How to Remove and Install the Engine Opel Agila A

Warning: When working with the common rail system, wait one minute after switching off the engine. The system relieves the pressure itself.

Important: When working on the fuel system, cleanliness is vital because even the smallest dirt particles can lead to faults in engine operation or in the fuel system. Seal open fuel connections with suitable sealing plugs 1) . Sealing plugs are only intended to be used once.

Remove

1. 1. Open bonnet
2. 2. Disconnect battery • Detach ground cable • 1 fastening nut
3. 3. Empty climate control system
4. 4. Lift vehicle
5. 5. Place collecting basin underneath.
6. 6. Drain coolant • Open drain bolt (1)

7. 7. Remove ribbed V-belt cover • 4 clips (arrows)

8. 8. Attach holder KM-6056 • To right engine damping block bracket • Install KM-6056-1 (1) • Install KM-6056-10 (2) – Turn adjuster screw (4) until KM-6056-10 abuts right engine damping block bracket – Tighten fastening bolts (3)

9. 9. Lower vehicle
10. 10. Remove air cleaner housing
11. 11. Remove charge air hose (1) • From charge air pipe – 1 fastening clamp • From intake manifold – 1 fastening clamp

Note. Seal intake manifold opening

12. 12. Detach ground cable (1) and (2) • from camshaft housing – 2 off – 2 fastening bolts • 5 cable ties • Lay aside ground cable

13. 13. Disconnect wiring harness of engine control unit • Disconnect wiring harness plug (2) – 1 retainer (1) • Disconnect wiring harness plug (4) of engine control unit – 1 retainer (3) • Lay aside wiring harness

14. 14. Disconnect wiring harness plug (1) • At relay holder bracket – 1 wiring harness plug – Release 1 clip (2)

15. 15. Remove upper coolant hose (1) • From thermostat housing – 1 fastening clamp

16. 16. Remove coolant compensation tank (1) • Detach 3 coolant hoses – 3 fastening bolts • 2 fastening bolts

17. 17. Disconnect wiring harness plug (1) of reversing lamp switch • From relay holder bracket – 1 wiring harness plug – 1 clip (2) • Lay wiring harness on drive unit

18. 18. Detach relay holder (1) and preheating control unit (2) • Unclip from bracket • Lay aside relay holder and preheating control unit

19. 19. Detach Bowden clutch actuation cable (2) • Tension clutch lever (3) • Remove Bowden clutch actuation cable from clutch lever • Unclip Bowden clutch actuation cable from bracket (1) • Lay aside Bowden clutch actuation cable

20. 20. Detach shift cables (3) • Unclip from ball heads • Release retainer (1) in direction of arrow and remove from bracket (2)

Note. Mark order of shift cables

21. 21. Remove brake servo vacuum line (2) • From vacuum pump • 1 quick-release fitting • 1 clip (1)

22. 22. Detach coolant hoses (1) from heat exchanger • 2 coolant hoses – 2 fastening clamps

23. 23. Remove wiring harness plug • From charge pressure sensor (1)

Note. Release wiring harness plug

24. 24. Remove charge air hose (1) • From intercooler – 1 fastening clamp

25. 25. Detach fuel feed line (1) • From fuel pipe – 1 fastening clamp

26. 26. Detach fuel return line (1) • from pressure chamber – 1 fastening clamp

27. 27. Detach right engine damping block bracket from right engine damping block • 3 fastening bolts (1)

28. 28. Loosen front wheels
29. 29. Lift vehicle • Half height
30. 30. Remove front wheels
31. 31. Remove tie rods • 2 fastening nuts • Use remover KM-507-C (1)

32. 32. Remove guide joints • Unscrew 2 fastening bolts (arrow)

33. 33. Detach lower coolant hose (1) • From radiator – 1 fastening clamp

34. 34. Lift vehicle • Half height
35. 35. Detach exhaust system • From catalytic converter – 1 fastening clamp (1)

36. 36. Remove exhaust system • Detach damper rings – 4 off

Note. 2nd mechanic

37. 37. Detach engine wiring harness • From alternator (2) – 2 fastening nuts • From starter (1) – 2 fastening nuts • From oil quantity sensor (4) – 1 wiring harness plug • From cylinder block – 2 ground cables – 2 fastening bolts - (3) and (5)

38. 38. Detach refrigerant line from compressor (1) • High pressure line – 1 fastening bolt • Low pressure line – 1 fastening bolt

39. 39. Press out axle shafts (1) • With assembly lever

40. 40. Suspend axle shafts
41. 41. Insert hydraulic jack • With base frame KM-904 (2)
42. 42. Attach holder KM-6054 (1) • To base frame KM-904 • Insert cotter pins – Attach 2 connecting pieces – Install 4 bolts

Important. The holder and base frame must be aligned parallel to the drive unit

43. 43. Adjust holder KM-6054 • Adjust 2 connecting pieces – Spindle (4) under lug of cylinder block base plate – Spindle (5) between compressor bracket and cylinder block base plate • Adjust transmission mounting (3)

Important. After KM-6054 is adjusted, all fastening nuts and fastening bolts must be tightened

Important. Transmission mounting must abut transmission housing recess horizontally

44. 44. Detach holder KM-6056 • From right engine damping block bracket
45. 45. Remove rear engine damping block (1) • 2 fastening nuts

46. 46. Detach left engine damping block bracket (1) • From transmission – 3 fastening bolts

47. 47. Remove drive unit • Remove drive unit

Note. 2nd mechanic

Important. Carefully lower engine with transmission out of engine compartment - be careful not to damage attaching parts

Install

48. 48. Install drive unit • Install drive unit

Note. 2nd mechanic

Important. Carefully position engine with transmission in engine compartment - be careful not to damage attaching parts

49. 49. Attach left engine damping block bracket • On transmission – 3 fastening bolts – Tightening torque 55 Nm
50. 50. Fit rear engine damping block • 2 new fastening nuts – Tightening torque 55 Nm
51. 51. Attach holder KM-6056 • Install KM-6056-1 (1) • Install KM-6056-10 (2) – Turn adjuster screw (4) until KM-6056-10 abuts right engine damping block bracket – Tighten fastening bolts (3)

52. 52. Remove hydraulic jack • With base frame KM-904 and KM-6054
53. 53. Install axle shafts • Replace retaining rings

Note. Axle shafts must audibly engage

54. 54. Attach coolant hoses to heat exchanger • 2 coolant hoses

Note. Fastening clamps are attached from above

55. 55. Connect alternator/starter wiring harness • 2 ground cables to cylinder block – 2 fastening bolts • Wiring harness to starter – 2 fastening nuts • Wiring harness to alternator – 2 fastening nuts • Wiring harness to oil level sensor – 1 wiring harness plug – 1 clip
56. 56. Install exhaust system • Install damping rings – 4 off

Note. 2nd mechanic

57. 57. Attach exhaust system • To catalytic converter – 1 fastening clamp
58. 58. Attach refrigerant line to compressor • Renew seal rings • High pressure line – 1 fastening bolt – Tightening torque 25 Nm • Low pressure line – 1 fastening bolt – Tightening torque 25 Nm
59. 59. Lower vehicle • Half height
60. 60. Attach lower coolant hose • To cooler – 1 fastening clamp
61. 61. Attach guide joints • 2 fastening bolts – Tightening torque 60 Nm
62. 62. Install tie rods • Replace fastening nuts • 2 fastening nuts – Tightening torque 45 Nm
63. 63. Mount wheels
64. 64. Lower vehicle • Half height
65. 65. Fasten wheels • Tightening torque 110 Nm
66. 66. Attach right engine damping block bracket to right engine damping block • 3 fastening bolts – Tightening torque 55 Nm
67. 67. Attach fuel return line • to pressure chamber – 1 fastening clamp
68. 68. Attach fuel feed line • To fuel pipe – 1 fastening clamp
69. 69. Fit charge air hose • To charge air cooler – 1 fastening clamp – Tightening torque 3,5 Nm • To charge air pipe – 1 fastening clamp – Tightening torque 3,5 Nm
70. 70. Connect wiring harness of charge pressure sensor

Note. Lock wiring harness plug

71. 71. Fasten coolant hoses to heat exchanger • 2 fastening clamps
72. 72. Attach brake servo vacuum line • To vacuum pump Warning: Quick-release fitting must audibly engage • 1 quick-release fitting • 1 clip
73. 73. Attach shift cables • Mount in bracket – Engage retainer • Clip onto ball heads

Note. Make sure shift cables are fitted in correct order

74. 74. Attach Bowden clutch actuation cable • Insert Bowden clutch actuation cable in bracket • Tension clutch lever • Insert Bowden clutch actuation cable in clutch lever
75. 75. Install preheating control unit and relay holder • Clip into bracket
76. 76. Connect wiring harness of reversing lamp switch • To relay holder bracket – 1 wiring harness plug – 1 clip
77. 77. Install coolant compensation tank • Attach 3 coolant hoses – 3 fastening bolts • 2 fastening bolts
78. 78. Connect wiring harness plug • To relay holder bracket – 1 wiring harness plug – 1 clip
79. 79. Attach upper coolant hose • On thermostat housing – 1 fastening clamp
80. 80. Connect wiring harness of engine control unit • Connect 1 wiring harness plug – Lock wiring harness plug • Connect 1 wiring harness plug to engine control unit • Lock wiring harness plug
81. 81. Connect ground cable. • to camshaft housing – 2 fastening bolts • 5 cable ties
82. 82. Attach charge air hose. • To charge air pipe – 1 fastening clamp – Tightening torque 3,5 Nm • To intake manifold – 1 fastening clamp – Tightening torque 3,5 Nm
83. 83. Install air cleaner housing
84. 84. Lift vehicle
85. 85. Detach holder KM-6056 • from engine damping block bracket
86. 86. Install ribbed V-belt cover • 4 clips
87. 87. Check transmission fluid level, correct if necessary
88. 88. Lower vehicle
89. 89. Top up coolant and correct coolant level • Observe specified quantity of coolant
90. 90. Connect battery • Connect ground cable. – Tightening torque 5,5 Nm
91. 91. Program volatile memories
92. 92. Top up climate control system
93. 93. Close bonnet.

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) Protective caps are available in the Opel Parts Catalogue under catalogue number: 45 06 154 / part number: 9201697