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Vauxhall Workshop Service and Repair Manuals

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Manual Transmission, Remove from Engine and Install > < Engine cover, remove and install

Astra H

Engine, Remove and Install

  Remove

1.   Open bonnet
2.   Remove steering column interim spindle
•   Move steering wheel to straight-ahead position
•   Remove ignition key and engage steering lock
•   Unscrew bolt (1)
Object Number: 3446122 Size: DEFAULT


3.   Detach radiator grille (2)
•   Detach 4x body-bound rivets (1)
•   Unclip from front panelling
Object Number: 3446548 Size: DEFAULT


4.   Empty climate control system
•   Connect service station
•   Blue hose to low-pressure service connection with small diameter
•   Red hose to high-pressure service connection with large diameter
Note:   Read Service Station operating instructions carefully
•   Determine quantity of condenser extracted at the oil separator of the Service Station
Object Number: 3446584 Size: DEFAULT


5.   Raise vehicle by its full height
6.   Detach the lower engine cover and right engine splash guard
7.   Place collecting basin underneath.
8.   Drain coolant
•   Open drain bolt on radiator (1)
•   Collect coolant
•   Close drain bolt
Object Number: 3446550 Size: DEFAULT


9.   Lower vehicle by its full height
10.   Remove battery
•   Detach 2x earth cable from earth connection
– Unscrew 2x bolts (4)
•   Detach earth terminal from battery
•   Detach positive cable from positive clamp
– Unscrew bolt (3)
•   Detach positive connection from battery
•   Remove bracket 1)
•   Unscrew bolt (2)
Object Number: 3446569 Size: DEFAULT


11.   Remove battery support.
•   Remove pre-glow system control unit (4)
•   Remove wiring harness plug (3)
•   Detach coolant hose
– Unclip clip (5)
•   Detach wiring harness
– Detach 2x cable ties (1)
•   Unscrew 3x bolts (2)
Object Number: 3446570 Size: DEFAULT


12.   Remove air cleaner housing (5) with air intake hose
•   Detach wiring harness plug (2) from hot film mass air flow meter
•   Detach air intake hose from air intake pipe
– Release clamp (1)
•   Detach air cleaner housing from wheel housing
– Unscrew bolt (4)
•   Detach water drain hose (3) from air cleaner housing
– Release clamp
Object Number: 3446547 Size: DEFAULT


13.   Remove engine cover (2)
•   Detach oil filler port closure cap (1)
•   Pull off engine cover
Note:   Rubber retainers (3) must remain on engine cover
•   Attach oil filler port closure cap
Object Number: 2412632 Size: DEFAULT


14.   Disconnect refrigerant line
•   Unscrew bolt (1)
Object Number: 2412694 Size: DEFAULT


15.   Detach fuel supply lines from high-pressure pump
•   Detach from return line connection (1)
– Release clamp
•   Detach from supply line connection (2)
– Release clamp
Object Number: 2412695 Size: DEFAULT


16.   Remove brake force amplifier vacuum line (2)
•   Release clamp
•   Unclip brake force amplifier vacuum line and set aside
Object Number: 2412698 Size: DEFAULT


17.   Disconnect 2x coolant hose (1) from heater core
•   Release 2x coolant hoses in direction of arrow
Object Number: 3446571 Size: DEFAULT


18.   Detach 3x coolant hoses (1) from coolant expansion tank
•   Undo 3x clamps
Object Number: 3446572 Size: DEFAULT


19.   Disconnect starter wiring harness
•   Disconnect wiring harness plug (2)
•   Put wiring harness (1) aside on drive unit
Object Number: 3446573 Size: DEFAULT


20.   Detach pressure line (1) from wiring harness connection piece
•   Release clamp with screwdriver in direction of arrow and remove
•   Bend clip together a little and insert back into connecting piece
Object Number: 3446574 Size: DEFAULT


21.   Disconnect shift cables (1) from shift assembly with KM-6042
Important:   Shift cables must not be stretched, twisted or kinked
•  
Object Number: 2414960 Size: DEFAULT


22.   Remove coolant expansion tank (1)
•   Pull from bracket in direction of arrow
Object Number: 3446575 Size: DEFAULT


23.   Disconnect steering wiring harness
•   Remove fuse carrier cover (1)
•   Detach positive cable (2) from fuse carrier
Note:   Mark installation position
– Unscrew nut
•   Disconnect wiring harness connector (3)
•   Expose wiring harness and put aside on drive unit
– Detach 4x cable ties
Object Number: 3446576 Size: DEFAULT


24.   Disconnect upper engine timing wiring harness
•   Detach positive cable (1) from fuse carrier
Note:   Mark installation position
– Unscrew nut
•   Disconnect wiring harness plug (2)
•   Put engine timing wiring harness with pre-heating system control unit (3) aside on drive unit
Object Number: 3446577 Size: DEFAULT


25.   Slacken front wheels
26.   Raise vehicle by half its height
27.   Remove front wheels
28.   Undo front panelling (1)
•   Remove 5x body-bound rivets (3)
•   Unscrew 4x bolts (4)
29.   Remove front panelling
Note:   Second mechanic
•   Push front panelling upwards in direction of arrow and pull out of bracket
•   Remove front panelling
– Unclip 4x clips (2)
•   Unclip outside temperature sensor
Object Number: 3446563 Size: DEFAULT


30.   Detach front part of right wheelhouse panelling
•   Remove 3x body-bound rivets
31.   Disconnect cooling module wiring harness
•   Unscrew nut (1)
•   Disconnect wiring harness plug (2)
•   Unfasten 3x cable ties
Object Number: 3446578 Size: DEFAULT


32.   Detach lower engine timing wiring harness
•   Detach wiring harness plug (1) from engine control unit
•   Detach 2x cable ties
Object Number: 3446579 Size: DEFAULT


33.   Detach refrigerant line (1)
•   Remove from desiccant box
– Unscrew bolt
Object Number: 2412699 Size: DEFAULT


34.   Detach 2x swing arms (2)
•   Unscrew 2x nuts
– Use spanner (1) to hold against flat surface
35.   Detach 2x tie rods
•   2x nuts
– Force back from steering knuckle with KM-507-C (3)
36.   Detach 2x steering knuckle pins
•   Detach 2x screw connections
•   Spread steering knuckle pins with KM-915 (4) and draw guiding joint out of steering knuckle
Object Number: 2415185 Size: DEFAULT


37.   Detach 2x axle shafts
•   Unscrew 2x nuts
– Counterhold at wheel hub with KM-468-B (1)
Object Number: 2418002 Size: DEFAULT


38.   Raise vehicle by half its height
39.   Remove front exhaust pipe
•   Detach from start-up catalytic converter
– Unscrew 3x nuts (1)
•   Detach from central silencer
– Release clamp (2)
Object Number: 2412700 Size: DEFAULT


40.   Insert KM-6173 (3)
•   Align support bearing (1)
•   Raise support bearing until journal (2) sits flush in mount (4)
•   Fasten KM-6173
– Screw in 2x bolts
Object Number: 2412781 Size: DEFAULT


41.   Attach KM-6001-A (1)
Note:   Attaching KM-6001-A guarantees perfect alignment of the drive unit with the front axle body
•   Slacken 4x bolts (arrows) in adjusting rails
•   Insert KM-6001-A
– Insert journals (2) and (5) in guide holes in front axle body
•   Tighten 4x bolts in adjusting rails
•   Adjust support bearings, front (4) and rear (3)
– Raise support bearings up to the stop on the guide journals
Note:   The guide journals must be seated free from play in the support bearings
Object Number: 2414110 Size: DEFAULT


42.   Lower vehicle by its full height
43.   Detach left engine damping block from transmission
•   Unscrew 3x bolts (1)
Object Number: 3446581 Size: DEFAULT


44.   Detach right engine damping block from engine damping block adapter
•   Unscrew 3x bolts (1)
Object Number: 3446580 Size: DEFAULT


45.   Raise vehicle by its full height
46.   Attach KM-904 with KM-6390
•   Attach to hydraulic lifter
Note:   Use hydraulic jack that can be lowered to a height of at least 100 cm
•   Lower centring pins (1)
– Remove 2x splines
•   Place under front axle body, ensure there is no play
– Centring pins (2) must engage in the relevant holes in the front axle body
Object Number: 3446252 Size: DEFAULT


Important:   It is not permissible to disassemble the front axle body with an impulse or impact screwdriver
47.   Remove front axle body
•   Unscrew 10x bolts (1...4)
Note:   Note different bolt lengths
Object Number: 2397674 Size: DEFAULT


Important:   Ensure that no attached parts are damaged
48.   Move out front axle body
Note:   2 people

  Install

49.   Check thread
•   Check ease of movement of 10x cage nuts, replacing if necessary
Important:   Ensure that no attached parts are damaged
50.   Lift front axle body
Note:   2 people
Important:   It is not permissible to assemble the front axle body with an impulse or impact screwdriver
51.   Fit front axle body
•   Tighten 10x new bolt 90 Nm + 45° + 15°
52.   Detach KM-904 and KM-6390
•   Lower hydraulic lifter
53.   Lower vehicle by its full height
54.   Fit right-hand engine damping block
•   Tighten 3x bolt 55 Nm
55.   Fit left-hand engine damping block
•   Tighten 3x bolt 55 Nm
56.   Raise vehicle by its full height
57.   Remove engine mount KM-6173
•   Unscrew 2x bolts
58.   Remove engine mount KM-6001-A
•   Undo 4x bolts
59.   Install front exhaust pipe
•   Attach to start-up catalytic converter
– Replace gasket
– Tighten 3x new nuts
•   Attach to central silencer
– Fasten clamp
60.   Install lower engine cover and right engine splash guard
61.   Lower vehicle by half its height
62.   Install axle shafts in wheel hub
•   Insert guiding joint into steering knuckle
•   Tighten 2x nut 150 Nm , slacken 45° , then tighten to 250 Nm
– Use new nuts
•   Counterhold at wheel hub with KM-468-B
63.   Attach guide joint to steering knuckle
•   Tighten 2x new screwed joint 50 Nm
64.   Attach tie rods to steering knuckle
•   Screw in 2x new nut 30 Nm + 90° + 15
65.   Attach swing arm to spring strut support tube
•   Tighten 2x nut 65 Nm
•   Use spanner to counterhold against flat surface
66.   Attach refrigerant line to desiccant bottle
•   Replace gasket
•   Tighten bolt 22 Nm
67.   Attach lower engine timing wiring harness
Note:   Ensure cable is routed correctly
•   Connect wiring harness plug to engine control unit
•   Attach 2x cable ties
68.   Connect cooling module wiring harness
Note:   Ensure cable is routed correctly
•   Tighten nut
•   Fix wiring harness plug
•   Attach 3 cable ties
69.   Attach front part of right wheelhouse panelling
•   Install 3x body-bound rivets
70.   Insert front panelling
Note:   Second mechanic
•   Clip in outside temperature sensor
•   Insert front panelling
– Clip in 4x clips
71.   Fit front panelling
•   Install 5x body-bound rivets
•   Screw in 4x bolts
72.   Install front wheels
•   Screw in 5x bolt
73.   Lower vehicle by half its height
74.   Tighten front wheels
•   Tighten 5x bolts 110 Nm
75.   Connect engine timing wiring harness (top)
Note:   Ensure cable is routed correctly
•   Lay wiring harness for engine timing with preheater system control unit
•   Attach positive cable to fuse carrier
– Tighten nut
•   Fix wiring harness plug
76.   Connect steering wiring harness
Note:   Ensure cable is routed correctly
•   Detach positive cable from fuse carrier
– Tighten nut
•   Attach fuse carrier cover
•   Fix wiring harness plug
•   Attach 3 cable ties
77.   Install coolant expansion tank
•   Clip into bracket
78.   Attach shift cables to shift assembly
Important:   Shift cables must not be stretched, twisted or kinked
•   Clip shift cables into bracket
Important:   Retaining clamp must engage correctly
79.   Attach pressure line to wiring harness connection piece
80.   Connect starter wiring harness
Note:   Note routing of wires
•   Fix wiring harness plug
81.   Attach 3x coolant hoses to coolant expansion tank
•   Attach 3x clamps
Important:   It is imperative to adhere to the following assembly order
82.   Attach cooling hoses to heater core
•   Slide 2x quick release fitting locking mechanisms in direction of arrow as far as they will go
– Plastic rings (green) will be covered
•   Fit 2x quick release fittings onto heater core connecting piece (1) as far as they will go
Note:   Pay attention to coloured markings
•   Slide 2x quick release fitting locking mechanisms (3) in direction of arrow as far as they will go
– Plastic rings (green) must be visible
•   Check that quick release fittings are correctly seated and that plastic rings (arrows) are visible
Object Number: 3446293 Size: DEFAULT


83.   Fit brake force amplifier vacuum line
•   Clip in brake force amplifier vacuum line
•   Fasten clamp
84.   Attach fuel line to high-pressure pump
•   Attach 2x clamps
85.   Connect refrigerant line
•   Replace gasket
•   Tighten bolt 22 Nm
86.   Install engine cover
•   Detach oil filler port closure cap
•   Refit engine cover
•   Attach oil filler port closure cap
87.   Install air cleaner housing with air intake hose
•   Attach water drain hose to air cleaner housing
– Fasten clamp
•   Tighten bolt 15 Nm
•   Attach air intake hose to air intake pipe
– Fasten clamp 3.5 Nm
•   Connect wiring harness plug to air mass flow meter
88.   Install battery holder
•   Tighten 3x bolts
•   Attach pre-glow system control device
•   Attach wiring harness plug
•   Clip in coolant hose
•   Attach wiring harness
– Connect 2x cable ties
89.   Install battery
•   Install bracket
– Tighten bolt
90.   Connect battery
•   Attach earth connection to battery
– Tighten nut
•   Attach 2x earth cable to earth connection
– Tighten 2x bolts
•   Attach positive connection to battery
– Tighten nut
•   Attach positive cable to positive terminal
– Tighten bolt
91.   Top up coolant, correct if necessary
92.   Top up coolant or ensure correct quantity is present.
93.   Vent hydraulic clutch actuator LUREF_1.gif
94.   Top up climate control system
•   Connect service station
•   Connect blue hose to low pressure service connection with small diameter
•   Connect red hose to high pressure service connection with large diameter
Note:   Read Service Station operating instructions carefully
•   Use the Service Station to insert the quantity of new compressor lubricant into the climate control system that was extracted when it was emptied.
– Fill air conditioning system with R 134a refrigerant
Object Number: 3446584 Size: DEFAULT


95.   Install radiator grille
•   Clip upwards into front panelling
•   Install 4x body-bound rivets
96.   Install intermediate shaft clamp bolt, steering column
•   Coat new bolt with locking compound (red) and screw in 22 Nm
97.   Program volatile memories
98.   Close bonnet

Manual Transmission, Remove from Engine and Install > < Engine cover, remove and install