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Vauxhall Workshop Service and Repair Manuals

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Component Locator > < Engine, Remove and Install

Astra H

Repair engine using a short block

  Remove

1.   Remove engine
2.   Remove manual transmission from engine LUREF_1.gif
3.   Place collecting basin underneath.
4.   Drain engine oil
•   Open drain bolt
•   Tighten drain bolt 14 Nm
5.   Remove cylinder head
6.   Remove right engine damping block support
•   Unscrew 3 bolts
7.   Remove compressor
•   Unscrew 3x bolts (1)
•   Set aside
Object Number: 9007873 Size: DEFAULT


8.   Remove oil pressure switch
•   Disconnect wiring harness connector.
– Push back heat shield
•   Unscrew oil pressure switch
Object Number: 2412892 Size: DEFAULT


9.   Detach alternator
•   Disconnect alternator from power supply
– Unscrew 2x nuts (1) and (2)
•   Unscrew 2x bolts (3) and (4)
Object Number: 2412800 Size: DEFAULT


10.   Detach earth cable (1) from starter
•   Unscrew nut
11.   Detach 2x positive cable (2) starter
•   Unscrew 2x nuts
Object Number: 9007889 Size: DEFAULT


12.   Remove starter
•   Unscrew 2x bolts (1) and (2)
Object Number: 9007890 Size: DEFAULT


13.   Detach engine wiring harness
•   Disconnect 4x wiring harness plugs
•   Unclip wiring harness from brackets and expose
14.   Detach coolant flange (3)
•   Detach bracket (1)
– Unscrew 2x bolt (2)
•   Unscrew 4x bolts (4) and (5)
Object Number: 2412808 Size: DEFAULT


15.   Detach thrust plate and clutch disk LUREF_1.gif
16.   Remove flywheel
•   Lock flywheel via starter ring gear with KM-652 (1)
•   Unscrew 6x bolts
Object Number: 2412810 Size: DEFAULT


17.   Release flywheel lock
•   KM-652
18.   Rotate engine on engine overhaul stands through 180°
19.   Remove oil pan
•   Unscrew 15x bolts (arrows)
Object Number: 2412814 Size: DEFAULT


20.   Lever off oil pan evenly all the way round with suitable tool
Note:   To avoid damage to the oil filter, ensure that the oil filter (1) remains in the oil pan. If it remains attached to the cylinder head, press the oil filter into the oil pan using a screwdriver.
Object Number: 10681394 Size: DEFAULT


21.   Detach coolant pipe (2) from pump module
•   Unscrew 2x bolts (1)
•   Push coolant pipe into oil pump housing
22.   Detach coolant pipe (3) from pump module
•   Detach coolant pipe from oil filter housing
– Unscrew bolt (4)
•   Push coolant pipe into oil filter housing
Object Number: 9007908 Size: DEFAULT


23.   Remove toothed belt drive gear
24.   Detach toothed belt guide roller (1)
•   Unscrew bolt (2)
25.   Remove pump module
•   Unscrew 8x bolts (3) and (4)
Note:   Note different screw lengths
•   Remove gasket
Object Number: 2412815 Size: DEFAULT


26.   Remove heat exchanger
27.   Detach crankshaft pulse pick-up (2) from pulse pick-up bracket
•   Unscrew bolt (1)
Object Number: 9007891 Size: DEFAULT


28.   Detach knock sensor (1)
•   Unscrew bolt
Object Number: 10681417 Size: DEFAULT


  Install

29.   Emboss engine number
•   Onto flattened area on cylinder block (arrow) with numbers punches
Object Number: 2412818 Size: DEFAULT


30.   Attach knock sensor 20 Nm
31.   Attach crankshaft pulse pick-up to pulse pick-up bracket
•   Tighten bolt 4.5 Nm
32.   Install heat exchanger
33.   Install pump module
•   Replace gasket
Note:   Note different screw lengths
•   Tighten 8x bolt 20 Nm
34.   Attach coolant pipe to coolant module
•   Draw coolant pipe out of oil filter housing
•   Attach coolant pipe to oil filter housing
– Tighten bolt
35.   Attach coolant pipe to coolant module
•   Draw coolant pipe out of oil pump housing
•   Tighten 2x bolts
36.   Insert toothed belt guide roller
•   Tighten bolt 25 Nm
37.   Insert front crankshaft seal ring (1)
•   Clean sealing surfaces.
•   Slide protective sleeve of KM-6351 (2) onto crankshaft journal
•   Slide seal ring over protective sleeve on the crank pin
Object Number: 2412953 Size: DEFAULT


38.   Insert toothed belt drive gear
39.   Clean sealing surfaces.
40.   Check position of oil filter (1)
Object Number: 10681395 Size: DEFAULT


41.   Apply an approx. 3.5 mm thick bead of oil pan sealant to the joints (arrows)
Object Number: 8231010 Size: DEFAULT


Object Number: 8231009 Size: DEFAULT

42.   Apply oil pan sealant to the oil pan
Note:   The assembly time including torque check must take no longer than 10 min
•   Apply an approx. 3.5 mm thick bead of oil pan sealant (1) as illustrated

43.   Install oil pan
•   Tighten 15x bolt on cylinder block and pump module 10 Nm
44.   Rotate engine on engine overhaul stands through 180°
45.   Fit flywheel
•   Clean 6x threads
•   Insert KM-652
•   Renew bolts
•   Tighten 6x bolt 35 Nm + 30° + 15°
– Apply screw locking compound
46.   Attach thrust plate and clutch disk LUREF_1.gif
47.   Fit coolant flange
•   Use new gasket
•   Screw in 4x bolt evenly until the housing is in contact with the cylinder head
Important:   It is essential to comply with the specified tightening sequence - risk of fracture
•   Tighten 4x bolt (1), (2), (3) and (4) 8 Nm
Object Number: 10678102 Size: DEFAULT


48.   Attach wiring harness bracket to coolant flange
•   Tighten 2x bolt 8 Nm
49.   Detach engine wiring harness
•   Connect 4x wiring harness plugs
•   Route wiring harness and clip into bracket
50.   Install starter
•   Tighten 2x bolt 25 Nm
51.   Attach wiring harness to starter
•   Tighten 2x nuts
52.   Attach earth cable to starter
•   Tighten nut
53.   Attach alternator
•   Tighten 2x bolt 35 Nm
54.   Attach wiring harness to alternator
•   Tighten 2x nuts
55.   Attach right engine damping block support to engine block
Note:   Do not tighten bolts until the 3rd bolt of the engine damping block support has been screwed into the cylinder head.
•   Tighten 2x bolt
56.   Install cylinder head
57.   Attach manual transmission to engine LUREF_1.gif
58.   Install engine
59.   Top up engine oil.
•   Check engine oil level and top up if necessary

Component Locator > < Engine, Remove and Install