
Important:   When releasing the retaining nut on the high pressure pump, counterhold with open-ended wrench.
•   Unscrew 2x union nuts
Note:   Fuel connections that have been opened must be sealed with suitable plugs from the kit (45 06 154).
Object Number: 2408157 Size: DEFAULT


31.   Detach 4x high pressure line - accumulator to injector
Important:   When releasing the retaining nut, counterhold with open-ended wrench against the injector.
•   Unscrew 8x union nut (1)
Note:   Open fuel connections must be sealed with suitable blanking plugs
Object Number: 2408161 Size: DEFAULT


32.   Remove accumulator (1)
•   Unscrew 2x nut (arrows)
Object Number: 2408164 Size: DEFAULT


33.   Remove 4x injector
Note:   If the injectors cannot be reached by hand, use EN-46786 together with KM-328-B . Fit plugs to removed injectors (arrows).
•   Unscrew 4x nut
Object Number: 3446070 Size: DEFAULT


34.   Detach wiring harness for sheathed glow plugs (arrows)
•   Disconnect 4x glow plug wiring harness plug
•   Unclip wiring harness
Object Number: 3446037 Size: DEFAULT


35.   Remove 4x sheathed glow plug (1)
Object Number: 7360117 Size: DEFAULT


36.   Release high-pressure pump gear
Note:   Use a second person
•   Counterhold with KM-6347 (1) in combination with KM-956-1 (2)
•   Unscrew nut
Object Number: 7360968 Size: DEFAULT


37.   Detach high-pressure pump gear
•   Attach EN-46790 (1)
– Screw in 2x bolts
•   Pull off high-pressure pump drive gear
– Counterhold with open-ended wrench (2)
Object Number: 7360969 Size: DEFAULT


38.   Remove high pressure pump
•   Unscrew 3x nuts (1)
Object Number: 3446034 Size: DEFAULT


39.   Detach 3x alternator wiring harnesses
•   Unscrew 3x nuts (1)
Object Number: 7360975 Size: DEFAULT


40.   Detach alternator
•   Unscrew lower bolt
•   Unscrew 2x bolts
– Remove bracket
41.   Detach high-pressure pump bracket (1)
•   Detach coolant pipe bracket from high-pressure pump bracket
– Unscrew bolt
•   Unscrew 6x bolts
Note:   Note different bolt lengths
Object Number: 3446041 Size: DEFAULT


42.   Remove intake manifold (1)
•   Unscrew 9x nuts
•   Detach gasket
Object Number: 3446043 Size: DEFAULT


43.   Detach alternator bracket
•   Unscrew 2x bolts
Note:   Note different bolt lengths
44.   Detach cylinder head cover vent hose
•   Release clamp
45.   Detach crankshaft housing vent hose
•   Undo 2 clamps
46.   Detach charge air pipe bracket
•   Unscrew bolt
47.   Fit engine transport shackle
•   Tighten bolt
48.   Hitch engine up to workshop crane.
49.   Detach engine from KM-412
•   Unscrew 8x bolts
•   Set engine down
50.   Detach KM-412-36-1 and KM-412-36-2 from engine block
•   Unscrew 7x bolts
51.   Unhitch engine from workshop crane.
52.   Detach engine transport shackle
•   Unscrew bolt

  Install

53.   Attach engine transportation shackle to engine short block
•   Tighten bolt
54.   Hitch engine short block up to workshop crane
55.   Attach KM-412-36-1 an KM-412-36-2 to engine block
•   Tighten 7x bolts
56.   Attach engine short block to KM-412
•   Tighten 8x bolts
57.   Unhitch engine short block from workshop crane.
Important:   According to the engine preparers' regulations all particles of dust and liquids must be cleaned off every attaching part that is to be reassembled.
58.   Cleaning work on attaching parts
59.   Detach engine transport shackle
•   Unscrew bolt
60.   Attach charge air pipe bracket
•   Tighten bolt
61.   Attach crankshaft housing vent hose
•   Attach 2x clamps
62.   Attach cylinder head cover vent hose
•   Fasten clamp
63.   Attach alternator bracket
•   Tighten 2x bolts
Note:   Note different bolt lengths
64.   Install intake manifold
•   Replace seal
•   Tighten 9x new nut 25 Nm
65.   Attach high-pressure pump bracket
•   Tighten 6x bolt 25 Nm
Note:   Note different bolt lengths
•   Attach coolant pipe bracket to high-pressure pump bracket
– Tighten bolt
66.   Attach alternator
•   Insert bracket
– Screw in 2x bolts
•   Tighten lower bolt 70 Nm
•   Tighten 2x bolt 70 Nm
67.   Attach alternator wiring harness
•   Tighten 2x nut (M6) 5 Nm
•   Tighten nut (M8) 10 Nm
68.   Install high pressure pump
•   Tighten 3x nut 25 Nm
69.   Fit high pressure pump wheel
•   Screw in nut
70.   Fasten high-pressure pump gear
•   Use a second person
•   Tighten nut 50 Nm
•   Counterhold with KM-6347 in conjunction with KM-956-1
71.   Tighten 4x sheathed glow plugs to 8 Nm
72.   Attach wiring harness of sheathed glow plugs
•   Connect 4x wiring harness plug, sheathed glow plug
•   Attach wiring harness
73.   Cleaning work
•   Use EN-47632 (1) to clean the injector seats. Insert EN-47632 with coarse fleece in the injector shaft and clean the injector seat by turning. Finish by cleaning with the fine fleece.
Object Number: 8230690 Size: DEFAULT


74.   Install 4x injector
•   Remove closure plugs
•   Replace 4x seal rings
•   Tighten 4x nut 32 Nm
75.   Install accumulator
•   Tighten 2x nuts 25 Nm
76.   Install 4x new high-pressure line, accumulator to injector
•   Remove closure plugs
•   Tighten 4x union nut (M14) 23 Nm
Important:   Pressure lines must not be installed more than once. When fastening the retaining nut counterhold against the injector with an open-ended wrench.
•   Tighten 4x union nut (M12) 23 Nm
77.   Attach new high pressure line - accumulator to high pressure pump
•   Remove closure plugs
•   Tighten union nut (M14) 23 Nm
Important:   Pressure lines must not be installed more than once. When fastening the union nut to the high-pressure pump, counterhold against it with an open-ended wrench.
•   Tighten union nut (M12) 23 Nm
78.   Install fuel return damping case with oil leak line
•   Tighten 2x bolts
– Attach wiring harness bracket to fuel return damping case
•   Attach 2x hoses
– Attach 2x clamps
79.   Attach 4x oil leak line to injectors
•   Remove closure plugs
•   Clip 4x oil leak line to injector
80.   Attach wiring harness to engine
•   Clip in 5x wiring harnesses
•   Connect 11x wiring harness plug
– 4x injector
– Throttle valve module
– EGR valve
– Accumulator sensor
– High-pressure pump
– Intake air temperature sensor
– Camshaft sensor
– Pressure regulator
•   Clip in 2x leak oil line
•   Attach wiring harness bracket to camshaft housing cover
– Tighten 2x bolts
81.   Attach vacuum line
•   Tighten 2x bolts
82.   Clean 2x threads
83.   Install toothed belt guide roller
•   Tighten bolt 50 Nm
Note:   Use screw locking compound (red)
84.   Clean the thread
85.   Fit toothed belt tightening roll
Note:   Insert tension roller in guide
•   Screw in bolt
•   Use screw locking compound (red)
86.   Install toothed belt
Note:   Observe direction of rotation
Important:   Tightened end (1) must be taut
•   Position toothed belt
87.   Tension the toothed belt
•   Screw in bolt (6)
•   Tension the toothed belt
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


88.   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)
•   Detach positioning disk EN-46788
Object Number: 3446087 Size: DEFAULT


89.   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.
90.   Check crankshaft setting with EN-46788
Note:   If EN-46788 cannot be fitted, repeat the toothed belt positioning procedure
•   Attach positioning disk EN-46788
– Screw in bolt
– Screw in nut
•   Remove positioning disk and stud bolt EN-46788
•   Tighten oil pump bolt 9 Nm
91.   Install engine damping block adapter
Note:   Note different bolt lengths
•   Tighten 3x bolt (M10) 50 Nm
•   Tighten 2x bolt (M8) 25 Nm
92.   Install toothed belt cover
•   Tighten 4x bolt (M6) 9 Nm
•   Tighten 2x bolt (M8) 25 Nm
•   4x clip in camshaft sensor wiring harness
93.   Install upper ribbed V-belt guide roller
•   Tighten bolt 50 Nm
94.   Install torsional vibration damper
Note:   Observe correct fitting position
•   Tighten 4x bolt 25 Nm
Note:   Counterhold toothed belt drive gear at bolt
95.   Install coolant pipe assembly
•   Replace seal
•   Tighten 6x bolt
96.   Attach 2x compressor wiring harness bracket
•   Tighten 2x bolts
97.   Attach compressor support to engine block
Note:   Note guide sleeves
•   Tighten 4x bolt 50 Nm
98.   Attach compressor to support
•   Tighten 3x bolt 22 Nm
•   Fix wiring harness plug
99.   Insert ribbed V-belt
Note:   Note direction of travel
•   Position ribbed V-belt
– I Route of ribbed V-belt with air conditioning
– II Route of ribbed V-belt without air conditioning
•   Remove KM-6349
Object Number: 7360961 Size: DEFAULT


100.   Clean sealing surface
101.   Install vacuum pump
•   Insert new gasket
•   Tighten 3x bolt 20 Nm
•   Attach vacuum hose
102.   Clean sealing surface
103.   Install thermostat housing
•   Replace sealing ring
•   Attach coolant hose
– Fasten clamp
•   Tighten 2x bolt 25 Nm
•   Fix wiring harness plug
104.   Insstall EGR cooler
•   Tighten bolt 25 Nm
•   Tighten nut 9 Nm
•   Attach EGR valve metal tube
– Tighten clamp
•   Attach coolant hose
– Fasten clamp
105.   Attach vacuum reservoir and retaining plate
•   Tighten 3x bolt 25 Nm
•   Attach 2x vacuum hoses
106.   Attach heat shield
107.   Clean 6x threads
108.   Vehicles with automatic transmission: install drive disc
•   Attach EN-46792
•   Tighten 6x new bolt 160 Nm
109.   Vehicles with manual transmission: install flywheel
•   Attach EN-46792
– Tighten bolt
•   Tighten 6x new bolt 160 Nm
•   Remove EN-46792
– Unscrew bolt
110.   Vehicles with manual transmission: 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
111.   Vehicles with manual transmission: install clutch LUREF_1.gif
112.   Detach transmission from engine
•   Remove automatic transmission from engine LUREF_1.gif
•   Remove manual transmission from engine LUREF_1.gif
1 ) Protective caps are available from the Opel parts catalogue under catalogue number 45 06 154 / part number: 9201697

Pressure Loss Test, Charge Air System > < Manual Transmission, Remove from Engine and Install