Repair Engine Using a Short Block Opel Astra H

Remove

1. 1. Detach transmission from engine • For vehicles with manual transmission • For vehicles with automatic transmission
2. 2. Vehicles with manual transmission: detach clutch
3. 3. Vehicles with manual transmission: detach KM-6263 • Turn rotating spindle back to initial position • Remove centring drift • Unscrew 4x bolts • Remove KM-6263
4. 4. Vehicles with manual transmission: attach EN-46792 (1) • Tighten bolt
5. 5. Vehicles with manual transmission: remove flywheel • Unscrew 6x bolt (2) • Remove EN-46792 – Unscrew bolt

6. 6. Vehicles with automatic transmission: attach EN-46792 (2) • Tighten bolt
7. 7. Vehicles with automatic transmission: remove drive disc • Unscrew 6x bolts (1) • Remove EN-46792 – Unscrew bolt

8. 8. Detach heat shield • Unscrew 2x bolts
9. 9. Detach vacuum reservoir (1) and retaining plate • Detach 2x vacuum hose • Unscrew 2x bolts (2) • Unscrew bolt (3)

Note. If present

10. 10. Detach EGR cooler (1) • Unscrew bolt, nut (arrows) • Detach EGR valve metal tube – Release clamp • Detach coolant hose – Release clamp

11. 11. Remove thermostat housing (1) • Disconnect wiring harness connector. • Unscrew 2x bolts • Remove seal • Detach coolant hose – Release clamp

12. 12. Remove vacuum pump (1) • Remove vacuum hose • Unscrew 3x bolts (2) • Remove seal

13. 13. Remove ribbed V-belt (1) • Mark rotational direction of ribbed V-belt • Tension ribbed V-belt tensioner in direction of arrow • Insert KM-6349 (2)

14. 14. Remove compressor • Disconnect wiring harness plug (2) • Unscrew 3x bolts (1)

15. 15. Detach compressor support from engine block • Unscrew 4x bolts (1)

Note. Note guide sleeves

Note. Remove with ribbed V-belt guide roller (2)

16. 16. Detach 2x compressor wiring harness bracket • Unscrew 2x bolts – Set wiring harness aside
17. 17. Remove coolant pipe assembly (1) • Unscrew 6x bolt (2) • Remove seal

18. 18. Remove torsional vibration damper (1) • Unscrew 4x bolts

Note. Counterhold toothed belt drive gear at bolt (2)

19. 19. Remove upper ribbed V-belt guide roller (1) • Unscrew bolt

20. 20. Remove toothed belt cover • Unscrew 6x bolt (arrows) • 4x unclip camshaft sensor wiring harness

21. 21. Remove engine damping block adapter (1) • Unscrew 5x bolts

Note. Note different bolt lengths

22. 22. Set cylinder no. 1 to TDC of combustion stroke • The mark on the camshaft sprocket (1) must be aligned with the mark on the camshaft housing cover (2)

23. 23. Remove toothed belt (1) • Slacken the toothed belt tension roller – Loosen bolt (2)

Note. Mark direction of rotation

24. 24. Remove toothed belt tightening roller • Unscrew bolt
25. 25. Remove toothed belt guide roller (2) • Unscrew bolt (1)

26. 26. Detach vacuum line • Unscrew 2x bolts (arrows)

27. 27. Detach witing harness (1) from engine • Detach wiring harness bracket from camshaft housing cover – Unscrew 2x bolts • Unclip 5x wiring harnesses • Disconnect 11x wiring harness plugs – 4x injector – Throttle valve module – EGR valve – Accumulator sensor – High-pressure pump – Intake air temperature sensor – Camshaft sensor – Pressure regulator

28. 28. Detach 4x oil leak line (2) from injectors • Unclip 2x leak oil line (1) • Release 4x retaining clamp (3) from injector in direction of arrow – Pull off oil leak line

Note. The oil leak line must not be detached from the fuel return damping case. It if is detached, it must be replaced.

Note. Seal 4x injectors with suitable blanking plugs

29. 29. Remove fuel return damping case (1) with oil leak line • Unscrew 2x bolts • Detach 2x hoses – Undo 2 clamps

Note. Open fuel connections must be sealed with appropriate plugs

Important. After detaching the high pressure lines, seal off injector and pressure chamber openings with protective caps 1)

30. 30. Detach accumulator high pressure line (1) to high pressure pump • Unscrew 2x union nuts

Important. When releasing the retaining nut on the high pressure pump, counterhold with open-ended wrench.

Note. Fuel connections that have been opened must be sealed with suitable plugs from the kit (45 06 154).

31. 31. Detach 4x high pressure line - accumulator to injector • Unscrew 8x union nut (1)

Important. When releasing the retaining nut, counterhold with open-ended wrench against the injector.

Note. Open fuel connections must be sealed with suitable blanking plugs

32. 32. Remove accumulator (1) • Unscrew 2x nut (arrows)

33. 33. Remove 4x injector • Unscrew 4x nut

Note. If the injectors cannot be reached by hand, use EN-46786 together with KM-328-B . Fit plugs to removed injectors (arrows).

34. 34. Detach wiring harness for sheathed glow plugs (arrows) • Disconnect 4x glow plug wiring harness plug • Unclip wiring harness

35. 35. Remove 4x sheathed glow plug (1)

36. 36. Release high-pressure pump gear • Counterhold with KM-6347 (1) in combination with KM-956-1 (2) • Unscrew nut

Note. Use a second person

37. 37. Detach high-pressure pump gear • Attach EN-46790 (1) – Screw in 2x bolts • Pull off high-pressure pump drive gear – Counterhold with open-ended wrench (2)

38. 38. Remove high pressure pump • Unscrew 3x nuts (1)

39. 39. Detach 3x alternator wiring harnesses • Unscrew 3x nuts (1)

40. 40. Detach alternator • Unscrew lower bolt • Unscrew 2x bolts – Remove bracket
41. 41. Detach high-pressure pump bracket (1) • Detach coolant pipe bracket from high-pressure pump bracket – Unscrew bolt • Unscrew 6x bolts

Note. Note different bolt lengths

42. 42. Remove intake manifold (1) • Unscrew 9x nuts • Detach gasket

43. 43. Detach alternator bracket • Unscrew 2x bolts

Note. Note different bolt lengths

44. 44. Detach cylinder head cover vent hose • Release clamp
45. 45. Detach crankshaft housing vent hose • Undo 2 clamps
46. 46. Detach charge air pipe bracket • Unscrew bolt
47. 47. Fit engine transport shackle • Tighten bolt
48. 48. Hitch engine up to workshop crane.
49. 49. Detach engine from KM-412 • Unscrew 8x bolts • Set engine down
50. 50. Detach KM-412-36-1 and KM-412-36-2 from engine block • Unscrew 7x bolts
51. 51. Unhitch engine from workshop crane.
52. 52. Detach engine transport shackle • Unscrew bolt

Install

53. 53. Attach engine transportation shackle to engine short block • Tighten bolt
54. 54. Hitch engine short block up to workshop crane
55. 55. Attach KM-412-36-1 an KM-412-36-2 to engine block • Tighten 7x bolts
56. 56. Attach engine short block to KM-412 • Tighten 8x bolts
57. 57. Unhitch engine short block from workshop crane.

Important. According to the engine preparers' regulations all particles of dust and liquids must be cleaned off every attaching part that is to be reassembled.

58. 58. Cleaning work on attaching parts
59. 59. Detach engine transport shackle • Unscrew bolt
60. 60. Attach charge air pipe bracket • Tighten bolt
61. 61. Attach crankshaft housing vent hose • Attach 2x clamps
62. 62. Attach cylinder head cover vent hose • Fasten clamp
63. 63. Attach alternator bracket • Tighten 2x bolts

Note. Note different bolt lengths

64. 64. Install intake manifold • Replace seal • Tighten 9x new nut 25 Nm
65. 65. Attach high-pressure pump bracket • Tighten 6x bolt 25 Nm • Attach coolant pipe bracket to high-pressure pump bracket – Tighten bolt

Note. Note different bolt lengths

66. 66. Attach alternator • Insert bracket – Screw in 2x bolts • Tighten lower bolt 70 Nm • Tighten 2x bolt 70 Nm
67. 67. Attach alternator wiring harness • Tighten 2x nut (M6) 5 Nm • Tighten nut (M8) 10 Nm
68. 68. Install high pressure pump • Tighten 3x nut 25 Nm
69. 69. Fit high pressure pump wheel • Screw in nut
70. 70. Fasten high-pressure pump gear • Use a second person • Tighten nut 50 Nm • Counterhold with KM-6347 in conjunction with KM-956-1
71. 71. Tighten 4x sheathed glow plugs to 8 Nm
72. 72. Attach wiring harness of sheathed glow plugs • Connect 4x wiring harness plug, sheathed glow plug • Attach wiring harness
73. 73. Cleaning work • Use EN-47632 (1) to clean the injector seats. Insert EN-47632 with coarse fleece in the injector shaft and clean the injector seat by turning. Finish by cleaning with the fine fleece.

74. 74. Install 4x injector • Remove closure plugs • Replace 4x seal rings • Tighten 4x nut 32 Nm
75. 75. Install accumulator • Tighten 2x nuts 25 Nm
76. 76. Install 4x new high-pressure line, accumulator to injector • Remove closure plugs • Tighten 4x union nut (M14) 23 Nm • Tighten 4x union nut (M12) 23 Nm

Important. Pressure lines must not be installed more than once. When fastening the retaining nut counterhold against the injector with an open-ended wrench.

77. 77. Attach new high pressure line - accumulator to high pressure pump • Remove closure plugs • Tighten union nut (M14) 23 Nm • Tighten union nut (M12) 23 Nm

Important. Pressure lines must not be installed more than once. When fastening the union nut to the high-pressure pump, counterhold against it with an open-ended wrench.

78. 78. Install fuel return damping case with oil leak line • Tighten 2x bolts – Attach wiring harness bracket to fuel return damping case • Attach 2x hoses – Attach 2x clamps
79. 79. Attach 4x oil leak line to injectors • Remove closure plugs • Clip 4x oil leak line to injector
80. 80. Attach wiring harness to engine • Clip in 5x wiring harnesses • Connect 11x wiring harness plug – 4x injector – Throttle valve module – EGR valve – Accumulator sensor – High-pressure pump – Intake air temperature sensor – Camshaft sensor – Pressure regulator • Clip in 2x leak oil line • Attach wiring harness bracket to camshaft housing cover – Tighten 2x bolts
81. 81. Attach vacuum line • Tighten 2x bolts
82. 82. Clean 2x threads
83. 83. Install toothed belt guide roller • Tighten bolt 50 Nm

Note. Use screw locking compound (red)

84. 84. Clean the thread
85. 85. Fit toothed belt tightening roll • Screw in bolt • Use screw locking compound (red)

Note. Insert tension roller in guide

86. 86. Install toothed belt • Position toothed belt

Note. Observe direction of rotation

Important. Tightened end (1) must be taut

87. 87. Tension the toothed belt • Screw in bolt (6) • Tension the toothed belt • Tighten bolt, toothed belt tension roller (3) 25 Nm

Note. Push adjusting lever in direction of arrow with a screwdriver (5) until pointer (4) of toothed belt tension roller aligns with mark (2)

88. 88. Check crankshaft setting with EN-46788 • Unscrew oil pump bolt (arrow) • Tighten stud bolt (1) EN-46788 • Attach positioning disk (4) EN-46788 – Screw in bolt (3) – Screw in nut (2) • Detach positioning disk EN-46788

89. 89. Timing, Check • Turn crankshaft 720° in the direction of rotation of the engine • Check camshaft position – The mark on the camshaft sprocket must align with the mark on the cylinder head cover.
90. 90. Check crankshaft setting with EN-46788 • Attach positioning disk EN-46788 – Screw in bolt – Screw in nut • Remove positioning disk and stud bolt EN-46788 • Tighten oil pump bolt 9 Nm

Note. If EN-46788 cannot be fitted, repeat the toothed belt positioning procedure

91. 91. Install engine damping block adapter • Tighten 3x bolt (M10) 50 Nm • Tighten 2x bolt (M8) 25 Nm

Note. Note different bolt lengths

92. 92. Install toothed belt cover • Tighten 4x bolt (M6) 9 Nm • Tighten 2x bolt (M8) 25 Nm • 4x clip in camshaft sensor wiring harness
93. 93. Install upper ribbed V-belt guide roller • Tighten bolt 50 Nm
94. 94. Install torsional vibration damper • Tighten 4x bolt 25 Nm

Note. Observe correct fitting position

Note. Counterhold toothed belt drive gear at bolt

95. 95. Install coolant pipe assembly • Replace seal • Tighten 6x bolt
96. 96. Attach 2x compressor wiring harness bracket • Tighten 2x bolts
97. 97. Attach compressor support to engine block • Tighten 4x bolt 50 Nm

Note. Note guide sleeves

98. 98. Attach compressor to support • Tighten 3x bolt 22 Nm • Fix wiring harness plug
99. 99. Insert ribbed V-belt • Position ribbed V-belt – I Route of ribbed V-belt with air conditioning – II Route of ribbed V-belt without air conditioning • Remove KM-6349

Note. Note direction of travel

100. 100. Clean sealing surface
101. 101. Install vacuum pump • Insert new gasket • Tighten 3x bolt 20 Nm • Attach vacuum hose
102. 102. Clean sealing surface
103. 103. Install thermostat housing • Replace sealing ring • Attach coolant hose – Fasten clamp • Tighten 2x bolt 25 Nm • Fix wiring harness plug
104. 104. Insstall EGR cooler • Tighten bolt 25 Nm • Tighten nut 9 Nm • Attach EGR valve metal tube – Tighten clamp • Attach coolant hose – Fasten clamp
105. 105. Attach vacuum reservoir and retaining plate • Tighten 3x bolt 25 Nm • Attach 2x vacuum hoses
106. 106. Attach heat shield
107. 107. Clean 6x threads
108. 108. Vehicles with automatic transmission: install drive disc • Attach EN-46792 • Tighten 6x new bolt 160 Nm
109. 109. Vehicles with manual transmission: install flywheel • Attach EN-46792 – Tighten bolt • Tighten 6x new bolt 160 Nm • Remove EN-46792 – Unscrew bolt
110. 110. Vehicles with manual transmission: attach KM-6263 • Tighten 4x bolts • Insert clutch pin KM-6263-30 with KM-6263-22

Important. Fasten KM-6263 but only to engine block, not to oil pan

111. 111. Vehicles with manual transmission: install clutch
112. 112. Detach transmission from engine • Remove automatic transmission from engine • Remove manual transmission from engine

1

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