How to Remove and Install the Engine Opel Astra H

1. 1. Open bonnet
2. 2. Detach earth cable • Detach earth cables (4) and (5) from earth terminal (3) – Unscrew 2x bolts • Detach earth connection from negative terminal – Loosen bolt
3. 3. Detach positive cable • Detach positive cable (2) from positive terminal (1) – Unscrew bolt • Detach positive connection from positive terminal – Unscrew bolt

4. 4. Empty climate control system
5. 5. Remove lower driver's side cover • Release 2x retaining clips
6. 6. Detach steering column intermediate shaft • Set steering wheel in straight ahead position, remove ignition key and engage steering lock • Unscrew bolt

7. 7. Remove battery • Detach positive connection from positive terminal – Slacken nut • Remove battery bracket (2) – Unscrew bolt (1)

8. 8. Disconnect charge pressure sensor wiring harness plug
9. 9. Disconnect upper cooling module wiring harness • Disconnect wiring harness connector. • Unclip relay from bracket
10. 10. Remove battery support (2) • Detach wiring harness from battery support – Unfasten 3x cable ties • Unscrew 3x bolts (3)

11. 11. Remove air cleaner housing with mass air flow sensor • Disconnect air mass flow meter wiring harness plug • Detach air intake hose from air intake pipe – Release clamp • Unscrew bolt

Note. The wiring harness plug cannot be disconnected without first removing the mass air flow sensor from the air cleaner housing

12. 12. Detach brake servo vacuum line from intake manifold • Disconnect quick-release fitting • Unclip vacuum line from bracket
13. 13. Remove air intake pipe • Release clamp • Unscrew bolt • Remove engine vent hose from cylinder head cover – Release clamp

Note. Seal air intake pipe to turbocharger

14. 14. Place collecting basin underneath.
15. 15. Relieve fuel pressure using KM-J-34730-91 at test connection

Note. Collect exiting fuel in a suitable container - observe safety regulations and national legislation.

16. 16. Detach fuel supply line (2) • Undo quick-release fitting with KM-796-A • Seal off fuel line
17. 17. Detach fuel return line (1) • Undo quick-release fitting with KM-796-A • Seal off fuel line

18. 18. Detach venting line of tank vent valve • Undo quick-release fitting with KM-796-A • Unclip 3x from bracket
19. 19. Disconnect fuel vapour separator line • Undo quick-release fitting (1)
20. 20. Detach brake servo vacuum line from intake manifold • Disconnect quick-release fitting (2)

21. 21. Undo 2x front wheels
22. 22. Raise vehicle by half its height
23. 23. Remove 2x front wheels
24. 24. Remove front panelling (3) • Remove 5x body-bound rivets (2) • Unscrew 4x bolts (1)

25. 25. Place collecting basin underneath.
26. 26. Detach high-pressure headlamp cleaning system hose from reservoir • Disconnect quick-release fitting

Note. Escaping fluid

27. 27. Remove front panelling • Detach front panelling from bracket – Unclip 4x clips (1) • Unclip outside temperature sensor

Note. Use a second person

Note. Push front panelling upwards at side and pull out of bracket

28. 28. Remove engine splash guard (right-hand) • Unscrew 4x bolts • Remove 2x body-bound rivet
29. 29. Detach 2x axle shafts from wheel hub • Unscrew 2x nuts (2) from axle shaft – Counterhold with KM-6610 (1) at front wheel hub

30. 30. Undo tie rod end (6) from steering knuckle (5) • Attach CH-47658 (1) – Position CH-47658 (1) with suitable sleeve (4) – Fasten CH-47658 (1) to hexagonal section (2) • Unscrew tie rod end nut • Detach CH-47658 (1) – Release at hex (2)

Note. In order to centre CH-47658 , CH-47658 must be used with the appropriate socket wrench groove (3).

31. 31. Press tie rod out of steering knuckle using KM-161-B (1) in conjunction with hook KM-161-2

32. 32. Detach 2x swing arms (1) from spring strut support tube • Unscrew 2x nuts • Use open-ended wrench to hold against the flat surfaces
33. 33. Detach guide joint from steering knuckle • Detach 2x screw connections • Expand steering knuckle with KM-915 (2) • Pull guide joint out of steering knuckle
34. 34. Press axle shaft out of wheel hub

Note. Do not pull the steering knuckle outwards when doing so. Use a wheel hub puller if necessary.

35. 35. Raise vehicle by half its height
36. 36. Release left wheel housing inner panelling • Remove 3x body-bound rivets
37. 37. Detach cooling module wiring harness (1) • Detach earth cable – Unscrew nut • Disconnect wiring harness connector. • Unfasten 3x cable ties

38. 38. Place collecting basin underneath.
39. 39. Drain coolant • Unscrew coolant drain bolt • Screw in coolant drain bolt
40. 40. Detach catalytic converter control's oxygen sensor wiring harness • Disconnect wiring harness connector. • Unclip 4x clips
41. 41. Remove front exhaust pipe • Detach front exhaust pipe (1) from catalytic converter – Unscrew 3x nuts (2) • Detach front exhaust pipe from middle silencer – Unscrew 2x bolts

42. 42. Remove right drive shaft from intermediate shaft

Note. Drive out with soft metal drift

Note. Oil flows out. Place collecting pan underneath and seal the openings with a plug.

43. 43. Carefully place the axle shaft down

Note. Do not lay it on the boots.

44. 44. Insert KM-6173 (3) • Slacken 4x bolts (arrows) and hand-tighten • Align KM-6173 at front axle body • Wind up the support bearing (1) – Journal (2) must sit in mount at cylinder block • Tighten 4x bolts

45. 45. Attach KM-6001-A (1) • Slacken 3x bolts (arrows) in adjusting rails • Insert KM-6001-A – The journals (2) and (5) must sit in the guide holes of the front axle body • Tighten 3x bolts in adjusting 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

46. 46. Lower vehicle by its full height
47. 47. Remove coolant expansion tank (1) • Pull out of bracket in direction of arrow

48. 48. Detach 2x shift cables • Remove 2x from bracket • Unclip 2x
49. 49. Disconnect the pressure line for central disengagement at the clutch housing • Release clamp with screwdriver in direction of arrow and remove • Lock retaining clamp

Note. Seal of line ends

50. 50. Disconnect steering wiring harness • Remove fuse carrier cover • Detach positive cable from fuse carrier – Unscrew nut • Disconnect wiring harness connector. • Expose wiring harness – Remove 2x from wiring harness bracket
51. 51. Disconnect wiring harness plug of reversing lights
52. 52. Disconnect wiring harness plug (1) • Release retainer in direction of arrow

53. 53. Disconnect engine wiring harness • Unclip oxygen sensor wiring harness plug from bracket • Disconnect wiring harness connector. • Disconnect wiring harness plug of engine control unit • Unclip 2x retaining clips • Undo cable tie
54. 54. Detach coolant hoses (1) from heater core • Place collecting basin underneath. • Release 2x quick-release fittings in direction of arrow • Detach coolant hoses

Note. Mark assignment using coloured markings

55. 55. Disconnect refrigerant line (low pressure side) • Unscrew bolt
56. 56. Detach refrigerant line from condenser • Unscrew bolt
57. 57. Detach right engine damping block from engine damping block bracket • Unscrew 3x bolts (1)
58. 58. Detach left engine damping block from engine damping block bracket • Unscrew 3x bolts (2)

59. 59. Raise vehicle by its full height

60. 60. Attach KM-904 with KM-6390 • Attach to hydraulic lifter • Lower centring pins (1) – Remove 2x splines • Place under front axle body, ensure there is no play – Centring pins (2) must engage in the relevant holes in the front axle body

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

61. 61. Remove front axle body • Unscrew 10x bolts (1, 2, 3, 4)

Note. Note different bolt lengths

Important. Ensure that no attached parts are damaged

62. 62. Move out front axle body

Note. Use a second person

Important. Ensure that no attached parts are damaged

63. 63. 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

64. 64. Fit front axle body • Tighten 6x new bolt 90 Nm + 45° + 15°
65. 65. Remove KM-904 with KM-6390 • Lower hydraulic lifter • Detach KM-904 and KM-6100 from hydraulic jack
66. 66. Lower vehicle by its full height
67. 67. Attach right engine damping block to engine damping block adapter • Tighten 3x bolt 55 Nm
68. 68. Attach left engine damping block to engine damping block adapter • Tighten 3x bolt 55 Nm
69. 69. Attach refrigerant line to condenser • Insert new gasket • Tighten bolt 20 Nm
70. 70. Connect refrigerant line (low pressure side) • Insert new gasket • Tighten bolt 20 Nm

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

71. 71. 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

72. 72. Connect engine wiring harness • Connect wiring harness plug of engine control unit • Clip in 2x retaining clips • Connect cable ties • Fix wiring harness plug • Clip oxygen sensor wiring harness plug to bracket
73. 73. Fix wiring harness plug

Note. Front wiring harness plug to fuse carrier

74. 74. Connect wiring harness plug, reverse gear • Attach bracket
75. 75. Connect steering wiring harness • Clip in 2x wiring harness brackets • Attach positive cable to fuse carrier – Tighten nut • Fix wiring harness plug • Install fuse carrier cover
76. 76. Connect central release pressure line at clutch housing • Connect quick release fitting
77. 77. Attach 2x shift cables • Install 2x in bracket • Clip on 2x
78. 78. Raise vehicle by its full height
79. 79. Remove KM-6001-A • Undo 3x bolts
80. 80. Remove KM-6173 • Undo 4x bolts
81. 81. Install right drive shaft in intermediate shaft
82. 82. Install front exhaust pipe • Attach front exhaust pipe with new gasket to catalytic converter 20 Nm – Tighten 3x new nuts • Attach front exhaust pipe to middle silencer – Tighten 2x bolts
83. 83. Attach catalytic converter control oxygen sensor wiring harness • Fix wiring harness plug • Clip in 4x clips
84. 84. Lower vehicle by half its height
85. 85. Attach cooling module wiring harness • Install earth cable – Tighten nut • Fix wiring harness plug • Fasten 3 cable ties
86. 86. Fit left wheel housing inner panelling • Install 3x body-bound rivets
87. 87. Install 2x axle shafts into wheel hub • Tighten 2x new nuts – Counterhold at wheel hub with KM-468-B
88. 88. Attach 2x guide joints to steering knuckle • Tighten 2x new screwed joint 100 Nm
89. 89. Attach 2x swing arms to spring strut support tube • Tighten 2x new nut 65 Nm

Note. Use spanner to counterhold against flat surface

90. 90. Attach 2x tie rods to steering knuckle • Tighten 2x new nut 50 Nm
91. 91. Install right engine splash guard • Tighten 4x bolts • Install 2x body-bound rivets
92. 92. Insert front panelling • Second mechanic • Attach front panelling to bracket – Clip in 4x clips • Clip in outside temperature sensor

Note. Slide side front panelling into bracket

93. 93. Fit front panelling • Install 5x body-bound rivets • Tighten 4x bolts
94. 94. Attach high-pressure headlamp cleaning hose to reservoir • Connect quick release fitting
95. 95. Fit 2x front wheels
96. 96. Lower vehicle by half its height
97. 97. Fasten 2x front wheels 110 Nm
98. 98. Install vacuum reservoir vacuum line to turbocharger • Connect 2x lines • Clip into bracket
99. 99. Attach venting line of tank vent valve • Connect quick release fitting • Clip 2x in bracket
100. 100. Attach fuel return line to fuel rail • Tighten union nut • Clip on bracket
101. 101. Attach fuel supply line to fuel rail • Tighten union nut
102. 102. Install air intake pipe. • Attach engine vent hose to cylinder head cover – Fasten clamp • Fasten clamp; tighten bolt

Note. Install air intake pipe connection to turbocharger

103. 103. Attach brake servo vacuum line to intake manifold • Connect quick release fitting • Clip vacuum line into bracket
104. 104. Install air cleaner housing with mass air flow sensor • Insert the air cleaner housing • Attach air intake hose to air intake pipe – Fasten clamp • Tighten bolt • Connect mass air flow meter wiring harness plug
105. 105. Attach brake bleeder unit to bleeder valve • Remove valve cap from connecting piece's bleeder valve • Attach MKM-6174-1 to bleeder valve
106. 106. Attach brake bleeder unit to brake fluid reservoir • Attach brake bleeder unit adapter to brake fluid reservoir • Attach MKM-6174-2 to brake bleeder unit adapter
107. 107. Bleed clutch actuation • Activate brake bleeder unit • Open bleeder valve • Bleed clutch • Close bleeder valve hand-tight – Deactivate brake bleeder unit
108. 108. Detach brake bleeder unit from brake fluid reservoir • Detach brake bleeder unit adapter from brake fluid reservoir • Fit brake fluid reservoir cover
109. 109. Bleed transmission housing pressure line for central disengagement

Note. Second mechanic

110. 110. Detach brake bleeder unit from bleeder valve
111. 111. Check and correct brake fluid level
112. 112. Install battery holder • Tighten 3x bolt 15 Nm • Attach wiring harness to battery support – Fasten 3 cable ties
113. 113. Insert coolant expansion tank in bracket
114. 114. Connect upper cooling module wiring harness • Fix wiring harness plug • Clip relay into bracket
115. 115. Connect charge pressure sensor wiring harness plug
116. 116. Install battery • Install battery bracket – Tighten bolt • Attach positive connection to positive terminal – Tighten nut
117. 117. Attach positive cable to positive terminal • Tighten bolt
118. 118. Connect battery • Attach ground connection to ground terminal – Tighten nut
119. 119. Attach earth cable to earth terminal • Tighten bolt
120. 120. Fill with coolant and correct coolant level
121. 121. Top up climate control system
122. 122. Clean the thread
123. 123. Attach steering intermediate shaft • Coat bolts with bolt locking compound. • Tighten 2x bolt 22 Nm
124. 124. Install lower driver's side cover • Lock 2x retaining clips
125. 125. Programme transient memory
126. 126. Close bonnet