Repair Engine Using a Short Block Opel Astra H

Important: When working on the fuel system it is essential to pay attention to cleanliness as even the smallest dirt particles can lead to faults in engine operation or in the fuel system. Open fuel connections must be sealed with appropriate plugs from the Opel Parts Catalogue (catalogue number: 45 06 154 / part number: 9201697). Sealing plugs are only intended to be used once.

Remove

1. 1. Detach transmission from engine
2. 2. Remove clutch
3. 3. Remove KM-6263 • Turn rotating spindle back to initial position • Remove centring drift • Unscrew 4x bolts • Remove KM-6263
4. 4. Attach EN-46792 (1) • Tighten bolt
5. 5. Remove flywheel • Unscrew 6x bolt (2) • Remove EN-46792 – Unscrew bolt

6. 6. Detach heat shield • Unscrew 2x bolts
7. 7. Detach engine vent hose (2) • Undo 2 clamps • Unclip from bracket (1)

8. 8. Remove vacuum line (1) • Detach 4x vacuum hoses • Unscrew 3 bolts

Note. Mark vacuum hoses

9. 9. Remove oil separator/vacuum reservoir bracket (1) • Detach 2x hoses – Undo 2 clamps • Detach engine vent hose – Disconnect quick-release fitting • Unclip wiring harness bracket • Unscrew 3 bolts • Unscrew 2x nuts

10. 10. Disconnect wiring harness plug (2) from coolant temperature sensor (1)

11. 11. Remove thermostat housing (1) • Detach 4x coolant hoses – Undo 4x clamps • Unscrew 2x bolts (2)

12. 12. Detach 3x coolant hoses • Detach coolant hose (1) from top coolant pipe – Release clamp • Detach coolant hose (3) from bottom coolant pipe – Release clamp • Detach coolant hose (2) from EGR cooler – Release clamp

13. 13. Release EGR metal tube (3) from EGR valve • Detach from EGR valve – Unscrew 2x bolts • Release at EGR cooler – Release clamp

14. 14. Detach EGR cooler • Unscrew 2x bolts
15. 15. Detach intake connection piece (1) from throttle valve module • Unscrew 2x bolts (2)

16. 16. Remove engine oil filling nozzle (3) • Unscrew 3 bolts

17. 17. Remove vacuum pump (2) • Remove vacuum hose (1) • Unscrew 4x bolts

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

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

Note. Note guide sleeves

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

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

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

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

22. 22. Remove upper toothed belt cover • Unscrew 5x bolts (1) with EN-47631 • Unscrew 2x bolts (2)

23. 23. Remove engine damping block support (1) • Unscrew 5x bolts

Note. Note different bolt lengths

24. 24. Detach engine venting pipe (2) • Detach engine venting hose (3) from engine venting pipe – Release clamp • Unscrew 2x bolts (1)

25. 25. Install EN-46789 (1) in camshaft housing • Unscrew exhaust camshaft closure bolt • Screw in EN-46789
26. 26. Set cylinder no. 1 to TDC of combustion stroke • Rotate crankshaft in direction of engine rotation until reference drift EN-46789 audibly engages in exhaust camshaft

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

28. 28. Remove toothed belt tension roller • Unscrew bolt
29. 29. Remove toothed belt guide roller (2) • Unscrew bolt (1)

30. 30. Detach vacuum line from cable conduit • Detach 2x vacuum hose • Unclip 3x clip

31. 31. Detach compressor wiring harness bracket • Unscrew bolt • Set wiring harness aside

32. 32. Detach engine management wiring harness (1) • Disconnect wiring harness connector. – Swirl valve actuator – Load jolt sensor – EGR valve – Coolant temperature sensor – Rail pressure sensor – Pressure regulator – 4x sheathed glow plugs • Unclip 5x brackets • Detach cable conduit – Unscrew 2x bolts
33. 33. Detach coolant pipe (2) from intake manifold • Detach coolant hose from coolant pipe – Release clamp • Unscrew 3 bolts
34. 34. Detach leak oil line (1) • Release 4x retaining clamp (arrows) • 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.

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

35. 35. Detach 4x high pressure line (1), pressure chamber on injector • Release 8x retaining nut

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

Important. After detaching the high pressure lines, seal the apertures of the injectors and the pressure chamber with protective caps 1)

36. 36. Detach high-pressure pump high-pressure line (1) from accumulator • Unscrew 2x union nuts

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

37. 37. Remove accumulator (1) • Detach return line (2) – Release clamp • Unscrew 2x bolt (3)

38. 38. 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

39. 39. Detach bracket (1) for toothed belt cover • Unscrew bolt

40. 40. Remove 4x injector (2) • Unscrew 4x nuts (1) • Remove 4x injector with bracket • Remove 4x seal rings

Note. If injectors cannot be removed by hand, use EN-46786 in conjunction with KM-328-B

Note. After removal, close the injector openings with protective caps 1)

41. 41. Remove coolant pipe (1) • Unscrew 4x bolts • Remove gasket

42. 42. Remove 4x glow plugs with EN-48390 • Disconnect 4x wiring harness plug, sheathed glow plug (arrows)

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

Note. Use a second person

44. 44. 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)

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

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

47. 47. Detach alternator • Unscrew lower bolt • Unscrew 2x bolts – Remove bracket
48. 48. 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

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

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

Note. Note different bolt lengths

51. 51. Fit engine transport shackle • Tighten bolt
52. 52. Hitch engine up to workshop crane.
53. 53. Detach engine from KM-412 • Unscrew 8x bolts • Set engine down
54. 54. Detach KM-412-36-1 and KM-412-36-2 from engine block • Unscrew 7x bolts
55. 55. Unhitch engine from workshop crane.
56. 56. Detach engine transport shackle • Unscrew bolt
57. 57. Attach engine transportation shackle to engine short block • Tighten bolt

Install

58. 58. Hitch engine short block up to workshop crane
59. 59. Attach KM-412-36-1 an KM-412-36-2 to engine block • Tighten 7x bolts
60. 60. Attach engine short block to KM-412 • Tighten 8x bolts
61. 61. Unhitch engine short block from workshop crane

Important. According to the instruction provided by the engine preparer, all attaching parts to be refitted must be cleaned of dirt particles and liquids.

62. 62. Cleaning work for attaching parts
63. 63. Detach engine transport shackle • Unscrew bolt
64. 64. Attach alternator bracket • Tighten 2x bolts

Note. Note different bolt lengths

65. 65. Install intake manifold • Replace gasket • Tighten 9x new nut 25 Nm
66. 66. 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

67. 67. Attach alternator • Insert bracket – Screw in 2x bolts • Tighten lower bolt 70 Nm • Tighten 2x bolt 70 Nm
68. 68. Attach alternator wiring harness • Tighten 2x nut (M6) 5 Nm • Tighten nut (M8) 10 Nm
69. 69. Install high pressure pump • Tighten 3x nut 25 Nm
70. 70. Fit high pressure pump wheel • Screw in nut
71. 71. Fasten high-pressure pump gear • Tighten nut 50 Nm • Counterhold with KM-6347 in conjunction with KM-956-1

Note. 2nd mechanic

72. 72. Tighten 4x sheathed glow plugs to 8 Nm
73. 73. Attach wiring harness of sheathed glow plugs • Connect 4x wiring harness plug, sheathed glow plug • Attach wiring harness
74. 74. Install coolant pipe • Insert new gasket • Tighten 4x bolts
75. 75. 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.

76. 76. Install 4x injector • Remove closure plugs • Replace 4x seal rings • Tighten 4x nut 32 Nm
77. 77. Attach bracket, toothed belt cover • Tighten bolt
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. Fit accumulator • Attach return line – Fasten clamp • Tighten 2x bolt 25 Nm

Important. When tightening the retaining nut on the counterhold on the connection for the fuel high pressure pump with open-ended wrench

80. 80. Attach new high-pressure pump high-pressure line to pressure chamber • Tighten 2x union nuts 25 Nm

Important. When tightening the retaining nut, counterhold against the injector with open-ended wrench, Use new pressure lines

81. 81. Attach 4x high pressure line for pressure chamber to injector • Tighten 8x retaining nut – M12 22 Nm – M14 30 Nm
82. 82. Attach oil leak line • Clip 4x oil leak line into injector
83. 83. Attach coolant pipe to intake manifold • Attach coolant hose to coolant pipe – Fasten clamp • Tighten 3x bolt 9 Nm
84. 84. Attach engine management wiring harness • Connect 18x wiring harness plugs • Swirl valve actuator • EGR valve • Charge pressure sensor • Throttle body • Coolant temperature sensor • 4x sheathed glow plugs • Rail pressure sensor • Pressure-regulating valve • 4x injector – Detach cable conduit – Tighten 2x bolts • Camshaft sensor – Clip in 2x clips • Charge pressure control solenoid valve
85. 85. Attach compressor wiring harness • Tighten bolt
86. 86. Clip vacuum line into cable conduit • Clip in 3x clips • Attach 2x vacuum hoses
87. 87. Clean 2x threads
88. 88. Install toothed belt guide roller • Tighten bolt 50 Nm

Note. Use screw locking compound (red)

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

Note. Insert tension roller in guide

91. 91. Install EN-46789 (1) in camshaft housing • Unscrew exhaust camshaft closure bolt • Screw in EN-46789
92. 92. Check camshaft setting on cylinder 1 at TDC of combustion stroke • Reference tool EN-46789 must be engaged in exhaust camshaft

93. 93. 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

94. 94. Install toothed belt • Observe prescribed direction of rotation • Position toothed belt

Important. Tightened end (1) must be taut

95. 95. Block crankshaft. • Attach positioning disk EN-46788 – Screw in bolt – Screw in nut
96. 96. Tension the toothed belt • Screw in bolt (6) • Tension toothed belt tension roller • Tighten bolt, toothed belt tension roller (3) 25 Nm • Detach positioning disk EN-46788 – Unscrew bolt – Unscrew nut

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

97. 97. Remove EN-46788 • Remove positioning disk EN-46788 • Unscrew bolt • Unscrew nut
98. 98. Turn crankshaft 720° in the direction of rotation of the engine • Rotate crankshaft 720° in direction of engine rotation until reference drift EN-46789 audibly engages in exhaust camshaft

99. 99. 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

100. 100. Remove EN-46789 from camshaft housing • Screw in closure bolt
101. 101. Attach engine venting pipe • Attach engine venting hose to engine venting pipe – Fasten clamp • Tighten 2x bolt 9 Nm
102. 102. Install support for engine damping block • Tighten 4x bolt (M10) 50 Nm • Tighten bolt (M8) 25 Nm

Note. Note different bolt lengths

103. 103. Install upper toothed belt cover • 5x bolt (M6) with 9 Nm • Tighten 2x bolt (M8) 25 Nm
104. 104. Install upper ribbed V-belt guide roller • Tighten bolt 50 Nm
105. 105. Install torsional vibration damper • Tighten 4x bolt 25 Nm

Note. Observe correct fitting position

Note. Counterhold toothed belt drive gear at bolt

106. 106. Attach compressor support to engine block • Tighten 4x bolt 50 Nm

Note. Note guide sleeves

107. 107. Attach compressor to support • Tighten 3x bolt 22 Nm • Fix wiring harness plug
108. 108. Clean sealing surface
109. 109. Install vacuum pump • Insert new gasket • Tighten 4x new bolt 5 Nm + 50° • Attach vacuum hose
110. 110. Install engine oil filling nozzle • Insert new gasket • Tighten 3x bolts

Note. Recut thread before re-using and insert bolt with locking compound (red). The maximum installation time including torque check is 10 minutes

111. 111. Attach intake port to throttle valve module • Replace gasket • Tighten 2x bolts

Note. Coat with special grease (white)

112. 112. Attach EGR cooler • Tighten 2x bolt 25 Nm
113. 113. Attach EGR metal tube to EGR valve • Insert new gasket • Tighten 2x bolts • Tighten clamp
114. 114. Attach 3x coolant hoses • Attach coolant hose to top coolant pipe – Fasten clamp • Attach coolant hose to bottom coolant pipe – Fasten clamp • Attach coolant hose to EGR cooler – Fasten clamp
115. 115. Clean sealing surface
116. 116. Clean 2x threads
117. 117. Attach thermostat housing • Replace gasket • Tighten 2x bolt 25 Nm • Attach 4x coolant hoses to coolant pipe – Attach 4x clamps
118. 118. Connect coolant temperature sensor wiring harness plug
119. 119. Install oil separator/vacuum reservoir bracket • Tighten 3x bolts – Tighten 2x nuts • Attach 2x hoses – Attach 2x clamps • Attach engine venting hose – Quick-release fitting • Clip in wiring harness cover
120. 120. Install vacuum line • Connect 4x vacuum hoses • Tighten 3x bolts

Note. Pay attention to marks

121. 121. Attach heat shield
122. 122. Clean 6x threads
123. 123. Fit flywheel • Attach EN-46792 – Tighten bolt • Tighten 6x new bolt 160 Nm • Remove EN-46792 – Unscrew bolt
124. 124. 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

125. 125. Install clutch
126. 126. Attach transmission to engine

1

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