Engine Maintenance Using a Section Engine Opel Astra G

Important: When working on the fuel system it is essential to pay attention to cleanliness as even the smallest dirt particles can lead to faults in engine operation or in the fuel system. Open fuel connections must be sealed with appropriate plugs from the Opel Parts Catalogue (catalogue number: 45 06 154 / part number: 9201697). Sealing plugs are only intended to be used once.

Remove

1. 1. Remove manual transmission from engine
2. 2. Place collecting basin underneath.
3. 3. Drain engine oil
4. 4. Detach wiring harness for engine timing • Throttle body • EGR valve • From solenoid valve switchover valves • Injectors – 4 wiring harness plugs • Sheathed glow plugs – 4 wiring harness plugs • Pressure sensor • Sensor switchover valves • Sensor de presión sobrealimentación • Wiring harness plug, alternator • Solenoid valve, exhaust gas recirculation • Pressure sensor • Crankshaft sensor • Camshaft sensor • Detach 12 x clips
5. 5. Detach ribbed V-belt • Mark direction of rotation • Apply tension to ribbed V-belt tensioner – Via tension roller fastening bolt • Remove ribbed-V-belt
6. 6. Remove alternator wiring harness, starter • From alternator – 1 wiring harness plug – 1 fastening nut • Wiring trough • 1 fastening bolt – 1 Fastening clip • From starter – 2 fastening nuts – 1 fastening bolt • Oil pressure switch • Coolant temperature sensor • 1 cable tie, 2 fastening clips
7. 7. Remove compressor (1) • Remove coolant lines – 1 fastening bolt • 1 wiring harness plug • 3 fastening bolts

Note. Note different bolt lengths

8. 8. Remove compressor bracket (1) • Unscrew 3 fastening bolts

9. 9. Detach alternator • Solenoid valve vacuum line • Brake servo vacuum line – 1 union nut • Vacuum pump oil feed line from cylinder block – Unscrew 1 fastening bolt • Vacuum pump oil return hose from cylinder block – 1 clip • Unscrew 2 fastening bolts
10. 10. Detach alternator support • Unscrew 4 fastening bolts
11. 11. Remove air intake manifold (1) • Unclip wiring harness – 3 clips • 2 clips • 2 fastening bolts

12. 12. Detach dipstick guide tube with bracket • from upper part of oil pan – Unscrew 2 fastening bolts • from camshaft housing – Unscrew 2 fastening bolts
13. 13. Remove radiator exhaust gas recirculation • from exhaust manifold – 2 fastening bolts (3) • from exhaust recirculator body – 2 fastening bolts (2) • from camshaft housing – 1 tightening bolt (1) • Remove gaskets – 2 off

14. 14. Remove vacuum hose • from wastegate unit
15. 15. Remove oil return hose • From cylinder block – 1 clip
16. 16. Remove exhaust manifold heat shield • 4 fastening bolts (1)

17. 17. Detach turbocharger oil feed line • From turbocharger – Unscrew 1 banjo bolt • From cylinder block – Unscrew 1 fastening nut
18. 18. Remove exhaust manifold (1) with turbocharger. • From cylinder head – Unscrew 2 fastening bolts – Unscrew 7 fastening nuts • from catalytic converter bracket – Unscrew 2 fastening bolts

19. 19. Remove coolant hoses (1) • From coolant pipe – 2 off
20. 20. Remove coolant pipe • Remove from cylinder block – 1 fastening bolt (3) • Pull from coolant flange (2) in direction of arrow

21. 21. Remove coolant discharge connection • 2 fastening bolts (1)

22. 22. Detach throttle body (1) from camshaft housing • 1 fastening bolt

23. 23. Remove oil filter housing with heat exchanger • 2 coolant hoses – From coolant connection (1) • Oil return hose – from connection (2) • 1 fastening bolt (3)

24. 24. Remove starter • Detach cable ties – 1 cable tie (5) – 2 fastening nuts (2) and (3) – 1 tightening bolt (1) • 1 fastening bolt (4)

25. 25. Remove charge air pipe (1) • Unscrew 6 fastening bolts

26. 26. Remove engine transport shackle • 3 off
27. 27. Remove exhaust gas recirculator body (1) • 1 coolant hose • Detach radiator exhaust gas recirculator – 2 fastening bolts • 2 fastening bolts

Note. Note different bolt lengths

Important. After detaching the pressure lines, seal the openings on the injectors and the pressure chamber with protective caps 1)

28. 28. Remove high pressure lines (1) from pressure chamber to injectors • 8 union nuts – using KM-812 KM-6098 • Remove pressure lines

29. 29. Remove injector connection seals (1) • 4 off • 8 fastening bolts

30. 30. Remove oil leak hose (1) • from injectors – 4 securing clips • from pressure chamber • 2 fastening bolts • 1 fastening nut

Note. Press in direction of arrow

Note. Note different bolt lengths

31. 31. Remove injector seals (1) • 4 off • 8 fastening bolts

32. 32. Remove injectors (1) • Remove injector brackets (2) – 4 fastening bolts

Note. Identify injectors

Note. If the heat protection sleeve (5) is pulled out with an injector, the seals (3) must be replaced and the sleeve tapped into the cylinder head with KM-6357 (4)

33. 33. Check injector bracket New injector bracket Old injector bracket

Note. If an old injector bracket is fitted, this must be replaced with a new injector bracket

34. 34. Remove upper part of toothed belt cover (3) • 8 fastening bolts • Remove camshaft sensor bracket (1) – 1 fastening bolt (2)

Note. Note different bolt lengths

35. 35. Detach camshaft sensor with bracket • Unscrew 1 fastening bolt
36. 36. Remove engine damping block support • from engine damping block bracket – 3 fastening bolts (2) • From cylinder block – 3 fastening bolts (3) • Remove the engine damping block adapter (1)

37. 37. Remove torsional vibration damper (1) • 4 fastening bolts

Note. Counterhold at the toothed belt drive pulley fastening bolt (2)

38. 38. Remove the coolant pump drive pulley (1) • 3 fastening bolts

39. 39. Remove lower part of toothed belt cover (1) • 3 fastening bolts (2)

40. 40. Turn crankshaft in the direction of rotation of the engine to the adjusting position • The following factors must be present for the adjusting position 1. It must be possible to insert the TDC-fastening bolt M6 (1) in the camshaft drive pulley 2. It must be possible to insert the TDC-fastening bolt M8 (2) in the high pressure pump drive pulley 3. The mark (4) on the toothed belt drive pulley must align with the mark (3) on the oil pump housing cover

Note. Up to 6 turns of the crankshaft may be needed for this

41. 41. Remove toothed belt • Mark direction of rotation • Slacken the toothed belt tension roller – 1 tightening bolt (1) • Prestress toothed belt tension roller in direction of arrow – using the hexagon (2) • Fasten the toothed belt tension roller in the prestressed position – 1 fastening bolt

42. 42. Turn engine 60° against its direction of rotation
43. 43. Detach oil pump drive wheel (1) • 1 fastening nut

Note. Counterhold with socket wrench (2)

44. 44. Remove toothed belt drive pulley (2) • 1 fastening bolt – Counterhold with KM-662-C • Pull off with KM-161-B (1) • Remove spring washer

45. 45. Remove high pressure pump drive pulley • Counterhold with KM-6356 (1) – 1 fastening nut • Remove high pressure pump drive pulley – using KM-6355 (2) – Counterhold with KM-6356

46. 46. Remove toothed belt guide roller (1) • 1 fastening bolt (2)

47. 47. Remove rear toothed belt cover • 5 fastening bolts (1)

48. 48. Detach coolant pump • Unscrew 5 bolts

Important. After removing the pressure line, close off the openings of the high pressure pump and the pressure chamber with protective caps 1)

49. 49. Remove high pressure line (1) from high pressure pump to pressure chamber • Unscrew 2 union nuts – from pressure chamber with KM-812 – from high pressure pump with KM-6098

50. 50. Detach wiring harness bracket (2) • from pressure chamber – 2 fastening nuts (1)

51. 51. Detach pressure chamber (4) • Unscrew 2 fastening bolts

Note. Note different lengths of bolts (3) and spacers (1)

52. 52. Detach high pressure pump (2) • Unscrew 3 fastening nuts

53. 53. Remove camshaft housing • 12 fastening bolts – Slacken 1/2 turn at a time in the sequence shown (1 - 17) and then remove
54. 54. Remove seal

Important. Mark cup tappets, remove from cylinder head and lay aside in order, so that they can be allocated to correct valves on re-installation.

55. 55. Remove cup tappets (1) • 16 off

56. 56. Remove cylinder head bolts • Unscrew 10 bolts

Note. Loosen bolts in spiral pattern in steps of 1/2 to 1 turn in sequence illustrated

Important. Place cylinder head on wooden blocks, taking care not to damage glow plugs

57. 57. Remove cylinder head • Remove cylinder head gasket

Note. Use a second person

58. 58. Lock flywheel • KM-652
59. 59. Attach KM-6263
60. 60. Detach clutch pressure plate • 6 fastening bolts
61. 61. Remove flywheel • 8 fastening bolts
62. 62. Turn engine • using KM-412-A 180°

63. 63. Remove oil pan lower section (1) • from upper part of oil pan (2) – 15 fastening bolts

64. 64. Remove upper section of oil pan • Remove fastening bolts (2) and (3) and fastening nuts (1) for upper part of oil pan • Separate upper part of oil pan from cylinder block using a wide spatula
65. 65. Detach bracket, rear crankshaft seal ring (1) • 5 fastening bolts (2) • Lever off cover of rear crankshaft seal ring carefully

Important. Note guide sleeves when removing

66. 66. Remove oil pump cover (1) • Unscrew 9 bolts • Remove inner and outer rotors (2)

Note. Note different bolt lengths

67. 67. Remove oil intake pipe (2) • from oil baffle plate (1) – 1 fastening bolt

68. 68. Remove oil baffle plate (1). • 5 fastening bolts (arrows)

69. 69. Remove oil pressure switch (1) • 1 wiring harness plug

70. 70. Detach connection pieces • 2 pieces (oil circuit)
71. 71. Transfer cylinder block • Detach cylinder block from engine overhaul stand KM-412-A – Unscrew 8 fastening bolts • Remove KM-412-34 and KM-412-11-1 from cylinder block – Unscrew 6 fastening bolts • Cylinder Block from/to Transport Device, Detach and Attach – Attach KM-412-34 and KM-412-11-1 to cylinder block – Screw in 6 fastening bolts • Attach cylinder block to engine overhaul stand KM-412-A – Unscrew 8 fastening bolts
72. 72. Remove coolant pump plastic insert
73. 73. Clean components • Upper section of oil pan, lower section of oil pan, cylinder head, cylinder block, exhaust manifold, exhaust gas recirculation valve, coolant connections

Install

74. 74. Insert plastic insert into coolant pump
75. 75. Attach centring sleeves
76. 76. Attach connection pieces
77. 77. Fit oil pressure switch
78. 78. Remove crankshaft rear seal ring • Lever out seal ring with suitable tool

Important. Do not damage sealing surface

79. 79. Attach crankshaft rear seal ring holder • Apply adhesive sealant • 5 fastening bolts – Tightening torque 9.8 Nm

Note. Ensure guide sleeves are seated correctly

Note. Insert screws with screw locking compound. The assembly time including the torque test is 10 minutes max.

80. 80. Install crankshaft rear seal ring • Position KM-658-4 on crankshaft journal • Push sealing ring onto KM-658-2 • Knock in flush with KM-658-4

81. 81. Remove oil pump seal ring • Lever out seal ring

Note. Do not damage sealing surfaces

82. 82. Remove front crankshaft seal ring • Lever out seal ring

Note. Do not damage sealing surfaces

83. 83. Apply sealant • Apply a bead of adhesive sealing compound to sealing surface (cross-hatched) of oil pump cover.

Important. It should take no more than 10 minutes to apply adhesive sealing compound and install the oil pump cover including the torque check.

84. 84. Fit oil pump cover (2) • Insert inner and outer rotors in cylinder block – Coat with oil

85. 85. Install front crankshaft seal ring • Knock in flush with KM-656
86. 86. Install oil pump sealing ring • Drive in flush using KM-657
87. 87. Install oil baffle plate • 5 fastening bolts
88. 88. Replace seal
89. 89. Install oil intake pipe • Replace seal • 1 fastening bolt – Tightening torque 18.6 Nm
90. 90. Fit upper part of oil pan • Apply a bead of silicone sealant to sealing surfaces of upper part of oil pan. • 18 fastening bolts – Tightening torque 9.8 Nm
91. 91. Fit lower part of oil pan • Apply a bead of silicone sealant to sealing surfaces of lower part of oil pan. • Screw in 15 fastening bolts – Tightening torque 9.8 Nm
92. 92. Rotate engine 180° • using KM-412-A
93. 93. Fit flywheel • 8 fastening bolts – Tightening torque 29.4 Nm + 60° + 15°
94. 94. Attach clutch pressure plate • Centre pressure plate with KM-734 • 6 fastening bolts – Tightening torque 15 Nm
95. 95. Detach KM-6263
96. 96. Detach locking tool
97. 97. Cylinder Head, Check for Plane Surface

Note. Check cylinder head sealing surfaces for longitudinal and lateral deformation and for diagonal warpage – use straight edge.

98. 98. Insert MKM-571-B (1) into KM-301 (2) • Set dial to zero

Note. Note pretension

99. 99. Measure piston projection • Place probe on cylinder block • Measure projection of all 4 pistons – Measure at two different points; (1) and (2) or (3) and (4) – Turn the crankshaft to find the highest point

100. 100. Turn the crankshaft 60° against the direction of engine rotation

Important. The largest piston projection found is authoritative for selecting a cylinder head gasket with the corresponding identification (arrows). Take the corresponding values from the table in operation "Cylinder Head Gasket, Replace" .

101. 101. Replace cylinder head gasket • Lay cylinder head gasket in place – Note guide bushings

102. 102. Position cylinder head

Note. Use a second person

103. 103. Fasten cylinder head • Replace cylinder head bolts – In the sequence illustrated, from inside to outside with 39,2 Nm + 60°+ 60°

Note. Note correct tightening sequence

Important. Note identification of cup tappets

104. 104. Insert cup tappets

105. 105. Fit camshaft housing • Replace seal • Position on cylinder head and tighten the fastening bolts in the sequence illustrated (1 - 17) – Tightening torque (M8) 21.6 Nm – Tightening torque (M10) 26.5 Nm
106. 106. Install high pressure pump • 3 fastening nuts
107. 107. Install pressure chamber • 2 fastening bolts • Attach oil leak hose – from high pressure pump to pressure chamber

Note. Note different lengths of bolts and spacers

108. 108. Install wiring harness bracket • 2 fastening nuts
109. 109. Install high pressure line from high pressure pump to pressure chamber • 2 union nuts – using KM-812 KM-6098 – Tightening torque 25 Nm
110. 110. Attach coolant pump • Replace seal • Screw in 5 fastening bolts – Tightening torque 23.4 Nm
111. 111. Replace rear toothed belt cover • Screw in 5 fastening bolts – Tightening torque 9.8 Nm
112. 112. Insert toothed belt guide roller • Screw in 1 fastening bolt – Tightening torque 80.4 Nm
113. 113. Fit high pressure pump gear • Screw in 1 fastening nut – Tightening torque 68.6 Nm – Counterhold with KM-6356
114. 114. Remove camshaft drive sprocket • Screw in 1 fastening bolt – Tightening torque 63.7 Nm – Hold using KM-6347 • Screw in TDC fixing bolt

Note. Peg on camshaft must engage in hole in the camshaft drive sprocket

115. 115. Install oil pump gear • Tighten nut – 60 Nm – Hold 20 seconds – Slacken nuts – 60 Nm

Note. Observe installation position

Note. Counterhold with socket wrench

116. 116. Install toothed belt drive pulley • Attach to crankshaft • 1 fastening bolt – Tightening torque 196 Nm – Counterhold with KM-662-C

Note. Note spring washer

117. 117. Install toothed belt • Position toothed belt – The toothed belt must be pulled tight in the direction of the arrow, from its drive pulley (5) over the oil pump drive pulley (4) and the high-pressure pump drive pulley (2) to the camshaft pulley (1) – Observe direction of rotation • Slacken the toothed belt tension roller (3) • Remove 2x TDC fastening bolts • Turn the crankshaft 60° against the direction of engine rotation • Tighten the toothed belt tension roller – Tightening torque 38.2 Nm

Note. The TDC-fastening bolts must be installed in the camshaft drive pulley and the high pressure pump drive pulley and the markings (6) and (7) must align.

118. 118. Timing, Check • Turn crankshaft 6 revolutions in the direction of rotation of the engine to the adjusting position • The following factors must be present for the adjusting position 1. It must be possible to insert the TDC-fastening bolt M6 (1) in the camshaft drive pulley 2. It must be possible to insert the TDC-fastening bolt M8 (2) in the high pressure pump drive pulley 3. The mark (4) on the toothed belt drive pulley must align with the mark (3) on the oil pump housing cover • Remove 2x TDC fastening bolts

Note. If one of these factors is not present, the timing must be set

119. 119. Install lower part of toothed belt cover • 3 fastening bolts – Tightening torque 9.8 Nm
120. 120. Install coolant pump drive pulley • 3 fastening bolts – Tightening torque 12.3 Nm
121. 121. Install torsional vibration damper • Screw in 4 fastening bolts – Tightening torque 19.6 Nm

Note. Peg (1) on toothed belt drive pulley must engage in torsional vibration damper hole (2)

Note. Counterhold at the toothed belt drive pulley fastening bolt

122. 122. Turn engine as far as 2nd cylinder to max. valve clearance
123. 123. Measure valve clearance
124. 124. Replace 4 adjusting washers
125. 125. Rotate engine 180°
126. 126. Replace 4 adjusting washers
127. 127. Rotate engine 180°
128. 128. Replace 4 adjusting washers
129. 129. Rotate engine 180°
130. 130. Replace 4 adjusting washers
131. 131. Turn engine 720°
132. 132. Measure valve clearance
133. 133. Install engine damping block bracket • Insert engine damping block adapter • Engine damping block support to cylinder block – 3 fastening bolts – Tightening torque 40 Nm
134. 134. Install upper part of toothed belt cover • 8 fastening bolts – Tightening torque 9.8 Nm • Bracket, camshaft sensor – 1 fastening bolt – Tightening torque 9.8 Nm

Note. Note different bolt lengths

135. 135. Renew injector seals • 1 rubber seal (1) • 1 copper seal (2)

136. 136. Install 4x injector • Use KM-6358 (1) • Tighten 4x bolt firmly in three stages 1. Tighten bolt 40 Nm 2. Loosen bolt 3. Tighten bolt 32 Nm

137. 137. Apply sealing compound • Apply adhesive sealant to sealing surfaces (1) and (3)

Important. Oil return hole (2) must not be covered with adhesive sealing compound

138. 138. Fit camshaft housing cover • Replace seal • Tighten 9x bolt in the stated tightening sequence (1...9) 9.8 Nm

139. 139. Install 4x new injector seal (2) • Align injector seal • Coat 8x contact surface of bolt head (1) with special grease • Tighten injector seal firmly in 2 stages 1. Tighten 2x bolt 10 Nm 2. Tighten 2x bolt 19 Nm

Note. Sealing lip of the seal must be in contact with the injector with no gaps (arrow)

Note. Press injector seal against the camshaft housing cover with your hand during the tightening process

140. 140. Fit injector connection seals • 4 off • 8 fastening bolts

Note. "UP" mark must be at top

141. 141. Fit oil leak hose • 1 fastening nut • 2 fastening bolts • Attach to injectors – 4 off • Attach to pressure chamber

Note. Note different bolt lengths

Important. Pressure lines must be unstressed when fitted

142. 142. Fit high pressure lines from pressure chamber to injectors • Insert pressure lines • Attach pressure lines to injectors – 4 union nuts – Tightening torque 25 Nm

Important. Sealing ring (1) must stay in place during installation

143. 143. Assemble exhaust recirculation body • Replace seal • 2 fastening bolts – Tightening torque 24 Nm • Attach 1 coolant hose – 1 clip • Fit radiator exhaust gas recirculator – Replace seal – 2 fastening bolts – Tightening torque 28.5 Nm

Note. Note different bolt lengths

144. 144. Install engine transport shackle • 3 off • Screw in fastening bolts
145. 145. Install charge air pipe • Replace seals – 2 off • 6 fastening bolts – Tightening torque 24 Nm
146. 146. Attach starter • Tighten bolt 38,2 Nm
147. 147. Attach oil filter housing • Renew seal rings • Tighten fastening bolt 25.5 Nm • Fit oil return hose • Attach coolant hose.
148. 148. Fit throttle body bracket to camshaft housing • 1 fastening bolt – Tightening torque 24 Nm
149. 149. Attach coolant discharge connection • Screw in 2 fastening bolts

Note. Use sealant

150. 150. Install coolant pipe • Replace sealing ring • Screw in 1 fastening bolt • Attach 2 coolant hoses to thermostat housing – Fasten 2 clamps
151. 151. Attach exhaust manifold with turbocharger • Replace seal • Screw in 2 fastening bolts – Tightening torque 69 Nm • Screw in 7 fastening nuts – Tightening torque 69 Nm • To catalytic converter bracket – Screw in 2 fastening bolts

Note. Add 0.4 ml clean engine oil in the oil feed line opening

152. 152. Attach turbocharger oil feed line • Replace seals • To turbocharger – Screw in 1 banjo bolt • On cylinder block – Screw in 1 fastening nut
153. 153. Attach exhaust manifold heat shield • Screw in 4 fastening bolts – Tightening torque 11.7 Nm
154. 154. Attach vacuum hose • to waste-gate unit
155. 155. Fit radiator exhaust gas recirculator • Replace seals – 2 off • to exhaust manifold – Screw in 2 fastening bolts – Tightening torque 28.5 Nm • to exhaust gas recirculator body – Screw in 2 fastening bolts – Tightening torque 28.5 Nm • to camshaft housing – Screw in 1 fastening bolt – Tightening torque 24 Nm
156. 156. Fit dipstick guide tube holder • to camshaft housing – 2 fastening bolts • Clip in vacuum hose – 2 clips • Dipstick guide tube – 1 clip
157. 157. Install turbocharger oil feed line • To turbocharger – 1 hollow bolt – Tightening torque 20.6 Nm
158. 158. Fit oil return hose • On cylinder block – 1 clip
159. 159. Attach dipstick guide tube with bracket • to upper part of oil pan – Screw in 2 fastening bolts • to camshaft housing – Screw in 2 fastening bolts
160. 160. Attach alternator support • Screw in 4 fastening bolts
161. 161. Install alternator • Screw in 2 fastening bolts • Oil return hose, vacuum pump to cylinder block – 1 clip • Vacuum pump oil feed line to engine block – Replace 2 gaskets – Screw in 1 fastening bolt • Brake servo vacuum line – 1 union nut • 1 wiring harness plug • Solenoid valve vacuum line
162. 162. Install compressor bracket • Screw in 3 fastening bolts
163. 163. Install compressor • To bracket – 3 fastening bolts – Tightening torque 19 Nm • 1 wiring harness plug • Remove coolant lines – 1 fastening bolt – Tightening torque 20 Nm
164. 164. Install air intake pipe. • 2 clips • 2 fastening bolts • Clip wiring harness into position – 3 clips
165. 165. Attach alternator wiring harness, starter • Coolant temperature sensor • Oil pressure switch • To starter – 2 fastening nuts – 1 fastening bolt • Wiring trough • 1 fastening bolt – 1 Fastening clip • To alternator – 1 wiring harness plug – 1 fastening nut • 1 cable tie, 2 fastening clips

Note. Pay attention to laying

166. 166. Insert ribbed V-belt • Tension ribbed V-belt tensioner in direction of arrow using fastening bolt (1) and place ribbed V-belt in position – I. Ribbed V-belt without air conditioning – II. Ribbed V-belt with air conditioning

Note. Note the direction of running of the ribbed V-belt

167. 167. Attach wiring harness for engine timing • Camshaft sensor • Crankshaft sensor • Pressure sensor • Solenoid valve, exhaust gas recirculation • Sensor de presión sobrealimentación • Wiring harness plug, alternator • Sensor switchover valves • Pressure sensor • Sheathed glow plugs – 4 off • Injectors – 4 plugs • Switchover valves solenoid valve • EGR valve • Throttle body • Clip in 12 clips
168. 168. Top up engine oil. • Note quantity of oil specified
169. 169. Attach manual transmission to engine

1

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