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Vauxhall Workshop Service and Repair Manuals

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Engine Identification Code / Engine Number > < Resonator, Replace

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.   Remove air cleaner housing
•   Disconnect mass air flow sensor wiring harness plug (2)
•   Unclip tank vent line (3)
•   Detach engine vent hose (4) from air intake hose
– Release clamp
•   Detach air intake hose (5) from throttle valve body
– Release clamp
•   Detach air cleaner housing
– Unscrew bolt (1)
– Unclip rubber mounting at the bottom
– Remove air intake pipe (6)
Object Number: 3446127 Size: DEFAULT


4.   Detach earth cable
•   Detach earth cables (4) and (5) from earth terminal (3)
– Unscrew 2x bolts
•   Detach earth connection from negative terminal
– Loosen bolt
5.   Detach positive cable
•   Detach positive cable (2) from positive terminal (1)
– Unscrew bolt
•   Detach positive connection from positive terminal
– Unscrew bolt
Object Number: 3446123 Size: DEFAULT


6.   Remove battery
•   Unscrew bolt (1)
– Remove retaining plate (2)
•   Remove battery
Object Number: 3446124 Size: DEFAULT


7.   Remove battery support (2)
•   Unscrew 3x bolts (1)
•   Detach wiring harness
– Undo cable ties
Object Number: 3446125 Size: DEFAULT


8.   Detach tank vent valve hose (1) from tank vent valve
Object Number: 3446126 Size: DEFAULT


9.   Release fuel pressure with KM-J-34730-91 (2) via test connection
Note:   Collect exiting fuel in a suitable container - observe safety regulations and national legislation
•   Remove protective cap (1)
Object Number: 3446128 Size: DEFAULT


10.   Detach fuel supply line (2) with KM-796 (1) from fuel distributor pipe
•   Disconnect quick-release fitting
11.   Detach brake servo vacuum line (3) from intake manifold
•   Disconnect quick-release fitting
Object Number: 3446129 Size: DEFAULT


12.   Disconnect engine wiring harness
•   Disconnect wiring harness plug (1)
– Release retainer in direction of arrow
– Undo cable ties
•   Disconnect wiring harness plugs (2) from engine control unit (4)
– Unlatch fuse (3)
•   Unclip 3x wiring harnesses
Object Number: 3446131 Size: DEFAULT


13.   Disconnect wiring harness plug (1), reversing light switch
Object Number: 3446241 Size: DEFAULT


14.   Disconnect wiring harness plug, earth connection (1)
•   Release retainer in direction of arrow
Object Number: 3446242 Size: DEFAULT


15.   Remove coolant expansion tank (1)
•   Pull out of bracket in direction of arrow
Object Number: 3446130 Size: DEFAULT


16.   Disconnect steering wiring harness
•   Remove fuse carrier cover
•   Detach positive cable (2) from fuse carrier
– Unscrew nut (3)
•   Disconnect wiring harness plug (1)
•   Expose wiring harness
– Undo cable ties
– Unclip 3x wiring harnesses
Object Number: 3446243 Size: DEFAULT


17.   Detach pressure hose, central release (2)
•   Place collecting pan underneath.
•   Unlatch retaining clamp (1) with screwdriver and detach
•   Bend clip together a little and insert back into connecting piece
•   Tie up pressure line for central release
Object Number: 2411019 Size: DEFAULT


18.   Slacken front wheels
•   Slacken 8x bolt
19.   Raise vehicle by half its height
20.   Remove front wheels
•   Unscrew 8x bolts
21.   Remove radiator grille
•   Remove 4x body-bound rivets (1)
•   Unclip radiator grille (2) upwards from front panelling
Object Number: 3446256 Size: DEFAULT


22.   Raise vehicle by half its height
23.   Undo front panelling (1)
•   Remove 5x body-bound rivets (3)
•   Unscrew 4x bolts (4)
24.   Remove front panelling
Note:   Second man
•   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


25.   Remove right engine splash guard (2)
•   Unscrew 4x bolts (1)
•   Remove 2x body-bound rivets (3)
Object Number: 3446244 Size: DEFAULT


26.   Detach swing arm (2) from spring strut support tube
•   Unscrew 2x nuts
Note:   Use spanner (1) to hold against flat surface
27.   Detach tie rods from steering knuckle with KM-507-C (3)
•   Unscrew 2x nuts
28.   Detach guide joints (4) from steering knuckle
•   Unscrew 2x nuts
•   Remove 2x bolt
•   Expand steering knuckle bolts with KM-915
•   Pull guide joints out of steering knuckle
Object Number: 2415185 Size: DEFAULT


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


30.   Raise vehicle by half its height
31.   Drain coolant
•   Place collecting pan underneath.
•   Attach suitable hose to drain connection (2)
•   Open coolant drain screw (1)
– Drain coolant
•   Close coolant drain screw
Object Number: 3446245 Size: DEFAULT


32.   Disconnect cooling module wiring harness plug (1)
Object Number: 3446246 Size: DEFAULT


33.   Disconnect wiring harness plug of catalytic converter control oxygen sensor (1)
Object Number: 3446247 Size: DEFAULT


34.   Detach clamp (1) from shift rod
•   Loosen bolt
•   Detach shift guide from shift rod
Object Number: 2398380 Size: DEFAULT


35.   Remove end silencer (1)
•   Slacken fastening clamp (3)
– Unscrew nut
•   Remove from bracket
– Detach 2x rubber bearings (2)
•   Detach end silencer from front silencer
Note:   Second man
Object Number: 3446248 Size: DEFAULT


36.   Detach front exhaust pipe (2) from catalytic converter
•   Unscrew 3x nuts (1)
Object Number: 3446249 Size: DEFAULT


37.   Remove front exhaust pipe with front silencer
•   Unhook 2x rubber bearing (1)
Object Number: 3446264 Size: DEFAULT


38.   Insert KM-6173 (3)
•   Slacken 4x bolts (arrows) and hand-tighten
•   Align KM-6173 at front axle body
•   Wind up the support bearing (1)
– Journal (2) must sit in mount at cylinder block
•   Tighten 4x bolts
Object Number: 3446250 Size: DEFAULT


39.   Attach KM-6001-A (1)
Note:   Attaching KM-6001-A guarantees perfect alignment of the drive unit with the front axle body
•   Slacken 3x bolts (arrows) in adjusting rails
•   Insert KM-6001-A
– The journals (2) and (5) must sit in the guide holes of the front axle body
•   Tighten 3x 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


40.   Lower vehicle by its full height
41.   Detach coolant hoses (1) from heater core
Note:   Mark assignment using coloured markings
•   Place collecting pan underneath.
•   Release 2x quick-release fittings in direction of arrow
•   Detach coolant hoses
Object Number: 3446251 Size: DEFAULT


42.   Detach right engine damping block from engine damping block bracket
•   Unscrew 3x bolts (1)
43.   Detach left engine damping block from engine damping block bracket
•   Unscrew 3x bolts (2)
Object Number: 2412782 Size: DEFAULT


44.   Raise vehicle by its full height
45.   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
46.   Remove front axle body
•   Unscrew 10x bolts (1, 2, 3, 4)
Note:   Note different bolt lengths
Object Number: 2397674 Size: DEFAULT


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

  Install

48.   Check thread
•   Check ease of movement of 10x cage nuts, replacing if necessary
49.   Lock shift rod
•   Turn shift rod (1) in the direction of the arrow
•   At the same time, cause the locking pin (2) to engage by pressing it
Object Number: 3446253 Size: DEFAULT


Important:   Ensure that no attached parts are damaged
50.   Move front axle body back in
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
•   Use new bolts
•   Tighten 10x bolt 90 Nm + 45° + 15°
52.   Detach KM-904 and KM-6390
•   Lower hydraulic lifter
53.   Lower vehicle by its full height
54.   Attach right engine damping block to engine damping block adapter
•   Tighten 3x bolt 55 Nm
55.   Attach left engine damping block to engine damping block adapter
•   Tighten 3x bolt 55 Nm
Important:   It is imperative to adhere to the following assembly order
56.   Attach coolant hoses to heater core
•   Fit 2x quick release fittings (1) onto heater core connection port (2) as far as they will go
Note:   Pay attention to coloured markings
•   Slide the 2x quick-release fitting catches (3) in the direction of the arrow all the way to the stop by simultaneously pressing the release buttons (4)
– The colour rings (5) must be visible
•   Check that quick release fittings are correctly seated and that the colour rings (5) are visible
Object Number: 10680549 Size: DEFAULT


57.   Raise vehicle by half its height
58.   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
59.   Attach guide joint to steering knuckle
•   Use new nuts
– Tighten 2x screwed joint 50 Nm
60.   Attach tie rods to steering knuckle
•   Use new nuts
•   Tighten 2x nut 30 Nm + 90° + 15°
61.   Attach swing arm to spring strut support tube
•   Tighten 2x nut 65 Nm
– Use new nuts
– Use spanner to counterhold against flat surface
62.   Raise vehicle by half its height
63.   Remove KM-6173
•   Undo 2x bolts
64.   Remove KM-6001-A
•   Undo 3x bolts
65.   Insert front exhaust pipe with front silencer
Note:   Second man
•   Attach 2x rubber bearings
66.   Attach front exhaust pipe with front silencer to catalytic converter
•   Use new gasket
•   Use new nuts
•   Tighten 3x nut 20 Nm
67.   Install rear silencer
Note:   Second man
•   Fit rear silencer to front silencer
•   Attach 2x rubber bearings
•   Tighten nut
68.   Connect wiring harness plug for catalytic converter control oxygen sensor
69.   Attach wiring harness plug for cooling module
70.   Attach right engine splash guard
•   Tighten 4x bolts
•   Install 2x body-bound rivets
71.   Attach oil drain bolt to oil pan
•   Use new seal ring
•   Tighten drain bolt 10 Nm
72.   Fit front panelling
•   Second man
Note:   Slide side front panelling into bracket
•   Clip in outside temperature sensor
•   Install 5x body-bound rivets
•   Tighten 4x bolts
73.   Install radiator grille
•   Clip into front panelling
•   Install 4x body-bound rivets
74.   Install front wheels
•   Tighten 8x bolt 110 Nm
75.   Lower vehicle
76.   Attach pressure line for central release
•   Attach to connection
77.   Connect steering wiring harness
•   Attach positive cable to fuse carrier
– Screw in nut!
•   Fix wiring harness plug
•   Fasten wiring harness
– Connect cable ties
– Clip in 3x clips
•   Install fuse box cover
78.   Insert coolant expansion tank into bracket
79.   Attach earth cable to earth terminal
•   Tighten bolt
•   Connect one wiring harness plug
80.   Attach positive cable to positive terminal
•   Tighten bolt
81.   Connect engine wiring harness
•   Connect wiring harness plug to engine control unit
– Attach wiring harness
•   Attach wiring harness plug to reversing light switch
•   Connect wiring harness plug, engine wiring harness
82.   Attach brake servo vacuum line to intake manifold
83.   Attach fuel supply line to fuel rail
•   Connect quick release fitting
84.   Attach vent hose to tank vent valve
85.   Insert shift lever fixing KM-527-A (1) in shift lever housing
•   Unclip cover of central console
•   Detach shift lever cover from central console
– Unscrew 2x bolts
Object Number: 2412783 Size: DEFAULT


86.   Raise vehicle by its full height
87.   Attach shift guide clamp to shift rod
•   Tighten bolt 12 Nm + 180° to 225°
88.   Lower vehicle by its full height
89.   Vent hydraulic clutch actuator LUREF_1.gif
90.   Install battery holder
•   Tighten 3x bolts
•   Attach wiring harness to battery support
– Attach cable ties
91.   Install air cleaner housing
•   Attach air cleaner housing to wheelhouse
– Tighten bolt
•   Attach air intake hose to throttle valve module
– Fasten clamp
•   Attach engine vent hose to timing case
– Fasten clamp
•   Attach wiring harness plug to hot film mass air flow meter
•   Clip in tank vent line
92.   Install battery
•   Install battery bracket
– Tighten bolt
•   Attach positive connection to positive terminal
– Tighten nut
•   Attach earth connector to negative terminal
– Tighten nut
93.   Tighten bolt, intermediate steering spindle 22 Nm
•   Coat bolt with screw locking compound and insert
94.   Remove shift lever fixing
Note:   Locking pin in adjusting bore releases itself the first time the shift lever is engaged in the direction "R"
•   Draw KM-527-A out of shift lever housing
•   Clip shift lever cover into central console
95.   Check that gears shift correctly
•   Check ease with which gear changes are made with the vehicle stationary, the engine running and the clutch disengaged
96.   Fill with coolant and bleed LUREF_1.gif
97.   Program volatile memories
98.   Close bonnet

Engine Identification Code / Engine Number > < Resonator, Replace