Vauxhall Workshop Service and Repair Manuals

Engine Replacement - 1.6L LLU - 6T45

Special Tools

For equivalent regional tools, refer to Special Tools .

Removal Procedure

Warning: Refer to Petrol/Petrol Vapours Warning in the Preface section.

1. Remove the lower intermediate steering shaft bolt. Refer to Intermediate Steering Shaft Replacement .
2. Open the bonnet.
3. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .
4. Remove the battery tray. Refer to Battery Tray Replacement .





5. Remove the windscreen washer solvent container filler tube (1).





6. Remove the front compartment fuse block cover (1).





7. Remove the 3 front compartment fuse block bolts (1).
8. Remove the front compartment fuse block (2).





9. Unclip the 3 wiring harness plugs (3).
10. Disconnect the wiring harness plug from the front compartment fuse block.





11. Remove the 3 ground nuts (1) and put the 3 wiring harnesses (2) aside.





12. Disconnect the 2 wiring harness plugs (1, 2).
13. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Front Duct Replacement .
14. Remove the front bumper fascia. Refer to Front Bumper Fascia Replacement .
15. Remove the front tyre and wheel assembly. Refer to Tyre and Wheel Removal and Installation .
16. Drain the cooling system. Refer to Cooling System Draining and Filling .
17. Disconnect the coolant fill sensor plug.
18. Unclip the radiator surge tank.
19. Put the radiator surge tank aside.
20. Remove the range selector lever cable from the automatic transmission. Refer to Range Selector Lever Cable Replacement .
21. Remove the heater inlet and outlet hose from the bulkhead. Refer to Heater Inlet and Outlet Hose Replacement .





22. Disconnect the booster vacuum pipe (1) from the inlet manifold.
23. Disconnect reverse lamp switch wiring harness electrical connector.
24. Place collecting basin underneath.

Warning:  Petrol or petrol vapours are highly flammable. A fire could occur if an ignition source is present. Never drain or store petrol or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby.

25. Relieve the fuel pressure. Refer to Fuel Pressure Relief .





26. Remove the evaporative emission vent pipe (5) from the intake manifold (4).

•	Disconnect the wiring harness (6) from the evaporative emission vent purge valve (1).

•	Release the quick connector (3). Refer to Plastic Collar Quick Connect Fitting Service .

•	Close the vents with the EN-6015 plugs.

•	Remove the evaporative emission vent pipe retainer bolt (2).

•	Unclip the evaporative emission vent pipe from the engine wiring harness bracket.






27. Disconnect the fuel filler pipe (1) from the fuel rail (3).

•	Release the quick connector (2).

•	Close the vents with the EN-6015 plugs.

•	Unclip the fuel filler pipe from the engine wiring harness bracket.






28. Disconnect the fuel return pipe (1) from the fuel rail (3).

•	Release the quick connector (2).

•	Close the vents with the EN-6015 plugs.

•	Unclip the fuel return pipe from the engine wiring harness bracket.






29. Remove the A/C compressor and condenser hose nut (1) from the A/C condenser (2).





30. Remove the A/C compressor and condenser hose nut (1) from the refrigerant hose (2).
31. Remove the air conditioning evaporator hose assembly nut from the air conditioning condenser.
32. Unclip the radiator outlet hose from the radiator.
33. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
34. Remove the front compartment splash shield. Refer to Front Compartment Splash Shield Replacement .
35. Remove the upper stabiliser shaft link from the absorber on both sides. Refer to Stabilizer Shaft Link Replacement .
36. Remove steering linkage outer track rod from the steering knuckle on both sides. Refer to Steering Linkage Outer Track rod Replacement .
37. Remove the front lower control arm from the steering knuckle. Refer to Lower Control Arm Replacement .
38. Remove the front wheel shafts from the wheel hubs. Refer to Front Wheel Drive Shaft Replacement - Right Side and Front Wheel Drive Shaft Replacement - Left Side .
39. Disconnect the wheel speed sensors on both sides.
40. Remove the wheel speed sensor wiring harness retainers from the frame.





41. Unclip the 2 engine coolant fan wiring harnesses (1, 2) from the frame.
42. Remove the exhaust front pipe. Refer to Exhaust Front Pipe Replacement .
43. Install the CH-49290 engine support tool , for the assembly use attached installation manual.
44. Remove the engine mount. Refer to Engine Mount Replacement .
45. Remove the transmission mount. Refer to Transmission Mount Replacement - Left Side .





46. Disconnect the electronic power steering (EPS) electrical connector (3).

46.1.

Release the lock (2) by moving in direction of arrow, use suitable screwdriver.

46.2.

Push down the latch (1) and pull off the electrical connector, use suitable screwdriver.






47. Disconnect the electronic power steering (EPS) electrical connector (2).

47.1.

Gently lift latch (3), using angled screwdriver.

47.2.

Pull off electrical connector (2).

48. Disconnect the electronic power steering (EPS) electrical connector (1).

48.1.

Gently lift latch (4), using angled screwdriver.

48.2.

Pull off electrical connector (1).

49. Assemble the CH-49289 centring frame, for the assembly use attached installation manual.





50. Raise the CH-904 frame and CH-49289 centring frame with the hydraulic jack until it contacts the frame.






Note:  Positioning pins (2, 3) of CH-49289 centring frame MUST insert into holes of drivetrain frame.

51. Check if wheel alignment is required.

•	Move out position pins (1) and try to insert into underbody holes.

•	If guide pins CANNOT be inserted, the Wheel Alignment Measurement is required after installation of drive train frame.






52. Remove the frame front bolts (1).
53. Remove the frame rear bolts (2).
54. Remove the frame reinforcements (3).
55. Lower suspension frame (4) carefully with the engine transmission unit off the vehicle with hydraulic jack about 7 cm (2.75 in) .





56. Remove the 2 wiring harness bracket bolts (4).
57. Remove the bracket (2) from the vehicle.
58. Remove the suspension frame carefully with the engine transmission unit from the vehicle with hydraulic jack.
59. Remove the right wheel drive shaft from the transmission. Refer to Front Wheel Drive Shaft Seal Replacement - Right Side .
60. Remove the left wheel drive shaft from the transmission. Refer to Front Wheel Drive Shaft Seal Replacement - Left Side .





61. Loosen the radiator outlet hose clamp (2).
62. Remove the radiator outlet hose (3) from the water pump (1).





63. Loosen the radiator inlet hose clamp (4).
64. Remove the radiator inlet hose (3) from the engine coolant thermostat (5).
65. Install suitable cable at the 3 engine lift brackets.
66. Install a suitable engine lifting device to the cable.
67. Extend the engine lifting device until the steel cable are slightly tensioned.





68. Remove the front transmission mount through bolt (1).





69. Remove the rear transmission bracket mount to mount through bolt (1).
70. Lower and remove the frame.
71. Put the engine transmission unit down on a wooden pallet.
72. Loosen the 8 transmission bolts and remove 6 of them. Refer to Transmission Replacement .

Note:  A second technician is required.

73. Remove the last 2 transmission bolts and the transmission.
74. Install the engine to the EN-49271 engine stand .
75. Transfer parts as needed.

Installation Procedure

1. Remove the engine from the EN-49271 engine stand .
2. Put the engine down on a wooden pallet.

Note:  A second technician is required.

3. Install the transmission and 2 transmission bolts.
4. Install the 6 transmission bolts.

Caution: Refer to Fastener Caution in the Preface section.

5. Tighten the 8 transmission bolts. Refer to Transmission Replacement .
6. Install suitable cable at the 3 engine lift brackets. Install a suitable engine lifting device to the cable. Raise the engine transmission unit and extend the engine lifting device until the steel cables are slightly tensioned.
7. Raise the CH-904 frame and CH-49289 centring frame with the hydraulic jack until it contacts the frame.
8. Place the engine transmission unit into the front frame.





9. Install the rear transmission bracket mount to mount through bolt (1) and tighten to  100 N·m (74 lb ft) .





10. Install the front transmission mount through bolt (1) and tighten to  58 N·m (43 lb ft) .
11. Remove the cable from the 3 engine lift brackets.





12. Install the radiator inlet hose (3) to the engine coolant thermostat (5).
13. Install the radiator inlet hose clamp (4).





14. Install the radiator outlet hose (3) to the water pump (1).
15. Install the radiator outlet hose clamp (2).
16. Install the right wheel drive shaft to the transmission. Refer to Front Wheel Drive Shaft Seal Replacement - Right Side .
17. Install the left wheel drive shaft to the transmission. Refer to Front Wheel Drive Shaft Seal Replacement - Left Side .






Note:  Positioning pins (1) of CH-49289 centring frame MUST be extended in order to guide into underbody holes.

18. Move the frame with the engine transmission unit to the vehicle upwards, until wiring harness starter can be fixed.





19. Install and tighten the 2 wiring harness bracket bolts (4) to 9 N·m (80 lb in) .





20. Install the frame (4).
21. Install the frame reinforcements.
22. Install the frame rear bolts (2). Handtighten ONLY.
23. Install the frame front bolts . Handtighten ONLY.
24. Tighten the rear frame bolts (2) and tighten to  160 N·m (118 lb ft) .
25. Tighten the front frame bolts (1) and tighten to  160 N·m (118 lb ft) .





26. Lower the CH-49289 centring frame with the hydraulic jack until it is removable.
27. Disassemble the CH-49289 centring frame , for the assembly use attached installation manual.
28. Install the engine mount. Refer to Engine Mount Replacement .
29. Install the transmission mount. Refer to Transmission Mount Replacement - Left Side .
30. Remove the CH-49290 engine support tool , for the disassembly use attached installation manual.





31. Connect electrical connector (1) until you hear it click.
32. Connect electrical connector (2) until you hear it click.





33. Connect electrical connector (3) until you hear it click.
34. Push back lock (2) in opposite direction of arrow until you hear it click.
35. Install the exhaust front pipe. Refer to Exhaust Front Pipe Replacement .





36. Clip the 2 engine coolant fan wiring harnesses (1, 2) into the frame.
37. Install the wheel speed sensor wiring harness retainers from the frame.
38. Connect the wheel speed sensor on both sides.
39. Install the front wheel shafts to the wheel hubs. Refer to Front Wheel Drive Shaft Replacement - Right Side .
40. Install the front lower control arm to the steering knuckle. Refer to Lower Control Arm Replacement .
41. Install the steering linkage outer track rod to the steering knuckle on both sides. Refer to Steering Linkage Outer Track rod Replacement .
42. Install the upper stabiliser shaft link to the absorber on both sides. Refer to Stabilizer Shaft Link Replacement .
43. Install the front compartment splash shield. Refer to Front Compartment Splash Shield Replacement .
44. Check the transmission fluid level. Refer to Transmission Fluid Level Inspection .
45. Lower the vehicle.
46. Clip the radiator outlet hose into the radiator.

Note:  Use a NEW O-ring seal. Refer to Air Conditioning O-Ring Seal Replacement .

47. Install the air conditioning evaporator hose assembly nut to the air conditioning condenser and tighten to 19 N·m (14 lb ft) .






Note:  Use a NEW O-ring seal. Refer to Air Conditioning O-Ring Seal Replacement .

48. Install the A/C compressor and condenser hose nut (1) to the A/C condenser (2). Tighten the nut to 19 N·m (14 lb ft) .






Note:  Use a NEW O-ring seal. Refer to Air Conditioning O-Ring Seal Replacement .

49. Install the A/C compressor and condenser hose nut (1) to the refrigerant hose (2). Tighten the nut to 19 N·m (14 lb ft) .





50. Connect the fuel return pipe (1) to the fuel rail (3).

•	Remove the EN-6015 plugs.

•	Install the quick connector (2). Refer to Plastic Collar Quick Connect Fitting Service .

•	Clip in the fuel return pipe to the engine wiring harness bracket.






51. Connect the fuel filler pipe (1) to the fuel rail (3).

•	Remove the EN-6015 plugs.

•	Install the quick connector (2).

•	Clip in the fuel filler pipe to the engine wiring harness bracket.






52. Install the evaporative emission vent pipe (5) to the intake manifold (4).

•	Connect the wiring harness (6) to the evaporative emission vent purge valve (1).

•	Install the quick connector (3). Refer to Plastic Collar Quick Connect Fitting Service .

•	Remove the EN-6015 plugs.

•	Install the evaporative emission vent pipe retainer bolt (2) and tighten to 8 N·m (71 lb in) .

•	Clip in the evaporative emission vent pipe to the engine wiring harness bracket.

53. Connect reverse lamp switch wiring harness electrical connector.





54. Connect the booster vacuum pipe (1) to the inlet manifold.
55. Install the heater inlet and outlet hose from the bulkhead. Refer to Heater Inlet and Outlet Hose Replacement .
56. Install the range selector lever cable to the automatic transmission. Refer to Range Selector Lever Cable Replacement .
57. Clip in the radiator surge tank.
58. Connect the radiator surge tank wiring harness.
59. Fill the cooling system. Refer to Cooling System Draining and Filling .
60. Install the front tyre and wheel assembly. Refer to Tyre and Wheel Removal and Installation .
61. Install the front bumper fascia. Refer to Front Bumper Fascia Replacement .
62. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Front Duct Replacement .





63. Connect the 2 wiring harness plugs (1, 2).





64. Install the 3 wiring harnesses (2).
65. Install the 3 ground nuts (1) and tighten to  9 N·m (80 lb in) .





66. Clip in the 3 wiring harness plugs (3).
67. Connect the wiring harness plug to the front compartment fuse block.





68. Install the front compartment fuse block (2).
69. Install the 3 front compartment fuse block bolts (1) and tighten to  22 N·m (16 lb ft) .





70. Install the front compartment fuse block cover (1).





71. Install the windscreen washer solvent container filler tube (1).
72. Install the battery tray. Refer to Battery Tray Replacement .
73. Evacuate and charge the refrigerant system. Refer to Refrigerant Recovery and Recharging .
74. Check the oil level and fill engine oil, if necessary.
75. Close the bonnet.
76. Install the lower intermediate steering shaft bolt. Refer to Intermediate Steering Shaft Replacement .