How to Remove and Install the Engine Opel Astra H

Warning: When working on the Common Rail system, wait for one minute after switching off the engine. The system reduces the pressure automatically.

Important: When working on the fuel system, cleanliness is vital as even very small particles of dirt can lead to faults in engine operation or in the fuel system. Seal open fuel connections with suitable sealing plugs 1) . Sealing plugs must only be used once.

Remove

1. 1. Open bonnet
2. 2. Remove lower driver's side cover • Release 2x retaining clips

Important. Move steering wheel to straight-ahead position

3. 3. Remove steering column interim spindle • Engage steering wheel lock • Unscrew bolt (1)

4. 4. Detach 2x earth cable (1) from earth connection • Unscrew 2x bolts

5. 5. Disconnect battery • Detach ground connection from ground terminal – Slacken nut
6. 6. Remove engine cover (1) • Pull off engine cover

Note. Rubber retainers (2) must remain on engine cover

7. 7. Detach radiator grille (2) • Detach 4x body-bound rivets (1) • Release 6x lugs from front panelling

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

Note. For vehicles with climate control system

Note. Read Service Station operating instructions carefully

9. 9. Undo 2x front wheels
10. 10. Raise vehicle by half its height
11. 11. Remove 2x front wheels
12. 12. Undo front panelling (1) • Remove 5x body-bound rivets (3) • Unscrew 4x bolts (4)
13. 13. Remove front panelling • Push front panelling upwards in direction of arrow and pull out of bracket • Remove front panelling – Unclip 4x clips (2) • Unclip outside temperature sensor

Note. Use a second person

14. 14. Remove lower engine cover and right engine splash guard
15. 15. Disconnect cooling module wiring harness • Unscrew nut (1) • Disconnect wiring harness plug (2) • Unfasten 3x cable ties

16. 16. Detach lower engine timing wiring harness • Disconnect wiring harness plug from engine control unit (1) • Unfasten 3x cable ties

17. 17. Detach refrigerant line (1) from condenser • Unscrew bolt (2)

Note. For vehicles with climate control system

18. 18. Detach solenoid valve for charge pressure control (1) from bracket • Unscrew 2x nut (2)]

19. 19. Detach 2x swing arms (2) • Unscrew 2x nuts – Use spanner (1) to hold against flat surface
20. 20. Detach 2x tie rods • Unscrew 2x nuts – Force back from steering knuckle with KM-507-C (3)
21. 21. Detach 2x steering knuckle pins • Detach 2x screw connections • Spread steering knuckle pins with KM-915 (4) and draw guiding joint out of steering knuckle

22. 22. Detach 2x axle shafts • Unscrew 2x nuts – Counterhold at wheel hub with KM-468-B (1) • Remove axle shaft with KM-6282

23. 23. Raise vehicle by half its height
24. 24. Place collecting basin underneath.
25. 25. Drain coolant • Open drain bolt on radiator (1) • Collect coolant • Close drain bolt

26. 26. Remove rear muffler • Undo bolted connection (3) • Detach retaining ring (1) • Detach 2x damper rings (4) • Remove silencer (2)

Note. For vehicles without diesel particulate filter

Important. Prevent exhaust system from sagging in an uncontrolled manner. To do this, exhaust system with flexible pipe inside can be secured to underbody of vehicle using suitable material such as wire. Even flexible tube bending of 5 - 10 degrees from intended installation position can cause damage that may result in total failure of the flexible tube.

27. 27. Remove front exhaust pipe from central silencer • Detach from catalytic converter – Slacken screw connection (1) • Detach from catalytic converter – Remove 2x from damper ring (2)

Note. For vehicles without diesel particulate filter

28. 28. Detach front exhaust pipe from particulate filter • Detach 2x bracket (3), damper ring – Unscrew 2x nuts • Detach pipe, differential pressure line (1) from front exhaust pipe – Unscrew union nut • Detach particulate filter temperature sensor (2) – Unscrew union nut • Undo 3x nut, diesel particle filter flange joint • Detach front exhaust pipe from catalytic converter – Undo bolted connection

Note. For vehicles with diesel particulate filter

29. 29. Insert KM-6173 (3) • Align support bearing (1) • Raise support bearing until journal (2) sits flush in mount (4) • Fasten KM-6173 – Tighten 4x bolts

30. 30. Fit KM-6001-A • Detach front right bracket (1) • Insert KM-6001-A • Attach front right bracket • Insert journals (4) and (5) in guide holes in front axle body • Fasten 3x screw connection on guide rail • Adjust support bearings (2) and (3)

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

31. 31. Lower vehicle by its full height
32. 32. Remove battery • Detach positive cable (3) from positive terminal – Unscrew bolt (4) • Detach positive connection from positive terminal • Remove bracket 1) • Unscrew bolt (2)

33. 33. Remove battery support. • Remove pre-heating system control unit (4) • Remove wiring harness plug (3) • Detach coolant hose • Unclip clip (5) • Detach wiring harness – Detach 2x cable ties (1) • Unscrew 3x bolts (2)

34. 34. Remove air cleaner housing (4) with air intake hose • Disconnect mass air flow sensor wiring harness (2) • Unclip 2x vacuum line (5) • Detach air intake hose from air intake pipe – Release clamp (3) • Detach air cleaner housing from wheel housing – Unscrew bolt (1) • Detach water drain hose (6) from air cleaner housing – Release clamp

35. 35. Disconnect refrigerant line • Unscrew bolt (1)

Note. For vehicles with climate control system

36. 36. Detach fuel supply line (1) from high-pressure pump • Undo quick-release fitting with KM-796-A – Seal fuel line with KM-807 • Unclip 3x from bracket
37. 37. Detach fuel return line (3) from distributor pipe • Undo quick-release fitting with KM-796-A – Seal fuel line with KM-807 • Unclip 2x from bracket
38. 38. Remove brake servo vacuum line (2) • Disconnect quick-release fitting • Set aside vacuum line for brake servo

39. 39. Remove coolant expansion tank • Detach 3x coolant hose (1) – Undo 3x clamps

40. 40. Disconnect 2x coolant hose (1) from heater core • Release 2x coolant hoses in direction of arrow

41. 41. Disconnect shift cable (1) with KM-6042 from gearshift assembly • Unclip shift cable from bracket (2) and set aside

Note. In vehicles with manual transmission, except for M20-6 MTA transmission

Important. Shift cables must not be stretched, twisted or kinked

42. 42. Disconnect wiring harness plug, MTA-transmission (1) • Unclip 2x wiring harness

Note. In vehicles with M20-6 MTA transmission

43. 43. Disconnect wiring harness plugs, differential pressure sensor (1) and temperature sensor (3) • Unclip wiring harness from bracket (2)

Note. For vehicles with diesel particulate filter

44. 44. Disconnect starter wiring harness • Detach earth connections from body – Unscrew bolt • Detach positive distribution from battery terminal – Unscrew bolt • Disconnect wiring harness plug (2) and place wiring harness (1) on drive unit

Note. Note routing of wires

45. 45. Detach pressure line (1) from wiring harness connection piece • Release clamp with screwdriver in direction of arrow and remove • Bend clip together a little and insert back into connecting piece

Note. In vehicles with manual transmission, except for M20-6 MTA transmission.

46. 46. Disconnect steering wiring harness • Remove fuse carrier cover (1) • Detach positive cable (2) from fuse carrier – Unscrew nut • Disconnect wiring harness connector (3) • Expose wiring harness and put aside on drive unit – Detach 4x cable ties

Note. Mark installation position

47. 47. Disconnect upper engine timing wiring harness • Detach positive cable (1) from fuse carrier – Unscrew nut • Disconnect wiring harness plug (2) • Undo cable tie • Place engine timing wiring harness with pre-heating system control unit (3) on drive unit

Note. Mark installation position

48. 48. Detach oxygen sensor wiring harness plug (1) • Undo cable tie

Note. For vehicles without diesel particulate filter

49. 49. Remove wiring harness plug (1) on bracket, rear torsional vibration damper • Undo cable tie • Disconnect wiring harness connector.

50. 50. Detach left engine damping block from engine damping block support • Unscrew 3x bolts (1)

51. 51. Detach right engine damping block from engine damping block bracket • Unscrew 3x bolts (1)

52. 52. Raise vehicle by its full height
53. 53. Attach KM-904 with KM-6390 • Attach to hydraulic lifter • Place under front axle body, ensure there is no play

Note. Use hydraulic jack that can be lowered to a height of at least 100 cm

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

54. 54. Remove front axle body • Unscrew 10x bolt (1), (2), (3) and (4)

Note. Note different bolt lengths

Important. Ensure that no attached parts are damaged

55. 55. Move out front axle body

Note. Use a second person

Install

Important. Ensure that no attached parts are damaged

56. 56. Move front axle body back in

Note. Use a second person

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

57. 57. Fit front axle body • Tighten 10x new bolt (1), (2), (3) and (4) 90 Nm + 45° + 15°
58. 58. Remove KM-904 with KM-6390 • Lower hydraulic lifter • Detach KM-904 and KM-6390 from hydraulic jack
59. 59. Lower vehicle by its full height
60. 60. Fit right-hand engine damping block • Tighten 3x bolt 55 Nm
61. 61. Fit left-hand engine damping block • Tighten 3x bolt 55 Nm
62. 62. Attach wiring harness plug to bracket, rear torsional vibration damper • Connect wiring harness plug • Connect cable ties
63. 63. Lay engine timing wiring harness at the top
64. 64. Connect engine timing wiring harness (top) • Connect wiring harness plug • Detach positive cable from fuse carrier – Tighten nut • Connect cable ties

Note. Note installation position

65. 65. Connect oxygen sensor wiring harness plug • Connect cable ties

Note. For vehicles without diesel particulate filter

66. 66. Connect steering wiring harness • Attach positive cable to fuse carrier – Tighten nut • Attach fuse carrier cover • Connect wiring harness plug • Attach 3 cable ties

Note. Ensure cable is routed correctly

67. 67. Attach shift cables to shift assembly • Clip shift cables into bracket

Note. In vehicles with manual transmission, except for M20-6 MTA transmission

Important. Shift cables must not be stretched, twisted or kinked

68. 68. Attach pressure cable for hydraulic clutch to pressure line connector

Note. In vehicles with manual transmission, except for M20-6 MTA transmission

69. 69. Connect starter wiring harness • Connect wiring harness plug

Note. Note routing of wires

70. 70. Connect wiring harness plugs, differential pressure sensor and upper temperature sensor • Clip wiring harness into bracket

Note. For vehicles with diesel particulate filter

71. 71. Connect wiring harness plug, MTA-transmission • Clip in 2x wiring harnesses

Note. In vehicles with M20-6 MTA transmission

Important. It is imperative to adhere to the following assembly order

72. 72. Attach cooling hoses to heater core • Fit 2x quick release fittings (1) onto heater core connection port (2) as far as they will go • Slide the 2x quick-release fitting catches (3) in the direction of the arrow all the way to the stop by simultaneously pressing the release buttons (4) – The colour rings (5) must be visible • Check that quick release fittings are correctly seated and that the colour rings (5) are visible

Note. Pay attention to coloured markings

73. 73. Fit brake force amplifier vacuum line • Connect quick release fitting
74. 74. Install coolant compensation tank • Attach 3x coolant hoses – Attach 3x clamps
75. 75. Attach fuel return line to distributor pipe • Connect quick release fitting • Clip 2x in bracket
76. 76. Attach fuel supply line to high-pressure pump • Connect quick release fitting • Clip 3x in bracket
77. 77. Connect refrigerant line • Replace seal • Tighten bolt 22 Nm

Note. For vehicles with climate control system

78. 78. Install air cleaner housing with air intake hose • Attach water drain hose to air cleaner housing – Fasten clamp • Attach air cleaner housing to wheelhouse – Tighten bolt • Detach air intake pipe from air intake hose – Tighten clamp 3.5 Nm • Connect mass air flow meter wiring harness plug – Clip on bracket
79. 79. Raise vehicle by its full height
80. 80. Remove engine mount KM-6173 • Unscrew 2x bolts
81. 81. Remove engine mount KM-6001-A • Undo 4x bolts
82. 82. Attach lower engine timing wiring harness • Connect engine control unit wiring harness plugs • Attach 2x cable ties

Note. Note routing of wires

83. 83. Connect cooling module wiring harness • Connect wiring harness plug • Attach 3 cable ties • Install ground cable – Tighten nut

Note. Note routing of wires

Important. Prevent exhaust system from sagging in an uncontrolled manner. Even flex pipe bending of 5 - 10 degrees from intended installation position can cause damage that may result in total failure of the flex pipe

84. 84. Install front exhaust pipe with central silencer • Attach to catalytic converter – Tighten bolted connection • Attach to catalytic converter – Insert 2x in damping ring

Note. For vehicles without diesel particulate filter

85. 85. Install front exhaust pipe • Attach to catalytic converter – Tighten bolted connection

Note. For vehicles with diesel particulate filter

86. 86. Install rear silencer • Insert silencer • Attach 2x damper rings • Tighten bolted connection • Attach retaining ring

Note. For vehicles without diesel particulate filter

87. 87. Attach front exhaust pipe to particulate filter • Tighten 3x nut, flanged joint • Attach particulate filter temperature sensor – Tighten union nut • Attach pipe, differential pressure line – Tighten union nut • Attach bracket, damper ring – Tighten 2x nuts

Note. For vehicles with diesel particulate filter

88. 88. Lower vehicle by half its height
89. 89. Install 2x axle shafts into wheel hub • Insert guiding joint into steering knuckle • Tighten 2x nut 150 Nm , slacken 45° , then tighten to 250 Nm – Use new nuts • Counterhold at wheel hub with KM-468-B
90. 90. Attach 2x guide joints to steering knuckle • Tighten 2x new screwed joint 50 Nm
91. 91. Attach 2x tie rods to steering knuckle • Tighten 2x new nut 30 Nm + 90° + 15°
92. 92. Attach 2x swing arms to spring strut support tube • Tighten 2x new nut 65 Nm

Note. Use spanner to counterhold against flat surface

93. 93. Attach refrigerant line to condenser • Replace seal • Tighten bolt 22 Nm

Note. For vehicles with climate control system

94. 94. Attach solenoid valve for charge pressure control to bracket • Tighten 2x nuts
95. 95. Install lower engine cover and right engine splash guard • Tighten 4x bolts • Install 2x body-bound rivets
96. 96. Insert front panelling • Clip in outside temperature sensor • Insert front panelling – Clip in 4x clips

Note. Use a second person

97. 97. Fit front panelling • Install 5x body-bound rivets • Screw in 4x bolts
98. 98. Fit 2x front wheels • Screw in 5x bolt
99. 99. Lower vehicle by half its height
100. 100. Tighten 2x front wheel 110 Nm
101. 101. Vent hydraulic clutch actuator

Note. In vehicles with manual transmission, except for M20-6 MTA transmission

102. 102. Check and correct transmission fluid level

Note. In vehicles with manual transmission, except for M20-6 MTA transmission

103. 103. Install battery holder • Tighten 3x bolt 15 Nm • Attach pre-glow system control unit • Attach wiring harness plug • Clip in coolant hose • Attach wiring harness – Attach 2x cable ties
104. 104. Install battery • Install bracket – Tighten fastening bolt • Attach positive connection to positive terminal – Tighten nut • Attach positive cable to positive terminal – Tighten bolt
105. 105. Connect battery • Attach ground connection to ground terminal – Tighten nut
106. 106. Attach 2x earth cable to earth connection • Tighten 2x bolts
107. 107. Top up coolant or ensure correct quantity is present.
108. 108. Install engine cover • Clip in 4x
109. 109. Top up climate control system • Connect service station • Connect blue hose to low pressure service connection (1) with small diameter • Connect red hose to high pressure service connection (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. – Fill air conditioning system with R 134a refrigerant

Note. For vehicles with climate control system

Note. Read Service Station operating instructions carefully

110. 110. Install radiator grille • Clip upwards into front panelling – Clip in 5x clips • Install 4x body-bound rivets
111. 111. Install intermediate shaft clamp bolt, steering column • Coat new bolt with locking compound (red) and screw in 22 Nm
112. 112. Install lower driver's side cover • Lock 2x retaining clips
113. 113. Program volatile memories
114. 114. Close bonnet

1

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