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Oil Pump Seal Replacement > < Dual Mass Flywheel Diagnosis

Astra J

Oil Pump Housing Replacement (without Start/Stop System)

Special Tool

•  EN-470-B   Torque Wrench
•  EN-662-C   Holding Wrench
•  EN-46781   Fixing Tool Camshaft
•  EN-46785   Fixing Tool Crankshaft
•  EN-46775   Centering Tool Oil Pump Housing

For equivalent regional tools, refer to Special Tools .

Removal Procedure

1. Remove the oil pan. Refer to Oil Pan Replacement .
2. Remove the crankshaft pulley. Refer to Crankshaft Pulley Replacement .
3. Remove the drive belt tensioner. Refer to Drive Belt Tensioner Replacement .
4. Remove the engine mount bracket. Refer to Engine Mount Bracket Replacement .

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5. Remove the 2 oil filler tube bolts (2, 3).
6. Remove the oil filler tube (1) from the oil pump housing (4).

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Note:  The fuel rail may not be subjected to the effects of any external forces after the bracket has been removed.
7. Remove the 2 fuel rail bolts (1).
8. Remove the 3 fuel rail bracket bolts (3).
9. Remove the fuel rail bracket (4).
10. Remove the engine lift bracket (2).

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11. Remove the intake camshaft housing core hole plug (1) from the camshaft housing.
12. Clean the threads at the camshaft housing and the camshaft housing core hole plug.

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13. Mark (arrow) on the EN-46781   fixing tool (1).

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Note:  The EN-46781   fixing tool (1) must be installed in horizontal position.
14. Install the EN-46781   fixing tool (1) into the intake side.

Note:  If the EN-46781   fixing tool (1) does not rotate any longer, the tool is correctly engaged.
15. Turn the crankshaft at the crankshaft sprocket bolt carefully, until the EN-46781   fixing tool (1) engages at the intake camshaft.
16. Raise the vehicle.

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Note:  Turn the crankshaft carefully until EN-46785   fixing tool (1) engages in the flywheel.
17. Install the EN-46785   fixing tool (1).

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18. Install the EN-662-C   wrench (2).
19. Install the 2 bolts.
20. Loosen the crankshaft sprocket bolt (1).

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Note:  Mind the left-hand thread.
21. Remove and DISCARD the crankshaft sprocket bolt. (1)
22. Remove the flange (2).

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23. Remove the 14 oil pump housing bolts (3).
24. Remove the 3 oil pump housing nuts (4).
25. Remove the oil pump housing (2).
26. Remove the oil pump housing gasket (1).

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27. Remove the oil pump seal (1).

Installation Procedure

1. Ensure that EN-46781   fixing tool and EN-46785   fixing tool are already installed.

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Note:  The oil pump housing must be fitted within 10 minutes of applying the silicone sealing compound.
2. Apply silicone sealing compound to the transitions between the cylinder head and camshaft housing (1) and between the cylinder block and cylinder head (2).

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3. Install the oil pump housing gasket (1).

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4. Install the oil pump housing (2) with the EN-46775   fixing tool (1).

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5. Tighten the 14 oil pump housing bolts and the 3 oil pump housing nuts in sequence as shown:
  •  In first step and in sequence as shown, tighten to 4 N·m (35 lb in) .
  •  In second step and in sequence as shown, tighten to 9 N·m (80 lb in) .
  •  Remove the EN-46775   fixing tool .

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Note:  Slide the oil pump seal over the flange sealing the surface (arrow).
6. Install the oil pump seal (2) to the flange (1).

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7. Position the flange (2) with the oil pump seal (3) to the crankshaft.
8. Tighten carefully the flange bolt (1) to limit stop.
9. Remove the flange bolt (1).
10. Remove the flange (2).

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11. Position EN-46775   centering tool (2) with the plane surface at the oil pump housing.
12. Tighten carefully the flange bolt (1) until the EN-46775   centring tool is flush with oil pump housing (arrow).
13. Remove the flange bolt and the EN-46775   centring tool .

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14. Install the flange (2).
15. Loosely install the NEW crankshaft sprocket bolt (1).

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16. Install the EN-662-C   wrench (2).
17. Install the 2 bolts.

Caution: Refer to Fastener Caution .

Note:  Mind the left-hand thread.
18. Tighten the crankshaft sprocket bolt (1) to 50 N·m (37 lb ft) .
19. Tighten the crankshaft sprocket bolt to additional 90° . Use the EN-470-B   wrench .

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20. Remove the EN-46785   fixing tool (1).
21. Lower the vehicle.

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22. Remove the EN-46781   fixing tool (1) from the intake side.
23. Inspect the camshaft timing chain. Refer to Camshaft Timing Chain Inspection .

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24. Install the intake camshaft housing core hole plug (1) to the camshaft housing and tighten to 15 N·m (11 lb ft) .

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Note:  The fuel rail may not be subjected to the effects of any external forces after the bracket has been removed.
25. Install the engine lift bracket (2).
26. Install the fuel rail bracket (4).
27. Install the 3 fuel rail bracket bolts (3) and tighten to 25 N·m (18 lb ft) .
28. Install the 2 fuel rail bolts (1) and tighten to 25 N·m (18 lb ft) .

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29. Install the oil filler tube (1) to the oil pump housing (4).
30. Install the 2 oil filler tube bolts (2, 3) and tighten to 9 N·m (80 lb in) .
31. Install the engine mount bracket. Refer to Engine Mount Bracket Replacement .
32. Install the drive belt tensioner. Refer to Drive Belt Tensioner Replacement .
33. Install the crankshaft pulley. Refer to Crankshaft Pulley Replacement .
34. Install the oil pan. Refer to Oil Pan Replacement .

Oil Pump Seal Replacement > < Dual Mass Flywheel Diagnosis