Engine Maintenance Using a Section Engine Opel Astra H

Spezialwerkzeugliste:

KM-427 KM-6077 KM-6105 KM-6148 KM-6150 KM-6151 KM-652 KM-956 KM-J-38122-A

Remove

1. 1. Remove engine
2. 2. Detach transmission from engine • For vehicles with automatic transmission: – Detach automatic transmission • For vehicles with manual transmission: – Detach manual transmission
3. 3. Drain engine oil • Place collecting basin underneath. • Unscrew drain bolt
4. 4. For vehicles with automatic transmission: • Detach drive disc – Use KM-652 – Unscrew 6x bolts
5. 5. For vehicles with manual transmission: • Remove flywheel
6. 6. Detach ribbed V-belt • Use KM-6151

Note. Mark running direction.

7. 7. Detach ribbed V-belt tensioner - • Unscrew bolt

8. 8. Detach torsional vibration damper (2) • Unscrew bolt – Use KM-956 together with KM-J-38122-A (1)

9. 9. Detach engine damping block support (1) • Unscrew 3x bolts (2)

10. 10. Detach alternator • Unscrew 4x bolts (1)

11. 11. Remove oil pressure switch
12. 12. Remove crankshaft pulse pickup (1) • Unscrew bolt

13. 13. Remove oil filter element • Use KM-6150
14. 14. Remove thermostat housing • Unscrew stud bolt (3) • Unscrew 2x bolts (1)

Note. Pull thermostat housing with coolant pipe (2) out of coolant pump.

15. 15. Detach engine vent hose
16. 16. Detach rear wiring harness bracket • Slacken nut • Unscrew bolt
17. 17. Remove ignition module (1) • Unscrew 4x bolts (2)

18. 18. Detach front wiring harness bracket • Unscrew 2x nuts • Detach engine vent hose • Release clamp
19. 19. Remove cylinder head cover • Unscrew 14 bolts
20. 20. Remove camshaft sensor • Unscrew bolt (2) • Do not note position number (1)

21. 21. Remove upper sliding rail (1) • Unscrew 2x bolts (2)

22. 22. Detach timing case cover • Unscrew 11x bolts • Remove gasket

Note. Cover aperture in timing case with flap

23. 23. Remove chain tensioner of camshaft timing chain (1)

24. 24. Detach exhaust camshaft sprocket • Affix using cable tie (1) • Unscrew bolt (3)

Note. Counterhold at camshaft hexagon (arrow).

25. 25. Remove intake camshaft sprocket • Unscrew bolt (2)

Note. Counterhold at camshaft hexagon (arrow).

26. 26. Remove tension rail of camshaft timing chain • Unscrew bolt
27. 27. Remove guide rail of camshaft timing chain (1) • Unscrew sealing plug • Unscrew bolt (2)
28. 28. Remove camshaft timing chain

29. 29. Remove chain tensioner of balance shaft timing chain (8) • Unscrew 2x bolt (9)
30. 30. Remove tension rail of balance shaft timing chain (7) • Unscrew bolt (6)
31. 31. Remove upper guide rail of balance shaft timing chain (2) • Unscrew 2x bolts (3)
32. 32. Remove lower guide rail of balance shaft timing chain (5) • Unscrew 2x bolts (3)
33. 33. Remove balance shaft timing chain (1)
34. 34. Remove oil spray nozzle (1)
35. 35. Detach 2x timing chain drive gear • Remove wedge spring

36. 36. Slacken cylinder head • Unscrew 4x bolts (arrows) • Unscrew 10x bolt

Note. Unto cylinder head bolt 1/4 revolution, then 1/2 revolution.

37. 37. Remove cylinder head

Note. 2nd mechanic is required.

38. 38. Remove cylinder head gasket
39. 39. Clean sealing surfaces.
40. 40. Visually check components

Note. If testing and overhauling the cylinder head: Detach all outer components from cylinder head.

41. 41. Take engine

Install

42. 42. Emboss engine number
43. 43. Emboss guide sleeves • Use KM-427
44. 44. Check for plane surface • cylinder head

45. 45. Place cylinder head gasket in position
46. 46. Install cylinder head

Note. 2nd mechanic is required. Note guide sleeves

47. 47. Fasten cylinder head • Replace 10x bolt • Tighten 10x bolt 30 Nm + 90° + 60° + 15° • Tighten 4x bolt 35 Nm

Note. Note tightening sequence.

Note. Use screw locking compound (red)

48. 48. Install 2x timing chain crankshaft sprocket

Note. Pay attention to installation position

49. 49. Install oil spray nozzle • Tighten bolt 10 Nm

50. 50. Install balance shaft timing chain • Place timing chain in position – Copper-coloured chain link (2) on intake side balance shaft marking – Chain link (3) on marking of sprocket of balance shaft timing chain – Place chain on coolant pump sprocket – Chain link (1) on marking of balance shaft exhaust side

Important. Coloured timing chain links must tally with the sprocket markings.

Note. Affix using a plastic wedge.

51. 51. Install lower guide rail of balance shaft timing chain • Tighten 2x bolt 10 Nm
52. 52. Install upper guide rail of balance shaft timing chain • Tighten 2x bolt 10 Nm
53. 53. Install tension rail of balance shaft timing chain • Tighten bolt 10 Nm
54. 54. Install chain tensioner of balance shaft tension rail • Use KM-6077 (1) • Tighten 2x bolt 10 Nm • Remove KM-6077 • Remove plastic wedge

Note. Press in piston while rotating clockwise and lock using KM-6077 .

Note. Check markings and installation position.

55. 55. Insert camshaft timing chain
56. 56. Insert tension rail of camshaft timing chain
57. 57. Fasten tension rail of camshaft timing chain • Tighten bolt 10 Nm
58. 58. Install guide rail of camshaft timing chain • Tighten 2x bolt 10 Nm
59. 59. Attach intake camshaft sprocket • Undo cable tie • Replace bolt • Screw in bolt
60. 60. Attach KM-6148
61. 61. Remove front crankshaft seal ring

Note. Remove seal ring from oil pump using a suitable tool. Do not damage sealing surfaces.

62. 62. Clean sealing surfaces.
63. 63. Attach timing case cover • Replace gasket • Tighten 11x bolt 21 Nm

Note. Remove flap.

64. 64. Install guide rail sealing plug of camshaft timing chain • Replace sealing ring • Tighten sealing plug 65 Nm
65. 65. Install new front crankshaft seal ring (2) • Use KM-6105 (1 and 3), torsional vibration damper bolt (4)

66. 66. Install torsional vibration damper • Replace bolt • Tighten bolt 100 Nm + 75° + 15° – Use KM-956 together with KM-J-38122-A
67. 67. Adjust ignition TDC of cylinder 4 • Place crankshaft on marking
68. 68. Adjust intake camshaft

Note. Rotate intake camshaft on hexagonal section until locating bolt of KM-6148 fits in corresponding hole.

69. 69. Position camshaft timing chain

Note. The copper-coloured marking must be positioned at marking "INT" of the intake camshaft sprocket.

70. 70. Attach exhaust camshaft sprocket • Replace bolt • Screw in bolt

Important. The silver-coloured marking must be positioned at marking "EXH" of the exhaust camshaft sprocket. Rotate exhaust camshaft on hexagonal section until exhaust camshaft sprocket can be inserted.

71. 71. Pull back locating bolts • From intake camshaft sprocket
72. 72. Pre-tension chain tensioner • Replace 2x seal ring (2 and 3) • Pull pistons (4 and 6) out of housing (1) – Tension piston at square in vice – Lock inner pistons (4 and 6) to last detent (5) by turning clockwise

73. 73. Install chain tensioner • Replace 2x seal rings • Tension chain tensioner 75 Nm • Tension chain tensioner

Note. Undo lock by pressing down the chain in the area of the tension rail for the camshaft timing chain.

74. 74. Adjust ignition TDC of cylinder 4 • Place crankshaft on marking

Note. Turn crankshaft 720° in the direction of rotation of the engine

75. 75. Timing, Check • Slide in locating bolts (2)

Note. If the locating bolts do not fit in the camshaft sprocket holes provided, the camshaft timing chain must be reseated. The coloured chain links are no longer valid as TDC reference points.

76. 76. Remove KM-6148 (1) • Unscrew 2x bolts (3)

77. 77. Clean 2x threads
78. 78. Install upper sliding rail • Tighten 2x bolt 8 Nm

Note. Use screw locking compound (red)

79. 79. Fasten exhaust camshaft sprocket • Tighten bolt 85 Nm + 30° + 15°

Note. 2nd mechanic is required.

Note. Counterhold at camshaft hexagon.

80. 80. Fasten intake camshaft sprocket • Tighten bolt 85 Nm + 30°

Note. 2nd mechanic is required.

Note. Counterhold at camshaft hexagon.

81. 81. Install camshaft sensor • Replace sealing ring • Tighten bolt 8 Nm
82. 82. Attach cylinder head cover • Tighten 14 bolts 9 Nm
83. 83. Attach ignition module • Tighten 4x bolt 9 Nm
84. 84. Attach rear wiring harness bracket • Tighten nut • Tighten bolt
85. 85. Attach front wiring harness bracket • Attach engine vent hose • Tighten 2x nuts
86. 86. Attach engine vent hose
87. 87. Install thermostat housing • Replace 2x coolant pipe seal ring • Insert coolant pipe – In thermostat housing • Replace gasket • Tighten 2x bolt 9 Nm • Tighten stud bolt 9 Nm

Note. Coat gasket lightly with silicone grease (white).

Note. Sprue on coolant pipe engages in recess on thermostat housing.

Note. Coat gasket lightly with silicone grease (white).

88. 88. Install oil filter element • Replace sealing ring • Tighten cover of oil filter housing 25 Nm
89. 89. Install crankshaft pulse pick-up • Replace sealing ring • Tighten bolt 9 Nm
90. 90. Install oil pressure switch • Tighten oil pressure switch 18 Nm
91. 91. Replace 4x seal rings

Note. Coat seal rings with engine oil.

92. 92. Attach alternator • Tighten 4x bolt 21 Nm
93. 93. Attach ribbed V-belt tensioner - • Tighten bolt 43 Nm

Note. Sprue (1) engages in timing case hole (2).

94. 94. Attach right engine bracket • Tighten 3x bolt 55 Nm
95. 95. Fit ribbed V-belt • Use KM-6151

Note. Tension ribbed V-belt tensioner.

96. 96. For vehicles with automatic transmission: • Attach drive disc – Replace 6x bolt – Tighten 6x bolt 53 Nm + 25° + 25° – Use KM-652

Note. Use screw locking compound (red)

97. 97. For vehicles with manual transmission: • Install flywheel
98. 98. Install gearbox • For vehicles with automatic transmission: – Attach automatic transmission • For vehicles with manual transmission: – Attach manual transmission
99. 99. Top up engine oil. • Check engine oil level, correct if necessary

Note. Observe specified engine oil filling quantity.

100. 100. Install engine