Complete Engine Replacement Opel Agila B

Remove

1. 1. Remove engine with transmission – see operation “Engine with Transmission Remove and Install”
2. 2. Lower engine and transmission using hydraulic jack

Note. 2x technician are required.

3. 3. Remove axle shaft (2), right side from intermediate axle shaft (1) • Pull out

4. 4. Remove intermediate axle shaft assembly (1) from transmission • Remove 3x bolt (2), then withdraw intermediate axle shaft

5. 5. Remove axle shaft (1), left side from transmission • Prise out using suitable tool

6. 6. Disconnect harness connector (1) from reverse lamp switch
7. 7. Release harness (2) from transmission, then move to one side • Release from 4x clip

8. 8. Release earth strap from transmission • Remove bolt
9. 9. Disconnect harness from starter motor • Remove 2x nut (2, 3) • Disconnect harness connector
10. 10. Remove starter motor from engine and transmission • Remove rubber grommet • Remove 2x bolt (1, 4)

11. 11. Remove alternator from engine • Disconnect engine harness (4) from alternator – Remove 2x nut (1, 2) • Remove 3x bolt (3)

12. 12. Install engine hoist and support engine and transmission • Tension support chains in preparation for engine mount removal
13. 13. Release rear engine mount (1) from bracket • Remove bolt (2)
14. 14. Lift engine and transmission assembly from front axle body and support frame using engine hoist

15. 15. Lower engine and transmission using engine hoist

Note. 2x technician are required.

16. 16. Remove engine hoist from engine and transmission assembly • Remove support chains from engine and transmission assembly

17. 17. Release transmission from engine • Remove 6x bolt (1, 2, 3, 4)
18. 18. Remove transmission from engine

Note. 2x technician are required.

19. 19. Install Flywheel Locking Tool KM-652 (3) to engine
20. 20. Remove clutch cover (1) and clutch disc from flywheel • Remove 9x bolt (2)
21. 21. Remove Flywheel Locking Tool KM-652 from engine

Install

22. 22. Install Flywheel Locking Tool KM-652 (3) to new engine
23. 23. Install clutch disc and clutch cover (1) to flywheel • Use clutch alignment tool (commercially available) • Install 9x bolt (2) 15 Nm
24. 24. Remove Flywheel Locking Tool KM-652 from engine

25. 25. Install transmission to engine

Note. 2x technician are required.

26. 26. Secure transmission to engine • Install 6x bolt (1, 2, 3, 4) 55 Nm
27. 27. Install engine hoist to engine and transmission assembly • Install support chains to engine • Adjust engine hoist until weight of engine is fully supported
28. 28. Lift engine and transmission assembly using hoist, then position to support frame and front axle body

Note. 2x technician are required.

29. 29. Secure rear engine mount (1) to bracket • Install bolt (2) 55 Nm

30. 30. Remove engine hoist from engine and transmission assembly • Remove support chains from engine and transmission assembly
31. 31. Install alternator to engine • Install 3x bolt (3) 20 Nm • Connect engine harness (4) to alternator – Install nut (1) 10 Nm – Install nut (2) 4 Nm

32. 32. Install starter motor to engine and transmission • Install 2x bolt (1, 4) 25 Nm • Install rubber grommet
33. 33. Connect harness to starter motor • Connect harness connector • Install nut (3) 11 Nm • Install nut (2) 5.8 Nm
34. 34. Secure earth strap to transmission • Install bolt

35. 35. Secure harness (2) to transmission • Secure to 4x clip
36. 36. Connect harness connector (1) to reverse lamp switch

37. 37. Install axle shaft (1), left side to transmission • Install new clip • Push in

38. 38. Install intermediate axle shaft assembly (1) to transmission • Install 3x bolt (2) 25 Nm

39. 39. Install axle shaft (2), right side to intermediate axle shaft (1) • Install new clip • Push in

40. 40. Position engine and transmission to vehicle using hydraulic jack with support frame assembly

Note. 2x technician are required.

41. 41. Install engine with transmission – see operation “Engine with Transmission Remove and Install”