How to Remove and Install the Engine Opel Astra G

Remove

1. 1. Open bonnet • Steering wheel straight, withdraw ignition key and engage steering lock
2. 2. Remove steering column interim spindle • 1 clamping bolt (1)

3. 3. 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)

4. 4. 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

5. 5. Place collecting basin underneath.
6. 6. Drain coolant • Open radiator drain plug • Collect coolant • Close drain plug
7. 7. Detach ground terminal • Ground cable (3) from ground terminal (4) – 1 nut • Ground terminal of battery
8. 8. Detach plus terminal • Plus cable (2) from plus terminal (1) – 1 nut • Plus terminal of battery
9. 9. Remove battery • 1 bolt – Remove battery
10. 10. Remove battery carrier (5) • 3 bolts • Unclip 1 coolant hose (6) • Expose wiring harness

11. 11. Remove air filter casing (5) with air intake manifold • 1 mass air flow meter wiring harness plug (4) • Unclip tank ventilation hose (1) • 1 fastening bolt (2) • Air intake manifold (3) – 1 clip

12. 12. Detach tank vent valve hose • 1 clip • Detach tank vent valve (1) in direction of arrow

Important. Exiting fuel - observe safety regulations and national legislation

13. 13. Lower fuel pressure • Remove fuel pressure with pressure tester KM-J-34730-91 (2) via test connector (1) – Collect exiting fuel in a suitable container

14. 14. Remove fuel line (2) from fuel distribution pipe • Detach using KM-796-A (1)

15. 15. Remove coolant hose (2) • From throttle body (1) • 1 clip – Expose coolant hose – 3 clips

16. 16. Remove wiring harness plug (1) from bracket • Detach wiring harness plug in direction of arrow and disconnect • Unclip wiring harness from bracket • Unclip coolant hose (2)
17. 17. Disconnect central engine electronics plug (3) • 1 clip • Detach central plug in direction of arrow

18. 18. Remove coolant hoses (1) and (3) • From coolant compensation tank (2) – 2 clips

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. Place collecting basin underneath.
21. 21. 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

22. 22. Remove brake force amplifier vacuum line (1) • From intake manifold – 1 line

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

24. 24. Raise vehicle • Half height
25. 25. Remove front panelling • 4 bolts (2) and (4), 5 clips (1) and (3)

26. 26. Remove front panelling • 1 wiring harness plug
27. 27. Separate coolant lines • 2 bolts (1) and (2)

28. 28. Remove front wheels • 8 bolts
29. 29. Remove swing arm (2) • 2 nuts – Use spanner (1) to hold against flat surface
30. 30. Remove tie rods • 2 nuts – Force back from steering knuckle with KM-507-C (3)
31. 31. Remove steering knuckle pins • 2 bolts, 2 nuts • Spread steering knuckle pins with KM-915 (4) and draw guiding joint out of steering knuckle

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

33. 33. Remove radiator module control unit wiring harness • Remove ground cable (1) – 1 nut • Wiring harness plug (2) – Disengage in direction of arrow and remove • 1 clip

34. 34. Raise vehicle • Half height
35. 35. Expose lambda sensor wiring (1) • 1 cable tie (2) • Disconnect 1 wiring harness plug (3)

36. 36. Remove exhaust system • Remove exhaust front end (2) – 3 nuts (1) • Remove middle silencers (3) – 2 bolts (4) • Slacken exhaust system and remove – 4 brackets • Remove 1 seal

37. 37. Remove engine splash guard (2) • 4 bolts (1)

38. 38. Release circlip (1) from shift rail • 1 bolt • Separate steering deflector from shift rail

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

40. 40. Attach KM-6001-A (1) • Slacken tightening bolts (arrow) for adjusting rails • Insert KM-6001-A – The journals (2) and (5) must sit in the guide holes of the front axle body • Tighten fastening bolts for 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

41. 41. Lower vehicle
42. 42. Remove right-hand engine damping block • 3 bolts (1)
43. 43. Remove left-hand engine damping block • 3 bolts (2)

44. 44. Raise vehicle
45. 45. Install KM-904 with 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

46. 46. Remove front axle body • 10 bolts (1-4)

Note. Note different bolt lengths

Important. Take care not to damage attachments

47. 47. Lower front axle body

Note. 2 people

Install

48. 48. Check thread • Check 10 cage nuts for ease of action, replace if necessary
49. 49. Apply catch in gear housing • Engage latch pin (1) in gearshift cover by turning the shift rail (2) in direction of arrow

Important. Take care not to damage attachments

50. 50. 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

51. 51. Fit front axle body • Use new bolts • Tightening torque 90Nm + 45° + 15°
52. 52. Remove KM-904 with KM-6000 • Lower hydraulic lifter • Remove KM-904 and KM-6000 from hydraulic lifter
53. 53. Lower vehicle
54. 54. Fit right-hand engine damping block • Tightening torque 55Nm
55. 55. Fit left-hand engine damping block • Tightening torque 55Nm
56. 56. Connect coolant line • Use new sealing ring • Tightening torque 20Nm

Note. Under air filter housing

57. 57. Attach coolant line • Use new sealing ring • Tightening torque 20Nm
58. 58. Attach coolant hoses • 2 off • Place on heating element and fix in place • Ensure correct fitting
59. 59. Install brake force amplifier vacuum line • On intake manifold – 1 line
60. 60. Connect central clutch release discharge line • Install discharge line
61. 61. Connect steering wiring harness • Connect 1 wiring harness plug • 4 Clips • Place 1 fuse holder in bracket • Insert 1 fuse
62. 62. Attach coolant hoses • On coolant compensation tank – 2 circlips • on throttle body – 1 circlip
63. 63. Connect central engine electronic plug • 1 clip • Detach central plug
64. 64. Fit wiring harness plug to bracket • 1 wiring harness plug • Fix wiring harness plug • Clip in coolant hose
65. 65. Connect tank vent valve hose • 1 clip • Attach tank vent valve hose
66. 66. Attach fuel line to fuel distribution pipe
67. 67. Install air cleaner housing and air intake manifold • Place 1 mass air flow meter wiring harness plug • Clip in tank ventilation hose • 1 fastening bolt • 1 clip – Tightening torque 3.5Nm
68. 68. Install battery holder • Clip in 1 coolant hose • Route wiring harness • 3 bolts – Tightening torque 15 Nm
69. 69. Install battery • 1 bolt
70. 70. Raise vehicle
71. 71. Remove engine mount KM-6173
72. 72. Remove engine mount KM-6001-A
73. 73. Fit shift rail clamping screw • 1 bolt – Tightening torque 12Nm + 180° to 225Nm°
74. 74. Install engine splash guard • 4 bolts
75. 75. Install exhaust front-end with middle silencer. • Fit 4 shock absorption rings • Use new seals • 2 bolts, 3 nuts – Tightening torque 20Nm

Note. 2 people

76. 76. Install catalytic converter lamda sensor wiring harness • Route wiring harness • 3 clips
77. 77. Lower vehicle • Half height
78. 78. Route radiator module control unit wiring harness • Install ground cable – 1 nut • 1 clip
79. 79. Install radiator module control unit wiring harness • Install and fix in place
80. 80. 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 • Loosen castellated nut until it can be rotated 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
81. 81. Fit steering knuckle • Use new nuts – Tightening torque 100 Nm
82. 82. Install tie rods • Insert tie rod into steering knuckle • Use new nuts – Tightening torque 60 Nm
83. 83. Install swing arm • Use new nuts • Fit onto spring strut support - hold against the two flat surfaces with spanner – Tightening torque 65 Nm
84. 84. Install front wheels • Tightening torque 110 Nm
85. 85. Fit front panelling • Fit external temperature sensor • 4 bolts, 5 clips
86. 86. Lower vehicle • Half height
87. 87. Attach main power cable • Plus cable to plus terminal • Ground cable to ground terminal – 2 off
88. 88. Connect battery • Positive and negative pole
89. 89. Top up coolant or ensure correct quantity is present.
90. 90. Insert steering column interim spindle clamping bolt • Use new bolt – Insert bolt wetted with screw locking compound (red) – Tightening torque 22 Nm
91. 91. 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. The latch pin in the adjusting bore is automatically released the first time the "R" gear is selected

92. 92. Vent hydraulic clutch actuator • See operation "Vent Hydraulic Clutch Actuator (F17/F23)" in group "K"
93. 93. 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

94. 94. 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
95. 95. Programme transient memory
96. 96. Close bonnet