Astra J
Engine Front Cover with Oil Pump ReplacementRemoval Procedure
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| 1. | Open the hood. |
| 2. | Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection . |
| 3. | Set the engine to TDC. Refer to Camshaft Timing Chain Inspection . |
| 4. | Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . |
| 5. | Remove the front compartment splash shield right side. Refer to Front Compartment Splash Shield Replacement . |
| 6. | Disconnect all electrical connectors from the generator. Refer to Generator Replacement . |
| 7. | Fix the drive belt tensioner and remove the drive belt from crankshaft balancer, drive belt tensioner and air conditioning compressor. Refer to Drive Belt Replacement . |
| 8. | Remove the air conditioning compressor bracket. Refer to Air Conditioning Compressor Bracket Replacement . |
| 9. | Place a collecting basin underneath. |
| 10. | Remove the crankshaft balancer. Refer to Crankshaft Balancer Replacement . |
| 11. | Remove the oil pan. Refer to Oil Pan Replacement . |
| 12. | Lower vehicle. |
| 13. | Remove the engine mount bracket. Refer to Engine Mount Bracket Replacement - Right Side . |
| 14. | Remove the drive belt tensioner. Refer to Drive Belt Tensioner Replacement . |
| 15. | Remove the generator from above. Refer to Generator Replacement . |
| 16. | Remove the water pump pulley and the water pump. Refer to Water Pump Replacement . |
| 17. | Remove the camshaft position actuator solenoid valves. Refer to Camshaft Position Actuator Solenoid Valve Removal . |
| 18. | Loosen the camshaft sprocket bolts until the camshaft position exciter wheels are free rotatable. Refer to Camshaft Timing Chain Adjustment . |
| 19. | Remove the 13 engine front cover bolts M6 (1). |
| 20. | Remove the 2 engine front cover bolts M10 (2). |
| 21. | Remove the engine front cover (3). |
Note: Removal of timing chain is necessary to get access to engine front cover gasket. |
| 22. | Remove the camshaft timing chain. Refer to Camshaft Timing Chain Replacement . |
| 23. | Remove the engine front cover gasket (1). |
| 24. | Remove the intake and exhaust camshaft position sensors from the engine front cover. Refer to Engine Front Cover and Oil Pump Disassemble . |
Installation Procedure
| 1. | Install the intake and exhaust camshaft position sensors to the engine front cover. Refer to Engine Front Cover and Oil Pump Assemble . |
| 2. | Clean the engine front cover sealing surfaces on engine block and cylinder head. |
Note: The thickness of the sealing bead should be 2 mm (0.0787 in) . |
| 3. | Apply sealing compound to the shown areas (1) and (2). Refer to Adhesives, Fluids, Lubricants, and Sealers . |
Note: Mind the guide sleeves. |
| 4. | Install a NEW engine front cover gasket (1). |
| 5. | Install the timing chain. Refer to Camshaft Timing Chain Replacement . |
Note: Mind the guide sleeves when installing the engine front cover. The complete installation procedure of the engine front cover should not take longer than 10 minutes. |
| 6. | Install the engine front cover (3). |
| 7. | Install the 13 engine front cover bolts M6 (1). |
| 8. | Install the 2 engine front cover bolts M10 (2). |
Caution: Refer to Fastener Caution . |
| 9. | Tighten the 13 engine front cover bolts M6 to 8 N·m (71 lb in) . |
| 10. | Tighten the 2 engine front cover bolts M10 to 35 N·m (26 lb ft) . |
Note: Engine should be adjusted and fixed in TDC position. |
| 11. | Tighten the camshaft sprockets, install the upper timing chain guide and remove all special tools. Refer to Camshaft Timing Chain Adjustment . |
| 12. | Install the 2 camshaft position actuator solenoid valves. Refer to Camshaft Position Actuator Solenoid Valve Replacement . |
| 13. | Install the water pump and the water pump pulley. Refer to Water Pump Replacement . |
| 14. | Install the generator from above. Refer to Generator Replacement . |
| 15. | Install the drive belt tensioner. Refer to Drive Belt Tensioner Replacement . |
| 16. | Install the engine mount bracket. Refer to Engine Mount Bracket Replacement - Right Side . |
| 17. | Loosely install the drive belt to water pump pulley and generator pulley. |
| 18. | Install the engine mount. Refer to Engine Mount Replacement - Right Side . |
| 19. | Remove engine lifter from engine lift bracket. |
| 20. | Install the camshaft cover. Refer to Camshaft Cover Replacement . |
| 21. | Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement . |
| 22. | Raise the vehicle. |
| 23. | Install the crankshaft balancer. Refer to Crankshaft Balancer Replacement . |
| 24. | Install the oil pan. Refer to Oil Pan Replacement . |
| 25. | Install the air conditioning compressor bracket. Refer to Air Conditioning Compressor Bracket Replacement . |
| 26. | Install the drive belt to crankshaft balancer, drive belt tensioner and air conditioning compressor. Refer to Drive Belt Replacement . |
| 27. | Connect all electrical connectors to the generator. Refer to Generator Replacement . |
| 28. | Install the front compartment splash shield right side. Front Compartment Splash Shield Replacement . |
| 29. | Lower the vehicle |
| 30. | Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection . |
| 31. | Fill up engine oil. Refer to Engine Oil and Oil Filter Replacement . |
| 32. | Close the hood. |
