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Engine mechanics - 1.7L Diesel (LPL, LPV, LUB)|Description and Operation > < Upper Oil Sump Assemble

Astra J

Engine Replacement (1.7L Diesel LPL and LPV)

Special Tools

•  CH-904   Base Frame
•  EN-6015   Closure Plugs
•  CH-49289   Centering Adapter
•  CH-49290   Mounting Engine/Transmission

For equivalent regional tools, refer to Special Tools .

Removal Procedure

Warning:  Refer to Gasoline/Gasoline Vapors Warning .

1. Remove the lower intermediate steering shaft bolt. Refer to Intermediate Steering Shaft Replacement .
2. Open the hood.
3. Remove the engine sight shield. Refer to Engine Sight Shield Replacement .
4. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .
5. Remove the battery tray. Refer to Battery Tray Replacement .

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6. Remove the windshield washer solvent container filler tube (1).

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7. Remove the front compartment fuse block cover (1).
8. Remove the front compartment fuse block. Refer to Front Compartment Fuse Block Replacement .

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

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

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12. Disconnect the 2 wiring harness plugs (1, 2).
13. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement .
14. Remove the front bumper fascia. Refer to Front Bumper Fascia Replacement .
15. Remove the front tire and wheel assembly. Refer to Tire and Wheel Removal and Installation .
16. Drain the cooling system. Refer to Cooling System Draining and Filling .
17. Remove the radiator surge tank. Refer to Radiator Surge Tank Replacement .
18. Remove the manual transmission shift lever and selector lever cable from the transmission. Refer to Manual Transmission Shift Lever and Selector Lever Cable Replacement .
19. Remove the heater inlet and outlet hose from the bulkhead. Refer to Heater Inlet and Outlet Hose Replacement .
20. Disconnect the booster vacuum pipe from the vacuum pump.
21. Disconnect the backup lamp switch wiring harness electrical connector.
22. Place collecting basin underneath the vehicle.
23. Disconnect the clutch actuator cylinder front pipe. Refer to Clutch Actuator Cylinder Front Pipe Replacement .
24. Place a collecting basin underneath the vehicle.

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Warning: Always wear safety goggles when working with fuel in order to protect the eyes from fuel splash.


25. Disconnect the fuel feed pipe (2) from the fuel injection fuel pump connector (1). Refer to Plastic Collar Quick Connect Fitting Service .
26. Close all connections with EN-6015   plugs .
27. Close the connection from fuel injection pump by using EN-6368   plugs .
28. Remove the fuel feed pipe (2) from the retainer clip (3).

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29. Disconnect the fuel return pipe (2) from the fuel injector fuel return pipe (1). Refer to Plastic Collar Quick Connect Fitting Service .
30. Close all connections with EN-6015   plugs .
31. Remove the fuel return pipe (2) from the retainer clip (3).
32. Disconnect the air conditioning compressor and condenser hose from air conditioning evaporator hose assembly. Refer to Air Conditioning Compressor and Condenser Hose Replacement .
33. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
34. Remove the front compartment insulator. Refer to Front Compartment Insulator Replacement .
35. Remove the upper stabilizer shaft link from the absorber on both sides. Refer to Stabilizer Shaft Link Replacement .
36. Remove steering linkage outer tie rod from the steering knuckle on both sides. Refer to Steering Linkage Outer Tie 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.

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41. Unclip the 2 engine coolant fan wiring harnesses (1, 2) from the frame.
42. Remove the exhaust front pipe and particulate filter assembly. Refer to Exhaust Particulate Filter Replacement .

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Note:  The SPX installation manual is supplied with the special tool and is also available online from SPX directly. Go to www.spxtools-shop.com.
43. Assemble the CH-49290   engine support tool (1) according to the details provided in the SPX installation manual.
44. Support the CH-904   base frame on a jack.
45. Support the CH-49290   engine support tool on the CH-904   base frame .

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46. Install the CH-49290   engine support tool (1) according to the details provided in the SPX installation manual.
47. Remove the engine mount. Refer to Engine Mount Bracket Replacement - Right Side .
48. Remove the transmission mount. Refer to Transmission Mount Replacement - Left Side .
49. Detach the 3 wiring harness plugs from the electronic power steering (EPS).

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Note:  The SPX installation manual is supplied with the special tool and is also available online from SPX directly. Go to www.spxtools-shop.com.
50. Assemble the CH-49289   centering frame (1) according to the details provided in the SPX installation manual.
51. Support the CH-904   base frame on a jack.
52. Support the CH-49289   centring frame on the CH-904   base frame .

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Note:  The SPX installation manual is supplied with the special tool and is also available online from SPX directly. Go to www.spxtools-shop.com.
53. Install the CH-49289   centering frame (1) according to the details provided in the SPX installation manual.

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54. Remove the frame front bolts (1).
55. Remove the frame rear bolts (2).
56. Remove the frame reinforcements (3).
57. Lower the suspension frame (4) carefully with the engine transmission unit off the vehicle with hydraulic jack about 7 cm (2.75 in) .
58. Remove the 2 wiring harness starter bracket bolts.
59. Remove the wiring harness starter bracket from the electronic power steering (EPS).
60. Remove the suspension frame carefully with the engine transmission unit from the vehicle with hydraulic jack.
61. Remove the right and left wheel drive shaft from the transmission. Refer to Front Wheel Drive Shaft Replacement - Right Side and Front Wheel Drive Shaft Replacement - Left Side .

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Note:  Place a collecting basin underneath.
62. Remove the radiator outlet hose clamps (1, 5).

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63. Place a collecting basin underneath the vehicle.
64. Unlatch the radiator inlet hose bracket clip (1).
65. Remove the radiator inlet hose clamp (3).
66. Remove the radiator inlet hose (4) from the water outlet (2).
67. Install suitable cable to the 3 engine lift brackets.
68. Install a suitable engine lifting device to the cable.
69. Extend the engine lifting device until the steel cable are slightly tensioned.

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

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

Note:  A second technician is required.
75. Remove the last 2 transmission bolts and the transmission.
76. Install the engine to a suitable engine stand.
77. Transfer parts as needed.

Installation Procedure

1. Remove the engine from the 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 .
5. Tighten the 8 transmission bolts. Refer to Transmission Replacement .
6. Install a 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 cable are slightly tensioned.
7. Raise the CH-904   frame and CH-49289   adapter with the hydraulic jack until it contacts the frame.
8. Place the engine transmission unit into the front frame.

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

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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.

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12. Install and reposition the radiator outlet hose clamps (1), (5) to the water inlet.

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13. Install and reposition the radiator inlet hose (4) to water outlet (2).
14. Reposition and tighten the radiator inlet hose clamp (3).
15. Latch the radiator inlet hose bracket clip (1).
16. Install the right and left wheel drive shaft to the transmission. Refer to Front Wheel Drive Shaft Replacement - Right Side and Front Wheel Drive Shaft Replacement - Left Side .

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Note:  Positioning pins (1) of CH-49289   adapter MUST be extended in order to guide into underbody holes.
17. Move the frame (1) with the engine transmission unit to the vehicle upwards, till the wiring harness starter can be fixed.
18. Install the wiring harness starter bracket to the electronic power steering (EPS).
19. Install and tighten the 2 wiring harness starter bracket bolts.

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20. Install the frame (4).
21. Install the frame reinforcements (3).
22. Install the frame rear bolts (2). Hand tighten ONLY.
23. Install the frame front bolts (3). Hand tighten 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) .

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26. Lower the CH-49289   centring frame (1) with the CH-904   base frame and a jack.
27. Remove the CH-49289   centring frame from the CH-904   base frame .

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Note:  The SPX installation manual is supplied with the special tool and is also available online from SPX directly. Go to www.spxtools-shop.com.
28. Disassemble the CH-49289   centering frame (1) according to the details provided in the SPX installation manual.
29. Install the transmission mount. Refer to Transmission Mount Replacement - Left Side .
30. Install the engine mount. Refer to Engine Mount Bracket Replacement - Right Side .

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31. Lower the CH-49290   engine support tool (1) with the CH-904   base frame and a jack.
32. Remove the CH-49290   engine support tool from the CH-904   base frame .

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Note:  The SPX installation manual is supplied with the special tool and is also available online from SPX directly. Go to www.spxtools-shop.com.
33. Disassemble the CH-49290   engine support tool (1) according to the details provided in the SPX installation manual.
34. Connect the 3 wiring harness connectors to the electronic power steering (EPS).
35. Install the exhaust front pipe and particulate filter assembly. Refer to Exhaust Particulate Filter Replacement .

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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 Refer to Front Wheel Drive Shaft Replacement - Right Side and Front Wheel Drive Shaft Replacement - Left Side .
40. Install the front lower control arm to the steering knuckle. Refer to Lower Control Arm Replacement .
41. Install the steering linkage outer tie rod to the steering knuckle on both sides. Refer to Steering Linkage Outer Tie Rod Replacement .
42. Install the upper stabilizer shaft link to the absorber on both sides. Refer to Stabilizer Shaft Link Replacement .
43. Install the front compartment insulator. Refer to Front Compartment Insulator 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.
47. Connect the air conditioning compressor and condenser hose from air conditioning evaporator hose assembly. Refer to Air Conditioning Compressor and Condenser Hose Replacement .

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48. Remove the EN-6015   plugs from all connections.
49. Remove the EN-6368   plugs from the fuel injection pump.
50. Connect the fuel feed pipe (2) to the fuel injection fuel pump connector (1). Refer to Plastic Collar Quick Connect Fitting Service .
51. Install the fuel feed pipe (2) to the retainer clip (3).

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52. Install the fuel return pipe (2) into the bracket clip (3).
53. Remove the EN-6015   plugs from all connections.
54. Connect the fuel return pipe (2) to the fuel injector fuel return pipe (1). Refer to Plastic Collar Quick Connect Fitting Service .
55. Connect the clutch actuator cylinder front pipe. Refer to Clutch Actuator Cylinder Front Pipe Replacement .
56. Bleed the hydraulic clutch system. Refer to Hydraulic Clutch System Bleeding .
57. Fill the reservoir with clutch/brake fluid up to the MAX level.
58. Connect the backup lamp switch wiring harness electrical connector.
59. Connect the booster vacuum pipe to the vacuum pump.
60. Install the heater inlet and outlet hose from the bulkhead. Refer to Heater Inlet and Outlet Hose Replacement .
61. Install the manual transmission shift lever and selector lever cable to the transmission. Refer to Manual Transmission Shift Lever and Selector Lever Cable Replacement .
62. Clip in the radiator surge tank.
63. Connect the radiator surge tank wiring harness.
64. Fill the cooling system. Refer to Cooling System Draining and Filling .
65. Install the front tire and wheel assembly. Refer to Tire and Wheel Removal and Installation .
66. Install the front bumper fascia. Refer to Front Bumper Fascia Replacement .
67. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement .

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

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

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71. Clip in the 3 wiring harness plugs (3).
72. Connect the wiring harness plug to the front compartment fuse block.
73. Install the front compartment fuse block. Refer to Front Compartment Fuse Block Replacement .

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

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75. Install the windshield washer solvent container filler tube (1).
76. Install the battery tray. Refer to Battery Tray Replacement .
77. Evacuate and charge the refrigerant system. Refer to Refrigerant Recovery and Recharging .
78. Check the oil level and fill NEW engine oil up if necessary.
79. Install the engine sight shield. Refer to Engine Sight Shield Replacement .
80. Close the hood.
81. Install the lower intermediate steering shaft bolt. Refer to Intermediate Steering Shaft Replacement .

Engine mechanics - 1.7L Diesel (LPL, LPV, LUB)|Description and Operation > < Upper Oil Sump Assemble