Replace Oil Pump Seal Ring Opel Astra G

Remove

1. 1. Open bonnet
2. 2. Disconnect battery
3. 3. 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

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

5. 5. Detach ribbed V-belt • Mark direction of rotation • Tension ribbed V-belt tensioner in direction of arrow – using fastening bolt (1) • Remove ribbed-V-belt

6. 6. Remove cable duct (4) from upper section of toothed belt cover • 1 fastening bolt (2) • Camshaft sensor wiring harness plug with wiring harness (3) – 2 clips • Vacuum line (1) – 2 clips • Unclip cable duct in direction of arrow – 1 clip

7. 7. 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

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

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

11. 11. 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

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

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

13. 13. Lower vehicle
14. 14. 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)

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

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

17. 17. 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

18. 18. 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

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

20. 20. Remove oil pump drive pulley (1) • 1 fastening nut

Note. Counterhold with socket wrench (2)

21. 21. Remove oil pump seal ring (1) • Lever out seal ring

Important. Do not damage sealing surfaces

Install

22. 22. Install oil pump seal ring • Insert seal ring in oil pump cover • Drive in as far as the stop with KM-657 (1)
23. 23. Install oil pump gear • Tighten nut – 60 Nm – Hold 20 seconds – Slacken nuts – 60 Nm

Note. Observe installation position

Note. Counterhold with socket wrench

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

Note. Note spring washer

25. 25. 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.

26. 26. 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

27. 27. Install lower part of toothed belt cover • 3 fastening bolts – Tightening torque 9.8 Nm
28. 28. Install coolant pump drive pulley • 3 fastening bolts – Tightening torque 12.3 Nm
29. 29. Install engine damping block bracket • Insert engine damping block adapter • Engine damping block support to cylinder block – 3 fastening bolts – Tightening torque 40 Nm • Engine damping block support to engine damping block bracket – 3 fastening bolts – Tightening torque 55 Nm
30. 30. Raise vehicle

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

31. 31. Install torsional vibration damper • 4 fastening bolts – Tightening torque 19.6 Nm

Note. Counterhold at the toothed belt drive pulley fastening bolt

32. 32. Remove engine mount KM-6173
33. 33. Remove engine mount KM-6001-A

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

34. 34. 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

35. 35. Lower vehicle
36. 36. Install upper part of toothed belt cover • 8 fastening bolts – Tightening torque 9.8 Nm • Install camshaft sensor bracket – 1 fastening bolt – Tightening torque 9.8 Nm

Note. Note different bolt lengths

37. 37. Mount cable channel on upper part of toothed belt cover • 1 fastening bolt – Tightening torque 6 Nm • Camshaft sensor wiring harness plug with wiring harness – 2 clips • Vacuum line – 2 clips • Clip in cable channel – 1 clip
38. 38. 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

39. 39. 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
40. 40. Install engine cover • Remove oil filler cap • Push in engine cover – 3 rubber retainers • Replace oil filler cap
41. 41. Connect battery
42. 42. Programme volatile memories
43. 43. Close bonnet