vauxhall Workshop Repair Guides

Vauxhall Workshop Service and Repair Manuals

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Replace engine damping block (front) > < Manual Transmission, Remove from Engine and Install

Astra H

Engine maintenance using a section engine

  Remove

1.   Remove manual transmission from engine LUREF_1.gif
2.   Place collecting basin underneath.
3.   Drain engine oil
•   Unscrew oil drain bolt (1)
Object Number: 2413383 Size: DEFAULT


4.   Attach engine timing wiring harness
•   Disconnect wiring harness plug of:
– Throttle body
– EGR valve
– Change-over valves for solenoid valve
– Injectors
– Sheathed glow plugs
– Pressure sensor
– Sensor for change-over valves
– Charge pressure sensor
– Alternator wiring harness plug
– EGR solenoid valve
– Pressure sensor
– Crankshaft pulse pick-up
– Camshaft sensor
•   Unclip 12x clip
5.   Remove ribbed V-belt
•   Mark direction of rotation
•   Apply tension to ribbed V-belt tensioner via bolt (1) in the direction of the arrow
•   Fix ribbed V-belt tensioner to bore (2)
•   Remove ribbed-V-belt
Object Number: 3447354 Size: DEFAULT


6.   Detach wiring harness from starter alternator
•   Detach from alternator
– Disconnect wiring harness connector.
– Unscrew nut
•   Remove cable conduit
•   Unscrew bolt
•   Detach from starter
– Unscrew 2x nuts
– Unscrew bolt
•   Unscrew oil pressure switch
•   Remove coolant temperature sensor
•   Undo cable ties
•   Unclip 2x clips
7.   Remove compressor (1)
•   Unscrew 3 bolts
Note:   Note different bolt lengths
Object Number: 2413385 Size: DEFAULT


Object Number: 2412716 Size: DEFAULT

8.   Remove alternator
•   Detach vacuum line - solenoid valves (6)
•   Disconnect electrical connection (2)
– Unscrew nut
•   Disconnect wiring harness plug (1)
•   Remove brake force amplifier vacuum line (3)
– Unscrew union nut
•   Detach oil feed line, vacuum pump (5)
– Unscrew banjo bolt
•   Detach oil return hose, vacuum pump (4)
– Release clamp
•   Unscrew 2x bolt (7)

9.   Detach alternator support
•   Unscrew 4x bolts
10.   Remove air intake manifold (1)
•   Undo 2 clamps
•   Unscrew 2x bolts
Object Number: 2412653 Size: DEFAULT


11.   Detach oil dipstick guide tube with bracket
•   Detach from upper part of oil pan
– Unscrew 2x bolts
•   Detach from camshaft housing
– Unscrew 2x bolts
12.   Remove EGR cooler -
•   Detach from intake manifold
– Unscrew 2x bolts (3)
•   Detach from exhaust gas recirculation port
– Unscrew 2x bolts (2)
•   Detach from camshaft housing
– Unscrew bolt (1)
•   Remove 2x gasket
Object Number: 2412715 Size: DEFAULT


13.   Disconnect vacuum hose (2) from turbocharger control unit (1)
Object Number: 3447359 Size: DEFAULT


14.   Detach oil return hose from cylinder block
•   Release clamp
15.   Remove exhaust manifold heat shield
•   Unscrew 4x bolts (1)
Object Number: 2413390 Size: DEFAULT


16.   Detach turbocharger oil feed line
•   Detach from turbocharger
– Unscrew banjo bolt
•   Detach from cylinder block
– Unscrew nut
17.   Remove exhaust manifold (1) with turbocharger
•   Remove from cylinder head
– Unscrew 2x bolts
– Unscrew 7x nuts
•   Detach from catalytic converter bracket
– Unscrew 2x bolts
Object Number: 2413391 Size: DEFAULT


18.   Detach 2x coolant hoses (1)
•   From coolant pipe
– 2 off
19.   Remove coolant pipe
•   Detach from cylinder block
– Unscrew bolt (3)
•   Pull out of coolant flange (2) in direction of arrow
Object Number: 2413392 Size: DEFAULT


20.   Remove coolant discharge port
•   Unscrew 2x bolts (1)
Object Number: 2413585 Size: DEFAULT


21.   Detach bracket, throttle valve body (1), from camshaft housing
•   Unscrew bolt
Object Number: 2413397 Size: DEFAULT


22.   Remove oil filter housing with heat exchanger
•   Detach 2x coolant hoses from coolant port (1)
•   Detach oil return hose from port (2)
•   Unscrew bolt (3)
Object Number: 2412659 Size: DEFAULT


23.   Remove starter
•   Detach cable connections
– Cut cable tie (5)
– Unscrew 2x nut (2) and (3)
– Remove bolt (1)
•   Unscrew lower bolt (4)
•   Unscrew upper bolt on the transmission side
Object Number: 2412678 Size: DEFAULT


24.   Remove charge air pipe (1)
•   Unscrew 6x bolts
Object Number: 3447355 Size: DEFAULT


25.   Remove 3x engine transport shackle
26.   Remove EGR-port (1)
•   Detach coolant hose
– Release clamp
•   Detach EGR cooler
– Unscrew 2x bolts
•   Unscrew 2x bolts
Note:   Note different bolt lengths
Object Number: 2412688 Size: DEFAULT


Important:   After detaching the pressure lines, seal off injector and pressure chamber openings with protective caps 1)
27.   Remove high pressure lines (1), pressure chamber to injectors
•   Unscrew 8x union nut with KM-812 or KM-6098
•   Take out pressure lines
•   Seal 4x pressure chamber opening with protective cap
•   Seal 4x injector opening with protective cap
Object Number: 2412664 Size: DEFAULT


28.   Remove 4x seals, connection for injectors (1)
•   Unscrew 8x bolts
Object Number: 2413399 Size: DEFAULT


29.   Detach fuel return line (1)
•   Detach 4x fuel return line from injector
– Press 4x retaining clamps in direction of arrow
•   Detach fuel return line from pressure chamber
•   Unscrew 2x bolts
Note:   Note different bolt lengths
•   Unscrew nut
Object Number: 2412662 Size: DEFAULT


30.   Remove 4x seal, injectors (1)
•   Unscrew 8x bolts
Object Number: 2413398 Size: DEFAULT


31.   Remove 4x injector (1)
Note:   Mark injectors
•   Remove 4x bracket, injector (2)
– Unscrew 4x bolts
Note:   If a heat protection sleeve (5) also has to be removed when removing an injector, the gaskets (3) must be replaced and the heat protection sleeve must be hammered into the cylinder head with KM-6357 (4)
Object Number: 2413401 Size: DEFAULT


32.   Detach front toothed belt cover (top) (4)
•   Detach vacuum line (3)
– Unclip 3x clip
•   Unscrew 8x bolts
Note:   Note different bolt lengths
•   Remove camshaft sensor bracket (1)
– Unscrew bolt (2)
Object Number: 3447353 Size: DEFAULT


33.   Detach camshaft sensor with bracket
•   Unscrew 1 bolt
34.   Remove engine damping block support
•   Detach from engine damping block bracket
– Unscrew 3x bolts (2)
•   Detach from cylinder block
– Unscrew 3x bolts (3)
•   Remove engine damping block adapter (1)
Object Number: 2412638 Size: DEFAULT


35.   Detach torsional vibration damper (1)
•   Unscrew 4x bolts
Note:   Counterhold at bolt (2)
Object Number: 2412637 Size: DEFAULT


36.   Remove coolant pump drive gear (1)
•   Unscrew 3 bolts
Object Number: 2412639 Size: DEFAULT


37.   Remove front toothed belt cover (lower) (1)
•   Unscrew 3x bolts (2)
Object Number: 2412640 Size: DEFAULT


38.   Move crankshaft in direction of engine rotation to "Cylinder no.1 combustion stroke TDC"
Note:   Marking on toothed belt drive gear must align with projection on oil pump cover (arrows)
•   Fix with TDC fixing bolt (M6) (1) camshaft drive gear
•   Fix with TDC fixing bolt (M8) (2) high pressure pump gear
Object Number: 2404425 Size: DEFAULT


39.   Remove toothed belt
•   Mark direction of rotation
•   Slacken the toothed belt tension roller
– Loosen bolt (1)
•   Apply preliminary tension to toothed belt tension roller with hexagon (2) in direction of arrow
•   Fix toothed belt tension roller in pre-tensioned position
– Tighten bolt
Object Number: 2412642 Size: DEFAULT


40.   Turn engine 60°against the direction of engine rotation
41.   Detach oil pump gear (1)
•   Unscrew nut
Note:   Counterhold with socket wrench (2)
Object Number: 2413409 Size: DEFAULT


42.   Remove toothed belt drive gear (2)
•   Unscrew bolt
Note:   Counterhold with KM-662-C
•   Remove toothed belt drive gear with KM-161-B (1)
•   Remove spring washer
Object Number: 2413410 Size: DEFAULT


43.   Remove high-pressure pump gear
•   Counterhold with KM-6356 (1)
– Unscrew nut
•   Remove high pressure pump gear with KM-6355 (2)
Note:   Counterhold with KM-6356
Object Number: 2412646 Size: DEFAULT


44.   Remove toothed belt guide roller (1)
•   Remove bolt (2)
Object Number: 2412647 Size: DEFAULT


45.   Remove rear toothed belt cover
•   Unscrew 5x bolts (1)
Object Number: 2412648 Size: DEFAULT


46.   Detach coolant pump
•   Unscrew 5x bolts
Important:   After detaching the high pressure line, seal the apertures of the high pressure pump and the pressure chamber with protective caps 1)  
47.   Remove high pressure line (1) from high pressure pump to pressure chamber
•   Unscrew 2x union nuts
– From pressure chamber with KM-812
– From high pressure pump with KM-6098
•   Seal 2x opening with protective cap
Object Number: 2412665 Size: DEFAULT


48.   Detach wiring harness bracket (2) from pressure chamber
•   Unscrew 2x nuts
Object Number: 2412672 Size: DEFAULT


49.   Remove pressure chamber (4)
•   Detach fuel return line from connection (2)
•   Unscrew 2x bolts (1)
Note:   Note different lengths of the bolt (3) and spacer sleeves (1)
Object Number: 2412668 Size: DEFAULT


50.   Slacken high pressure pump
•   Disconnect wiring harness connector.
•   Unscrew stud bolts (1) and (2)
Object Number: 2413584 Size: DEFAULT


Object Number: 2416020 Size: DEFAULT

51.   Remove camshaft housing
•   Unscrew 17x bolt
– Slacken in the order shown (1 - 17) 1/2 turn and then remove

52.   Remove gasket
Important:   Mark cup tappet, draw out of the cylinder head and set aside in order so that the cup tappets can be allocated to the valves when reinstalled
53.   Take out 16x cup tappet (1)
Object Number: 2413403 Size: DEFAULT


Object Number: 2416025 Size: DEFAULT

54.   Remove cylinder head bolts
•   Unscrew 10x bolt
Note:   Slacken bolts in a spiral in the order shown in stages of 1/2 to 1 turn

Important:   Place cylinder head on wooden blocks, be careful of glow plugs
55.   Remove cylinder head
Note:   Use a second person
•   Remove cylinder head gasket
56.   Lock flywheel with KM-652
57.   Attach KM-6263
58.   Detach clutch pressure plate
•   Unscrew 6x bolts
59.   Remove flywheel
•   Unscrew 8x bolts
60.   Using KM-412-A , turn engine through 180°
Object Number: 2416063 Size: DEFAULT

61.   Detach lower part of oil pan (1) from upper part of oil pan (2) with KM-J-37228
•   Unscrew 15x bolts

Object Number: 2416064 Size: DEFAULT

62.   Detach upper part of oil pan from cylinder block
•   Unscrew bolt (2) and (3)
•   Unscrew nut (1)
•   Separate upper part of oil pan from cylinder block with a broad spatula

63.   Remove bracket for rear crankshaft seal ring (1)
•   Unscrew 5x bolt (2)
Important:   Note guide sleeves when removing
•   Prise out seal ring carefully from cover, rear of crankshaft
Object Number: 2405634 Size: DEFAULT


64.   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


65.   Remove oil intake pipe
•   Unscrew bolt (1)
66.   Remove oil baffle plate
•   Unscrew 5x bolt (arrows)
Object Number: 2411062 Size: DEFAULT


67.   Remove oil pressure switch (1)
Object Number: 2412686 Size: DEFAULT


68.   Unscrew 2x oil line connection piece
69.   Transfer cylinder block
•   Detach cylinder block from engine overhaul stand KM-412-A
– Unscrew 8x bolts
•   Detach KM-412-34 KM-412-11-1 from cylinder block
– Unscrew 6x bolts
•   Cylinder Block from Transport Device, Detach and Attach
– Attach KM-412-34 and KM-412-11-1 to cylinder block
– Tighten 6x bolt
•   Attach engine to engine overhaul stand KM-412-A
– Tighten 8x bolts
70.   Remove plastic insert from coolant pump
71.   Clean the components
•   Lower part of oil pan, upper part of oil pan, cylinder head, cylinder block, exhaust manifold, EGR valve, coolant connections

  Install

72.   Insert plastic insert in coolant pump
73.   Attach centring sleeves
74.   Tighten 2x oil line connection piece
75.   Tighten oil pressure switch
76.   Prise rear crankshaft seal ring (3) out of bracket for rear crankshaft seal ring (1) with a suitable tool
77.   Clean sealing surfaces.
78.   Removing seal remains
79.   Apply a bead (2) of adhesive sealing compound (black) to the sealing surfaces of the bracket for the rear crankshaft seal ring
80.   Attach bracket for rear crankshaft seal ring to cylinder block
•   Tighten 5x bolt 9.8 Nm
2)
81.   Insert new rear crankshaft seal ring into bracket for rear crankshaft seal ring
82.   Drive in rear crankshaft seal ring as far as the stop with KM-658 (4)
Object Number: 2414892 Size: DEFAULT


83.   Remove crankshaft seal ring (1)
Important:   Do not damage sealing surfaces
•   Prise out seal ring with suitable tool
Object Number: 2411148 Size: DEFAULT


84.   Install oil pump cover (2)
Important:   Applying the adhesive sealing compound (black) and the assembly of the oil pump cover including the torque test must take place 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
•   Tighten 9x bolt 9.8 Nm
Note:   Note different bolt lengths
Object Number: 2393052 Size: DEFAULT


85.   Install crankshaft seal ring
•   Drive in crankshaft seal ring with KM-656 (1) as far as the stop
Object Number: 2393089 Size: DEFAULT


86.   Install oil pump seal ring
•   Insert new seal ring in oil pump cover
•   Drive in as far as the stop with KM-657 (1)
87.   Fit oil pump drive gear
•   At oil pump
Note:   Note installation position (arrow)
•   Tighten nut 68.6 Nm
Object Number: 2393054 Size: DEFAULT


88.   Install oil baffle plate
•   Tighten 5x bolts
89.   Install oil intake pipe
•   Replace gasket
•   Tighten bolt 18.6 Nm
90.   Install upper part of oil pan
•   Apply a bead of silicone sealant (grey) to the sealing surface of the upper part of the oil pan
•   Tighten 18x bolt 9.8 Nm
91.   Remove lower part of oil pan
•   Apply a bead of silicone sealant (grey) to the sealing surfaces of the lower part of the oil pan
•   Tighten 15x bolt 9.8 Nm
92.   Using KM-412-A , turn engine through 180°
93.   Fit flywheel
•   Tighten 8x new bolt 29.4 Nm + 60° + 15°
94.   Attach clutch pressure plate
•   Centre pressure plate with KM-6263
•   Tighten 6x bolt 15 Nm
95.   Remove KM-6263
96.   Detach locking tool
97.   Cylinder Head, Check for Plane Surface
Note:   Check cylinder head for sag in length and width on the sealing surfaces and for distortion along the diagonals
98.   Insert MKM-571-B (1) in KM-301 (2)
Note:   Note pre-tension
•   Adjust dial to zero
Object Number: 2416026 Size: DEFAULT


99.   Measure piston projection
•   Place probe on cylinder block
•   Measure piston projection on all 4 pistons
– Perform measurements at two different points (1) and (2) or (3) and (4)
– Determine highest point by turning the crankshaft
Object Number: 2416027 Size: DEFAULT


100.   Turn crankshaft 60° against the direction of engine rotation
Object Number: 2412643 Size: DEFAULT


Object Number: 8125511 Size: DEFAULT

Important:   The largest piston projection is decisive for the selection of the cylinder head gasket with the corresponding marking
101.   Replace cylinder head gasket
Note:   2 different designs are available from Aftersales

Piston projection

Thickness of cylinder head gasket

Size

Number of holes
 

used

New

  

Version I

Version II

0.630 - 0.696 mm

1.350 mm

1.450 mm

A

-

1

0.697 - 0.763 mm

1.400 mm

1.500 mm

B

1

2

0.764 - 0.830 mm

1.450 mm

1.550 mm

C

2

3
•   Place cylinder head gasket in position
– Note guide sleeves

102.   Position cylinder head
Note:   Use a second person
Object Number: 2416029 Size: DEFAULT

Important:   Note correct tightening sequence
103.   Fasten cylinder head
•   Tighten 10x new bolt 39.2 Nm + 60°+ 60°
Note:   Tighten in the order shown in a spiral from inside to outside with MKM-610 and KM-470-B

Important:   Note marking on cup tappet
104.   Insert 16x cup tappets
Object Number: 2416021 Size: DEFAULT

105.   Install camshaft housing
•   Replace gasket
•   Attach to cylinder head and tighten in the order shown (1-17)
– Tighten 12x bolt (M8) 21.6 Nm
– Tighten 5x bolt (M10) 26.5 Nm

106.   Install high pressure pump
•   Tighten 3x stud bolt
107.   Install accumulator
Note:   Note different lengths of the bolt and spacer sleeves
•   Tighten 2x bolts
•   Attach fuel return line
– From high pressure pump to pressure chamber
108.   Attach wiring harness bracket to pressure chamber
•   Tighten 2x nuts
109.   Install high pressure line from high pressure pump to accumulator
•   Remove protective caps
•   Insert high pressure line
•   Tighten 2x union nut with KM-812 or KM-6098 25 Nm
110.   Attach coolant pump
•   Replace gasket
•   Tighten 5x bolt 23.4 Nm
111.   Replace rear toothed belt cover
•   Tighten 5x bolt 9.8 Nm
112.   Insert toothed belt guide roller
•   Tighten bolt 80.4 Nm
113.   Fit high pressure pump wheel
Note:   Counterhold with KM-6356
•   Tighten nut 68,6 Nm
114.   Install camshaft sprocket
Note:   Camshaft journal must engage in the bore in the camshaft drive gear
•   Tighten bolt 63.7 Nm
Note:   Hold using KM-6347
•   Screw in TDC fixing bolt
115.   Install oil pump gear
Note:   Note installation position
•   Tighten nut
Note:   Counterhold with socket wrench
– 60 Nm
– Hold for 20 seconds
– Slacken nut
– 60 Nm
116.   Install toothed belt drive gear
•   Insert disc spring
•   Attach toothed belt drive gear to crankshaft
Note:   Note spring washer
•   Tighten bolt 196 Nm
Note:   Counterhold with KM-662-C
117.   Install toothed belt
Note:   TDC fixing bolts must be installed in the high pressure drive gear and camshaft drive gear and markings (6) and (7) must align
•   Position toothed belt
– Toothed belt must be tensioned in the direction of the arrow from the toothed belt drive gear (5) via the oil pump drive gear (4) and high pressure pump drive gear (2) to the camshaft sprocket (1)
– Observe direction of rotation
•   Slacken the toothed belt tension roller (3)
•   Remove 2x TDC fixing bolt
•   Turn crankshaft 60° against the direction of engine rotation
•   Tighten toothed belt tension roller 38.2 Nm
Object Number: 2412651 Size: DEFAULT


118.   Timing, Check
•   Turn crankshaft 6 revolutions in direction of engine rotation to the adjustment position
•   The following factors must be present at the adjustment position
Note:   If one of these factors is not present, the timing must be adjusted
1. TDC fixing bolt M6 (1) must be able to be inserted in the camshaft drive gear
2. TDC fixing bolt M8 (2) must be able to be inserted in the high pressure pump drive gear
3. Marking (4) on the toothed belt drive gear must align with the marking (3) on the oil pump housing cover

•   Remove 2x TDC fixing bolt
Object Number: 8125296 Size: DEFAULT


119.   Install front toothed belt cover (lower)
•   Tighten 3x bolt 9.8 Nm
120.   Install coolant pump drive gear
•   Tighten 3x bolt 12.3 Nm
Important:   Journal (1) of toothed belt drive gear must engage in the bore (2) of the torsional vibration damper
121.   Install torsional vibration damper
•   Tighten 4x bolt 19.6 Nm
Note:   Counterhold against bolt, toothed belt drive gear
Object Number: 2412652 Size: DEFAULT


122.   Turn the crankshaft until the cam pair (1) and (2) faces upwards.
123.   Check valve lash with feeler gauge
Note:   Valve lash must be checked at room temperature when the engine is cold.
•   Test values: Intake valve/exhaust valve (0.35 - 0.45 mm)
124.   Adjust valve play
•   Turn the bucket tappet until the tappet groove faces outwards
Important:   Care should be taken that the valves do not strike the piston head
•   Press down cup tappet with KM-6090
Note:   Note different tool designs for intake and exhaust valve
– Marking - IN = intake side
– Marking - EX = exhaust side
•   Remove shim
Object Number: 2415968 Size: DEFAULT


125.   Example for determination of shim thickness:

1.

Thickness of installed shim

  

3.15 mm

2.

Measurement between cams and cup tappets

+

0.45 mm
   

=

3.60 mm

3.

Nominal valve play

-

0.40 mm

4.

Thickness of new shim

=

3.20 mm
126.   Insert shim
•   Coat new shim (7) with engine oil and insert in cup tappet with code facing down
127.   Check and adjust remaining valves
•   Turn crankshaft 180° in the direction of rotation of the engine
– Check and adjust valve pair (6) and (2)
•   Turn crankshaft 180° in the direction of rotation of the engine
– Check and adjust valve pair (5) and (3)
•   Turn crankshaft 180° in the direction of rotation of the engine
– Check and adjust valve pair (4) and (1)
Note:   Valve lash must be checked again on all adjusted valves
Object Number: 2415969 Size: DEFAULT


128.   Install engine damping block bracket
•   Insert engine damping block adapter
•   Attach engine damping block support to cylinder block
– Tighten 3x bolt 50 Nm
•   Engine damping block support to engine damping block bracket
– Tighten 3x bolt 55 Nm
129.   Install front toothed belt cover (top)
•   Tighten 8x bolt 9.8 Nm
Note:   Note different bolt lengths
•   Install camshaft sensor bracket
– Tighten bolt 9.8 Nm
•   Attach vacuum line to toothed belt cover
– Clip in 3x clips
130.   Replace 2x seals, injector
•   Rubber gasket (1)
•   Copper gasket (2)
Object Number: 2416067 Size: DEFAULT


131.   Install 4x injector
•   Use KM-6358 (1)
•   Tighten 4x bolt in three stages
1. Tighten bolt 40 Nm
2. Loosen bolt
3. Tighten bolt 32 Nm

Object Number: 2413404 Size: DEFAULT


Object Number: 2413405 Size: DEFAULT

132.   Apply sealing compound
Important:   Oil return bore (2) may not be covered with adhesive sealing compound
•   Apply adhesive sealing compound (white) to sealing surfaces (1) and (3)

133.   Install camshaft housing cover
•   Replace gasket
•   Tighten 9x bolt in the stated order (1...9) 9.8 Nm
Object Number: 8125294 Size: DEFAULT


134.   Install 4x new seal, injectors (2)
•   Align seal for injectors
Note:   Sealing lip of seal must be in full contact with the injector with no gaps (arrow)
•   Coat 8x bolt head contact surface (1) with special grease (white)
•   Tighten injector seal in 2 stages
Note:   During the tightening process, press injector seal against the camshaft housing cover with your hand
1. Tighten 2x bolt 10 Nm
2. Tighten 2x bolt 19 Nm

Object Number: 8125295 Size: DEFAULT


135.   Install 4x new seal, connection for injectors
Note:   Marking "UP" must point upwards
•   Tighten 8x bolts
Object Number: 2413406 Size: DEFAULT


136.   Install fuel return line
Note:   Note different bolt lengths
•   Tighten nut
•   Tighten 2x bolts
•   Attach 4x fuel return line to injector
•   Attach fuel return line to accumulator
Important:   Pressure lines must be installed so that they are not under tension
137.   Install 4x high-pressure lines from pressure chamber to injectors
•   Remove 8x protective cap
•   Insert pressure lines
•   Attach pressure lines to injector and pressure chamber
– Tighten 8x union nut 25 Nm
Important:   Seal ring (1) may not be displaced on installation
138.   Install EGR-port
•   Replace gasket
•   Tighten 2x bolt 24 Nm
Note:   Note different bolt lengths
•   Attach coolant hose
– Fasten clamp
•   Attach EGR cooler -
– Replace gasket
– Tighten 2x bolts 28.5 Nm
Object Number: 2412691 Size: DEFAULT


139.   Install 3x engine transport shackle
140.   Fit charge air pipe
•   Replace 2x gaskets
•   Tighten 6x bolt 24 Nm
141.   Install starter
•   Tighten lower bolt 38.2 Nm
•   Tighten upper bolt 60 Nm
•   Attach cable connections
– Tighten 2x nuts
– Tighten bolt
– Connect cable ties
142.   Install oil filter housing
•   Replace 2x gaskets
– Oil filter housing to cylinder block
– Bolt, oil filter housing
Important:   Turn oil filter housing in direction of arrow until projection (1) is in contact with bracket (2)
•   Tighten bolt (3) 110 Nm
•   Attach oil return hose to oil pan
•   Attach 2x coolant hose to coolant port
Object Number: 2412661 Size: DEFAULT


143.   Attach throttle valve body bracket to camshaft housing
•   Tighten bolt 24 Nm
144.   Attach coolant discharge port
Note:   Use sealant (grey)
•   Tighten 2x bolts
145.   Install coolant pipe
•   Replace gasket
•   Install in coolant flange
•   Attach to cylinder block
– Tighten bolt 95.1 Nm
146.   Attach exhaust manifold with turbocharger
•   Replace gasket
•   Tighten 2x bolts 69 Nm
•   Tighten 7x nut 69 Nm
•   Attach to catalytic converter bracket
– Tighten 2x bolts
147.   Install turbocharger oil feed line
•   Replace 4x seal
•   Attach to turbocharger
– Tighten banjo bolt 27.5 Nm
•   Attach to cylinder block
– Tighten nut 20.6 Nm
148.   Attach exhaust manifold heat shield
•   Tighten 4x bolt 11.7 Nm
149.   Attach vacuum hose to turbocharger control unit
150.   Attach EGR cooler -
•   Replace 2x gaskets
•   Attach to exhaust manifold
– Tighten 2x bolts 28.5 Nm
•   Attach to exhaust gas recirculation port
– Tighten 2x bolts 28.5 Nm
•   Attach to camshaft housing
– Tighten bolt 24 Nm
151.   Install dipstick guide tube
•   On upper part of oil pan
– Replace gasket
– Tighten 2x bolts
•   Attach to camshaft housing
– Tighten 2x bolts
•   Attach vacuum line
– Clip in 2x clips
152.   Attach oil return hose to cylinder block
•   Fasten clamp
153.   Attach alternator support
•   Tighten 4x bolts
154.   Install alternator
•   Tighten 2x bolts
– Tightening torque (M8) 18.6 Nm
– Tightening torque (M10) 46.1 Nm
•   Attach oil return hose to vacuum pump
– Fasten clamp
•   Attach oil feed line to vacuum pump
– Replace 2x gaskets
– Tighten bolt
•   Attach vacuum line to brake force amplifier
– Tighten union nut
•   Attach solenoid valve vacuum line
155.   Attach compressor
Note:   Note different bolt lengths
•   Tighten 3x bolt 24.5 Nm
156.   Install air intake pipe.
•   Fasten 2x clamp 3.5 Nm
•   Tighten 2x bolts
•   Attach wiring harness
– Clip in 3x clips
157.   Attach wiring harness from starter alternator
Note:   Note routing of wires
•   Attach to alternator
– Fix wiring harness plug
– Tighten nut
•   Install cable conduit
•   Tighten bolt
•   Attach to starter
– Tighten 2x nuts
– Tighten bolt
•   Tighten oil pressure switch
•   Tighten coolant temperature sensor
•   Attach cable ties
•   Clip in 2x clips
158.   Insert ribbed V-belt
Note:   Note running direction of ribbed V-belt
•   Position ribbed V-belt
– I. Ribbed V-belt without air conditioning
– II. Ribbed V-belt with air conditioning
•   Apply tension to ribbed V-belt tensioner via bolt (1) in the direction of the arrow
•   Take out fixing
•   Release ribbed V-belt tensioner
Object Number: 2415977 Size: DEFAULT


159.   Attach engine timing wiring harness
•   Connect wiring harness plug to:
– Throttle body
– EGR valve
– Change-over valves for solenoid valve
– Injectors
– Sheathed glow plugs
– Pressure sensor
– Sensor for change-over valves
– Charge pressure sensor
– Alternator wiring harness plug
– EGR solenoid valve
– Pressure sensor
– Crankshaft pulse pick-up
– Camshaft sensor
•   Clip in 12x clip
160.   Top up engine oil.
•   Observe specified oil quantity
161.   Attach manual transmission to engine LUREF_1.gif
162.   Install engine
Important:   Wear protective goggles
163.   Carry out leak test on high pressure system
Note:   Engine must be at operating temperature
•   Carry out actuator test (fuel leak)
•   Visual inspection of high pressure system for fuel leak
1 ) Protective caps are available from the Opel parts catalogue under catalogue number 45 06 154 / part number: 9201697
2 ) Re-cut thread before re-using and insert bolt with locking compound (red). The maximum installation time including torque test is 10 minutes

Replace engine damping block (front) > < Manual Transmission, Remove from Engine and Install