vauxhall Workshop Repair Guides

Vauxhall Workshop Service and Repair Manuals

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Component Locator > < Check crankshaft bearing clearance (with micrometer gauge internal measuring device)

Astra H

Crankshaft, Remove and Install - Diesel engine

  Remove

1.   Remove gearbox
2.   Place collecting basin underneath.
3.   Drain engine oil
4.   Remove right engine damping block bracket
•   Unscrew 3 bolts
5.   Remove injector wiring harness retaining plate (1)
•   Unscrew bolt (3)
•   Unscrew nut (2)
•   Set retaining plate aside
Object Number: 10678293 Size: DEFAULT


6.   Detach camshaft sensor (1)
•   Disconnect wiring harness connector.
•   Unscrew bolt (2)
Object Number: 10678296 Size: DEFAULT


7.   Detach toothed belt cover (top)
•   Unscrew 8x bolts
Note:   Note different bolt lengths
•   Unclip 4x fuel return line
8.   Remove torsional vibration damper (1)
•   Unscrew 4x bolts
Note:   Counterhold at bolt (2)
Object Number: 2412637 Size: DEFAULT


9.   Remove lower toothed belt cover (1)
•   Unscrew 3x bolts (2)
•   Remove engine damping block adapter
Object Number: 2412640 Size: DEFAULT


10.   Set cylinder 1 to TDC of combustion stroke
•   Fix camshaft sprocket in position using TDC locking bolt (M6x25) (1)
•   Turn crankshaft evenly in direction of engine rotation, until mark (3) of toothed belt drive gear is in line with mark (2) on oil pump cover
Object Number: 2412641 Size: DEFAULT


11.   Release toothed belt tension roller (1)
•   Slacken bolt of toothed belt tension roller (2)
•   Turn toothed belt tension roller approx. 90° anticlockwise
•   Tighten bolt - toothed belt tension roller
Object Number: 2406524 Size: DEFAULT


12.   Remove toothed belt
•   Mark direction of rotation
13.   Lock flywheel with KM-652
14.   Remove thrust plate and clutch disk LUREF_1.gif
15.   Remove flywheel (1)
•   Unscrew 8x bolts
Object Number: 10679573 Size: DEFAULT


16.   Remove locking tool KM-652
17.   Using KM-412-A , turn engine through 180°
18.   Remove lower part of oil pan
•   Unscrew 15x bolts
•   Detach lower part of oil pan with KM-J-37228
Object Number: 10678260 Size: DEFAULT


19.   Remove residual oil quantity sensor
•   Disconnect wiring harness plug (4)
•   Release retaining clamp (3)
•   Unscrew 2x bolt (1 and 2)
Object Number: 10679167 Size: DEFAULT


20.   Detach oil dipstick guide tube (1)
•   from top of oil pan
– Unscrew 2x bolts (2)
•   From cooler, exhaust gas recirculation
– Unscrew bolt
Object Number: 10678241 Size: DEFAULT


21.   Detach bracket for wiring harness plug (2)
•   Unclip wiring harness plug (1)
•   Unscrew bolt (3)
Object Number: 10679168 Size: DEFAULT


22.   Release wiring trough (1)
•   Unscrew 2x nuts (2)
Object Number: 10679169 Size: DEFAULT


23.   Remove upper part of oil pan
•   Unscrew 14x bolts,
•   Unscrew 2x nuts
24.   Detach oil intake pipe (2)
•   Unscrew bolt
25.   Detach oil baffle plate (1)
•   Unscrew 5x bolts
Object Number: 2416040 Size: DEFAULT


26.   Detach toothed belt drive gear (1)
•   Unscrew bolt
– Counterhold with KM-662-C
•   Remove with KM-161-B (1)
•   Remove spring washer
Object Number: 2413410 Size: DEFAULT


27.   Detach oil pump gear (1)
•   Unscrew nut
Note:   Counterhold with socket wrench (2)
Object Number: 2413409 Size: DEFAULT


28.   Remove oil pump cover (1)
•   Unscrew 9x bolts
Note:   Note different bolt lengths
•   Remove inner rotor and outer rotor (2)
Object Number: 2393053 Size: DEFAULT


29.   Remove crankshaft seal ring (1)
Important:   Do not damage sealing surfaces
•   Prise out seal ring
30.   Install oil pump seal ring (2)
Important:   Do not damage sealing surfaces
•   Prise out seal ring
Object Number: 2411148 Size: DEFAULT


31.   Detach bracket for crankshaft seal ring (1) from cylinder block
•   Unscrew 5x bolt (2)
•   Separate crankshaft rear seal ring bracket (1) from cylinder block using a suitable tool (3)
Object Number: 2414891 Size: DEFAULT


Important:   The fracture surfaces of the con-rods and the con-rod bearing caps build an individual fit and must not at any time be confused or damaged. To prevent damage, do not not place the con-rods or con-rod bearing caps on the fracture surfaces.
32.   Remove 4x con-rod bearing cap
•   Unscrew 8x nut
33.   Take off 8x con-rod bearing shell
Note:   Note identification mark on con-rod bearing cap and con-rod. Apply identification mark if not present
Object Number: 2416034 Size: DEFAULT


34.   Remove crankshaft
•   Remove 5x crankshaft bearing cap
– Release 10x bolt in the order shown (1 - 10)
– Unscrew 10x bolt
•   Place crankshaft on wooden blocks
Object Number: 2405635 Size: DEFAULT


35.   Take out 10x crankshaft bearing shell
•   Identify crankshaft bearing shells
Note:   Note identification on crankshaft bearing cap
36.   Remove wearing rings
Object Number: 2393068 Size: DEFAULT


37.   Detach crankshaft pulse pick-up disc (1)
•   Unscrew 3 bolts
Object Number: 2416087 Size: DEFAULT


  Install

38.   Clean the components
•   Lower part of oil pan, upper part of oil pan, cylinder block
39.   Visually check components
40.   Attach crankshaft pulse pick-up disc
•   Tighten 3x new bolts 12 Nm
Important:   Note mark and allocation
41.   Insert 8x con-rod bearing shell
•   In con-rod, con-rod bearing cap
– Coat with engine oil
Important:   Note mark and allocation
42.   Insert 10 crankshaft bearing shells
•   In cylinder block, crankshaft bearing cap
– Coat with engine oil
Important:   Oil grooves point outwards
43.   Replace wearing rings
•   Coat with engine oil [77.5x155 F4490)
Object Number: 2393068 Size: DEFAULT


Object Number: 2416042 Size: DEFAULT

44.   Insert crankshaft
•   Coat crankshaft journal with engine oil
Note:   Pay attention to wearing rings
45.   Attach 5x crankshaft bearing cap
Note:   Note installation position. arrows point to engine timing side
•   Tighten 10x new bolts in the specified tightening sequence 39 Nm + 60°
Important:   Note marking (11) and cylinder sequence on con-rod bearing cap and con-rod. Narrow bead is toward engine timing side
46.   Attach 4x con-rod bearing cap
•   Tighten 8x new nuts 25 Nm + 100° + 15°

47.   Clean sealing surfaces.
48.   Attach bracket for rear crankshaft seal ring to cylinder block
•   Apply a bead of adhesive sealing compound to sealing surfaces of crankshaft rear seal ring bracket (arrow)
Note:   Select a suitable sealing compound from the replacement parts catalogue
•   Tighten 5x bolts in the stated order (1 - 5) 10 Nm
49.   Clean sealing surfaces.
50.   Fit oil pump cover (2)
Important:   The application of adhesive sealing compound and installation of oil pump cover, including torque test, must be completed within 10 minutes
•   Apply a bead of adhesive sealing compound (black) to the sealing surface (cross-hatching) of the oil pump cover
•   Replace gasket (1)
•   insert inner and outer rotor in cylinder block
– Coat with oil
•   Fit oil pump cover
– Tighten 9x bolts 10 Nm
Object Number: 2393052 Size: DEFAULT


51.   Fit toothed belt drive gear seal ring
•   Insert seal ring in oil pump cover
•   Drive in as far as the stop with KM-656 (1)
Object Number: 2393089 Size: DEFAULT


52.   Remove oil pump seal ring
•   Insert new seal ring in oil pump cover. Do not forget to apply silicone grease to the sealing lip of the ring.
•   Drive in as far as the stop with KM-657 (1)
53.   Fit oil pump drive gear
Note:   Note installation position
•   Tighten nut
– 60 Nm
– Hold for 20 seconds
– Slacken nut
– 60 Nm
– Counterhold with socket wrench
Object Number: 2393054 Size: DEFAULT


54.   Replace toothed belt drive gear
•   Insert disc spring
•   Attach to crankshaft
Note:   Note spring washer
•   Tighten bolt 196 Nm
– Counterhold with KM-662-C
55.   Attach oil baffle plate
•   Tighten 5x bolts 19 Nm
56.   Attach oil intake pipe
•   Insert oil intake pipe
– Replace seal ring
•   Tighten bolt 26 Nm
57.   Clean sealing surfaces.
•   Upper part of oil pan and engine block
58.   Fit upper part of oil pan
•   Apply a bead of silicone sealant to the sealing surface of the upper part of the oil pan
•   Tighten 14x bolts and 2x nuts 10 Nm
Note:   Note different bolt lengths
59.   Fasten wiring trough
•   Tighten 2x nuts 10 Nm
60.   Attach wiring harness plug bracket
•   Tighten bolt
•   Clip in wiring harness plug
61.   Attach dipstick guide tube
•   Tighten 3x bolt 10 Nm
62.   Install residual oil quantity sensor
•   Fix wiring harness plug
•   Clamp retaining clip
•   Tighten 3x bolts
63.   Clean sealing surfaces.
•   Lower part of oil pan
•   Upper part of oil pan
64.   Install lower part of oil pan
•   Apply a bead of silicone sealing compound to sealing surfaces of lower part of oil pan
•   Tighten 15x bolts 10 Nm
65.   Using KM-412-A, turn engine through 180°
66.   Insert locking tool KM-652
67.   Fit flywheel
•   Clean 8x threads
•   Tighten 8x new bolts 85 Nm + 30° + 15°
68.   Install thrust plate and clutch disc LUREF_1.gif
69.   Remove locking tool KM-652
70.   Install toothed belt
Note:   TDC locking bolt must be installed in camshaft sprocket (9) and high-pressure pump gear (8) and marks (6) and (7) must align
•   Position toothed belt
– Observe direction of rotation
– Toothed belt must be tensioned in the direction of the arrow from the toothed belt drive gear (5), through the oil pump drive gear (4) and the high-pressure pump drive gear (2) to the camshaft sprocket (1)
•   Slacken the toothed belt tension roller (3)
•   Tighten toothed belt tension roller 49 Nm
Object Number: 10678301 Size: DEFAULT


71.   Timing, Check
•   Remove 2x TDC fixing bolt
•   Turn crankshaft approx. 720° in the direction of rotation of the engine
– To toothed belt drive gear
•   Mark (3) on toothed belt drive gear must be in line with the lug (2) on the oil pump cover
•   Screw in 2x TDC locking bolts
Note:   If it is not possible to screw in a TDC locking bolt, the basic setting must be carried out again.
•   Unscrew 2x TDC fixing bolt
72.   Attach toothed belt cover at the bottom
•   Insert engine damping block adapter
•   Tighten 3x bolt 10 Nm
73.   Fit torsional vibration balancer
•   Tighten 4x bolt 20 Nm
Note:   Counterhold toothed belt drive gear at bolt
74.   Fit upper toothed belt cover
•   Tighten 8x bolts 10 Nm
Note:   Note different bolt lengths
•   Clip in 4x fuel return line
75.   Replace camshaft sensor
•   Replace seal ring
•   Tighten bolt 10 Nm
•   Fix wiring harness plug
76.   Fit injector wiring harness retaining plate
•   Tighten bolt
•   Tighten nut
77.   Attach right engine damping block bracket
•   Tighten 3x bolt 60 Nm
78.   Top up engine oil
79.   Install gearbox

Component Locator > < Check crankshaft bearing clearance (with micrometer gauge internal measuring device)