Engine Replace Opel Antara I

Engine Replace

Tools Required

EN-48243 Engine Assembly Remove/Install Pallet

EN-48244 Engine Assembly Remove/Install Pallet Supporter

Remove

1. Remove the fuel pump fuse.
2. Start the engine. After it stalls, crank the engine for 10 seconds to rid the fuel system of fuel pressure.
3. Drain the engine oil. Warning: Observe relevant environmental regulations when disposing of used engine oil .
4. Drain the engine coolant. Refer to Draining and Refilling the Cooling System . Warning: Observe relevant environmental regulations when disposing of used coolant.
5. Drain the power steering oil. Warning: Observe relevant environmental regulations when disposing of used power steering fluid.
6. Drain the transmission oil. Refer to: Transmission Fluid Replacement for Manual Transmission. Warning: Observe relevant environmental regulations when disposing of used transmission oil .
7. Discharge the air conditioning system, if equipped.

8. Disconnect the intake air temperature (IAT) sensor connector.
9. Remove the engine beautification cover.
10. Disconnect the breather hose and PCV hose from the cylinder head cover.
11. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replace .
12. Remove the resonator from the electronic throttle body.

13. Disconnect the upper radiator hose from the thermostat.
14. Disconnect the lower radiator hose from the coolant pipe.
15. Disconnect the coolant hoses from the electronic throttle body.
16. Disconnect the surge tank hose from the cylinder block.
17. Disconnect the heater outlet hose from the coolant pipe.
18. Disconnect the heater inlet hose from the cylinder head.

19. Disconnect the fuel feed line from the fuel rail.
20. Disconnect the power steering return hose and the pressure hose from the power steering pump. Refer to Power Steering Pump Hoses and Pipes Replace .

21. Disconnect all of the necessary electrical connectors such as A/C pressure sensor, Exhaust Gas Recirculation valve, Direct Ignition System, Coolant Temperature Sensor, Electronic Throttle Control system, Oxygen sensor, Crankshaft Position sensor, Camshaft Position sensor, Manifold Absolute Pressure sensor, fuel injector, Engine Control Module, knock sensor, alternator and starter terminal etc.
22. Remove the ground terminals from the starter, intake manifold and cylinder block.

23. Remove all the necessary parts and disconnect all connectors and cables from the transmission. For Manual Transmission refer, to: Shift Control Lever Housing Replace . Shift Control Cable Replace . Shift Control Cable Adjustment .
24. Disconnect all of the necessary vacuum lines, including the brake booster vacuum hose.
25. Remove the A/C compressor. Refer to Compressor Replace .
26. Remove the engine electrical wires from the engine.
27. Remove the primary catalytic converter-to-exhaust front pipe retaining nuts.
28. Remove the exhaust front pipe mounting bracket bolt and nut.
29. Remove the exhaust front pipe from the primary catalytic converter. Refer to Exhaust Front Pipe Replace .
30. For the AWD vehicle, remove the propeller shaft. Refer to Propeller Shaft Replace .

31. Disconnect the stabilizer link. Refer to Stabilizer Link .
32. Disconnect the tie rod end joint. Refer to Front Control Arm Replace .
33. Disconnect the control arm joint. Refer to Front Control Arm Replace .
34. Remove the left and right axle shaft. Refer to Drive Axle Assembly Replace .
35. Remove the power steering gear intermediate shaft. Refer to Intermediate Shaft, Joint and Dash Seal Replace .

36. Remove the cradle support bracket retaining bolts. Refer to Cradle, Stabilizer Shaft Replace .
37. Remove the cradle mounting bolts.

Warning: Make sure that all components are set in the exact position on the engine assembly remove/install pallet EN-48243 and pallet supporter EN-48244 as shown.

• 1~4 : Cradle Supporter
• A : Diesel Engine Oil Pan Supporter
• B : FAM II 2.4D Engine Oil Pan Supporter
• C & D : HFV6 3.2L Engine Oil Pan Supporter
• E: Manual Transmission Supporter
• F : Automatic Transmission Supporter
• G : Transfer Case Supporter (M/T & A/T)
• H : Transmission Mount Supporter (M/T & A/T)

Important : Only lower the vehicle far enough to take the weight off the engine and transmission mount, or damage to the mount and pallet/pallet supporter failure may occur.

38. Lower the vehicle and position the engine assembly on to the engine assembly remove/install pallet EN-48243, with the pallet supporter EN-48244 to the cradle.

39. Remove the engine mount assembly. Refer to Engine Mount Assembly (RH Side) Replace .

40. Remove the transmission mount assembly. Refer to Transmission Mount Assembly (LH Side) Replace .

Important: Make sure that all the cables, connectors and hoses are disconnected from the engine and transmission assembly.

41. Raise the vehicle to remove from the engine and transmission assembly clear.
42. Install the hoist to the engine support bracket and lift the engine assembly far enough to take the weight off the transmission front and rear mount assembly.
43. Remove the transmission front mount assembly from the cradle. Refer to Transmission Front Mount Assembly Replace .

44. Remove the transmission rear mount assembly from the cradle. Refer to Transmission Rear Mount Assembly Replace .
45. Lift the engine assembly and remove the cradle from the engine and transmission assembly.
46. Separate the engine block from the transmission as follows:
47. Remove the transmission to engine block mounting bolts. Remove the oil flange to transmission mounting bolts. Remove the starter mounting bolts.

Install

I

1. Install the transmission to the engine block.

Tighten

Tighten the transmission bell housing bolts to 75 N•m (55 lb-ft).

Tighten the oil pan flange-to-transmission bolts to 50 N•m (37 lb-ft).

2. Install the starter mounting bolts.

Tighten

Tighten the starter-to-engine block mounting bolt to 75 N•m (55 lb-ft).

Tighten the transmission-to-starter mounting bolt to 75 N•m (55 lb-ft).

Warning: Make sure that all components are set in the exact position on the engine assembly remove/install pallet EN-48243 and pallet supporter EN-48244 as shown.

3. Install the engine and transmission assembly onto the cradle.

Note: Before tightening the transmission front mount through bolt, swing the engine assembly backwards and forwards or from the side to side for the proper alignment.

4. Install the transmission front mount assembly.

Tighten

Tighten the transmission front mount retaining bolts to 50 N•m (37 lb-ft).

Tighten the transmission front mount-to-transmission through bolt to 90 N•m (66 lb-ft).

Note : Before tightening the transmission rear mount through bolt, swing the engine assembly backwards and forwards or from the side to side for the proper alignment.

5. Install the transmission rear mount assembly to the cylinder block.

Tighten

Tighten the transmission rear mount retaining bolts to 90 N•m (66 lb-ft).

Tighten the transmission rear mount-to-bracket through bolt to 90 N•m (66 lb-ft).

6. Lift the vehicle.
7. Lower the vehicle and position the engine and transmission assembly with the cradle attached on to the engine assembly remove/install pallet EN-48243 with the pallet supporter EN-48244 to the vehicle.

8. Install the transmission mount. Refer to Transmission Mount Assembly (LH Side) Replace .

Tighten

Tighten the transmission mount assembly retaining bolts to 37 N•m (27 lb-ft).

Tighten the transmission mount bracket retaining bolts to 50 N•m (37 lb-ft).

9. Install the engine mount assembly. Refer to Engine Mount Assembly (RH Side) Replace .

Tighten

Tighten the engine mount frame side bracket retaining bolt to 100 N•m (74 lb-ft) and nuts to 90 N•m (66 lb-ft).

Tighten the engine mount adapter retaining bolts to 50 N•m (37 lb-ft).

10. Remove the engine assembly remove/install pallet EN-48243 with the pallet supporter EN-48244 from the vehicle.
11. Install the cradle-to-body mounting bolts. Refer to Cradle, Stabilizer Shaft Replace .

Tighten

Tighten the cradle mounting bolts to 155 N•m (114 lb-ft).

12. Install the cradle support bracket retaining bolts. Refer to Cradle, Stabilizer Shaft Replace .

Tighten

Tighten the cradle support bracket bolts to 50 N•m (37 lb-ft).

13. Install the power steering gear intermediate shaft. Refer to Intermediate Shaft, Joint and Dash Seal Replace .
14. Install the left and right axle shaft. Refer to Drive Axle Assembly Replace .
15. Install the control arm joint. Refer to Front Control Arm Replace .
16. Install the tie rod end joint. Refer to Front Control Arm Replace .
17. Install the stabilizer link. Refer to Stabilizer Link .

18. Install the exhaust front pipe-to-primary catalytic converter. Refer to Exhaust Front Pipe Replace .

Tighten

Tighten the primary catalytic converter-to-exhaust front pipe retaining nuts to 40 N•m (30 lb-ft).

Tighten the exhaust front pipe mounting bracket bolt and nut to 40 N•m (30 lb-ft).

19. For the AWD vehicle, install the propeller shaft. Refer to Propeller Shaft Replace .
20. Install the engine electrical wires to the engine.
21. Connect all of the necessary vacuum lines, including the brake booster vacuum hose.
22. Connect the ground terminals.
23. Install all the necessary parts and connect all connectors and cables to the transmission. For Manual Transmission, refer to: Shift Control Lever Housing Replace . Shift Control Cable Replace . Shift Control Cable Adjustment .

24. Connect the power steering hoses to the power steering pump. Refer to Power Steering Pump Hoses and Pipes Removal Procedure .
25. Connect the fuel feed line to the fuel rail.

26. Connect the heater inlet and outlet hose to the cylinder head.
27. Connect all of the necessary cooling hoses to electronic throttle body, thermostat, coolant pipe and cylinder block.

28. Install the resonator to the electronic throttle body.

29. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replace .
30. Install the breather hose and PCV hose to the cylinder head cover.
31. Connect the intake air temperature (IAT) sensor connector.
32. Install the engine beautification cover.

33. Install the fuel pump fuse.
34. Refill the engine crankcase with engine oil. Refer to General Specifications for engine capacities.
35. Refill the engine coolant system. Refer to Draining and Refilling the Cooling System .
36. Refill the power steering system and bleed the system.
37. Refill the A/C refrigerant system, if equipped.
38. Refill the transmission oil. Refer to: Transmission Fluid Replacement for Manual Transmission.