How to Remove and Install the Engine Opel Astra G

Remove

1. 1. Open bonnet

Important. For model with airbag: steering wheel in straight-ahead position, remove ignition key and engage steering wheel lock

2. 2. Remove steering column interim spindle • 1 clamping bolt (1)

3. 3. Empty climate control system • Connect service station • Blue hose on low pressure service connector (1) with small diameter • Red hose on high pressure service connector (2) with large diameter • Determine quantity of condenser extracted at the oil separator of the Service Station

Note. Read Service Station operating instructions carefully

4. 4. Raise vehicle
5. 5. Remove lower engine compartment cover • 2 fastening bolts (2) • 2 body-bound rivets (1) and (3) • 10 tightening bolts (4), (5), (6) and (7)

6. 6. Place collecting basin underneath.
7. 7. Drain coolant • Open radiator drain plug • Collect coolant • Close drain plug
8. 8. Lower vehicle
9. 9. Remove battery • Open battery insulation • Ground cable from ground terminal – 1 fastening bolt (6) • Ground terminal (5) from battery • Positive cable from positive terminal – 1 fastening bolt (3) • Positive terminal (4) from battery • Remove bracket 1) – 1 fastening bolt (2)

10. 10. Remove battery support. • Remove pre-glow system control unit (3) • Unclip 1 coolant hose – 2 clips (5) • Remove wiring harness – 1 body-bound rivet (1) • 3 fastening bolts (2) and (4)

11. 11. Remove air cleaner housing (4) • 1 wiring harness plug (1) • 1 fastening bolt (3) • Air intake manifold – 1 clamp (2)

12. 12. Remove bonnet (2) • Remove oil filler cap (1) • Pull off engine cover – 3 off • Replace oil filler cap

Note. Rubber retainers (3) must remain in cover

13. 13. Detach coolant line • 1 tightening bolt (1)

14. 14. Detach fuel lines from high pressure pump • from return line connection (1) • from feed line connection (2)

15. 15. Separate coolant hoses from heating element (1) • 2 coolant hoses – Detach in direction of arrow

16. 16. Remove brake servo vacuum line (2) • 1 clamp (1) • 3 clips • Set to one side

17. 17. Remove coolant hoses • From coolant compensation tank – 2 off (1) – 1 clip • From radiator (2)

18. 18. Disconnect wiring harness connector. • Remove 1 multiplug (twist lock) – from wiring harness plug (1) – Unclip wiring harness plug • Disengage and remove engine timing unit wiring harness plug (2) in direction of arrow – Unfasten 1 cable tie

19. 19. Disconnect steering wiring harness • Remove fuse (2) • Draw fuse holder (1) up and out of bracket • Disconnect 1 wiring harness plug (3) • 4 Clips

20. 20. Remove central clutch release discharge line (2) • Release clamp (3) with screwdriver (1) in direction of arrow and remove • Press clamp together slightly and re-insert into connector piece

21. 21. Raise vehicle • Half height
22. 22. Remove front wheels • 8 fastening bolts
23. 23. Remove front panelling • 4 fastening bolts (2) and (4), 5 clips (1) and (3) • 1 wiring harness plug

24. 24. Detach cooling module wiring harness • Remove cooling module control unit wiring harness plug (2) • Remove ground cable (1) – 1 fastening nut • Unclip from bracket

Note. Detach wiring harness plug in direction of arrow

25. 25. Remove coolant line (1) • Remove from desiccant box – 1 fastening bolt

26. 26. Remove swing arm (2) • 2 nuts – Use spanner (1) to hold against flat surface
27. 27. Remove tie rods • 2 fastening nuts – Force back from steering knuckle with KM-507-C (3)
28. 28. Remove steering knuckle pins • 2 bolts, 2 nuts • Spread steering knuckle pins with KM-915 (4) and draw guiding joint out of steering knuckle

29. 29. Remove axle body • 2 cotter pins, 2 castellated nuts – hold using KM-468-B (1)

30. 30. Raise vehicle • Half height
31. 31. Release clamp (1) from shift rail • 1 clamping bolt • Separate steering deflector from shift rail

32. 32. Remove front exhaust pipe • from starter cat – 3 fastening nuts (1) • from centre silencer – 1 clamp (2)

33. 33. Insert KM-6173 (3) • Raise support bearing (1) until journal (2) sits flush in the aperture (4) on the cylinder block

34. 34. Attach KM-6001-A (1) • Slacken tightening bolts (arrow) of adjusting rails • Insert KM-6001-A – Insert pegs (2) and (5) in the guide holes in the front axle body • Tighten fastening bolts of adjustment rails. • Adjust support bearings, front (4) and rear (3) – Raise support bearings up to the stop on the guide journals

Note. Attaching KM-6001-A guarantees perfect alignment of the drive unit with the front axle body

Note. The guide journals must be seated free from play in the support bearings

35. 35. Lower vehicle
36. 36. Remove left-hand engine damping block (1) • 3 fastening bolts
37. 37. Remove right-hand engine damping block (2) • 3 fastening bolts

38. 38. Raise vehicle
39. 39. Attach KM-904 and KM-6000 • Attach to hydraulic lifter • Place under front axle body, ensure there is no play

Note. Use hydraulic lifter which can be lowered to at least 100 cm

Important. It is not permissible to disassemble the front axle body with an impulse or impact screwdriver

40. 40. Remove front axle body • 10 tightening bolts (1), (2), (3) and (4)

Note. Note different bolt lengths

Important. Take care not to damage attachments

41. 41. Lower front axle body

Note. 2 people

Install

Important. Take care not to damage attachments

42. 42. Lift front axle body • Place on chassis, ensure there is no play

Note. 2 people

Important. It is not permissible to assemble the front axle body with an impulse or impact screwdriver

43. 43. Fit front axle body • Use new bolts • Tightening torque 90 Nm + 45° + 15°
44. 44. Remove KM-904 with KM-6000 • Lower hydraulic lifter • Remove KM-904 and KM-6000 from hydraulic lifter
45. 45. Attach selector shaft

Note. Only tighten after adjusting

46. 46. Lower vehicle • Half height
47. 47. Fit steering knuckle • Insert axle body into wheel hub • Insert guiding joint into steering knuckle • Install washer • Fit new castellated nut – Tightening torque 120 Nm – Hold using KM-468-B • Release castellated nut until it can be turned by hand – Hold using KM-468-B • Tighten castellated nut – Tightening torque 20 Nm + 80° – Hold using KM-468-B • Insert new cotter pin • Fit safety cap
48. 48. Fit steering knuckle • Use new nuts – Tightening torque 100 Nm
49. 49. Install tie rods • Insert tie rod into steering knuckle • Use new nuts – Tightening torque 60 Nm
50. 50. Install swing arm • Attach to spring strut supporting tube - counterhold with spanner against flat surface • Use new nuts – Tightening torque 65 Nm
51. 51. Lower vehicle • Half height
52. 52. Fit left-hand engine damping block • 3 fastening bolts • Tightening torque 55 Nm
53. 53. Fit right-hand engine damping block • 3 fastening bolts • Tightening torque 55 Nm
54. 54. Engage locating pin (1) in hole • Turn selector shaft to the left (towards 3rd gear)

55. 55. Insert gear stick fixing • Unclip central console cover • Remove manual gear stick cover – 2 fastening bolts – Draw cover upwards with concertina section • Push gear stick to the left • Stop holes in gear stick and gear stick housing with KM-527-A (1)

56. 56. Raise vehicle
57. 57. Remove engine mount KM-6173
58. 58. Remove engine mount KM-6001-A
59. 59. Fit shift rail clamping bolt • Tightening torque 12 Nm + 180° to 225°
60. 60. Install front exhaust pipe • to starter cat – Replace seal – 3 new fastening nuts • to the centre silencer – 1 clip
61. 61. Lower vehicle • Half height
62. 62. Attach cooling module wiring harness • Clip into bracket • Ground cable – 1 fastening nut • Lock wiring harness plug of cooling module control unit
63. 63. Attach coolant line • Attach coolant line to desiccant box – Replace seal – 1 fastening bolt – Tightening torque 22 Nm
64. 64. Fit front panelling • Fit external temperature sensor • 4 bolts, 5 clips
65. 65. Install front wheels • Tightening torque 110 Nm
66. 66. Raise vehicle • Half height

Important. When installing make sure that the brake hose (8) is above the engine compartment cover

67. 67. Install lower engine compartment cover • 2 fastening bolts (2) • 2 body-bound rivets (1) and (3) • 10 tightening bolts (4), (5), (6) and (7) – Tightening torque 5 Nm

68. 68. Lower vehicle
69. 69. Attach central clutch release discharge line
70. 70. Connect steering wiring harness • Connect 1 wiring harness plug • 4 Clips • Press fuse carrier down into holder • Install fuse
71. 71. Fix wiring harness plug • 1 engine timing unit wiring harness plug – Lock wiring harness plug – Clip in wiring harness plug – 1 cable tie • Connect 1 multiplug (twist lock) – Clip in
72. 72. Attach coolant hoses • 1 hose to radiator • 2 hoses from coolant compensating reservoir – 1 clip
73. 73. Join coolant hoses to heating element • 2 coolant hoses
74. 74. Attach fuel lines to high pressure pump • Feed line – 1 clip • Return line – 1 clip
75. 75. Connect coolant line • 1 fastening bolt – Replace seal – Tightening torque 22 Nm
76. 76. Connect brake servo vacuum line • 3 clips • 1 clip
77. 77. Install air cleaner housing • 1 fastening bolt – Tightening torque 15 Nm • Air intake manifold – 1 clip – Tightening torque 3.5 Nm • 1 mass air flow meter wiring harness plug
78. 78. Install battery holder • 3 fastening bolts – Tightening torque 15 Nm • Clip in 1 coolant hose – 2 clips • Attach wiring harness – 1 body-bound rivet • Attach pre-glow system control device to battery carrier
79. 79. Install battery • 1 fastening bolt
80. 80. Connect battery • Ground terminal to battery • Ground cable to ground terminal – 1 fastening bolt • Positive terminal to battery • Plus cable to positive terminal – 1 fastening bolt • Close battery insulation
81. 81. If necessary: to up engine oil, correct as required
82. 82. Install engine cover • Remove oil filler cap • Push in engine cover • Replace oil filler cap
83. 83. Top up coolant or ensure correct quantity is present.
84. 84. Insert steering column interim spindle clamping bolt • Use new bolt – Insert bolt coated with screw locking compound – Tightening torque 22 Nm
85. 85. Remove gear stick fixing • Remove KM-527-A from the gearshift housing • Install gear stick cover on central console – 2 bolts • Clip in central console cover

Note. Locking pin on gear releases automatically when shift is first moved in "R" direction

86. 86. Vent hydraulic clutch actuator • See operation "Vent Hydraulic Clutch Actuator (F17/F23)" in group "K"
87. 87. Top up climate control system • Connect service station • Blue hose on low pressure service connector (1) with small diameter • Red hose on high pressure service connector (2) with large diameter • Use the Service Station to insert the quantity of new compressor lubricant into the climate control system that was extracted when it was emptied. – Top up climate control system with coolant R 134a - coolant filling quantity 700g

Note. Read Service Station operating instructions carefully

88. 88. Check gearshift action • Check for ease of gearshifts when the vehicle is at rest, when the engine is running and when the clutch is disengaged
89. 89. Programme transient memory
90. 90. Close bonnet