Replace Right Engine Damping Block Opel Astra H

Spezialwerkzeugliste:

CH-47658 KM-161-2 KM-161-B KM-6001-A KM-6173 KM-915

Remove

1. 1. Remove air cleaner housing
2. 2. Undo front right wheel
3. 3. Raise vehicle by half its height
4. 4. Detach front right wheel
5. 5. 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).

6. 6. Detach tie rod end from steering knuckle • Press tie rod end using KM-161-B (1) out of steering knuckle in conjunction with KM-161-2

7. 7. Raise vehicle by half its height
8. 8. Remove lower engine compartment cover • Unscrew 4x bolts • Remove 2x body-bound rivet
9. 9. Detach right guide joint from steering knuckle • Remove bolted connection • Spread steering knuckle pins with KM-915 and draw guide joint out of steering knuckle
10. 10. Detach right axle shaft from intermediate shaft • Press off using installing bar • Suspend axe shaft from underbody
11. 11. 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

12. 12. Attach KM-6001-A (1) • Slacken 3x bolts (arrows) in adjusting rails • Insert KM-6001-A – Insert journals (2) and (5) in guide holes in front axle body • Adjust support bearings, front (4) and rear (3) – Raise support bearings up to the stop on the guide journals • Tighten 3x bolts in adjusting rails

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

13. 13. Lower vehicle by its full height
14. 14. Remove engine damping block, right hand side • Detach engine damping block bracket from engine damping block support – Unscrew 3x bolts (1) • Detach engine damping block from side member – Unscrew 3x bolts (2)
15. 15. Remove engine damping block with engine damping block bracket
16. 16. Detach bracket (3) from engine damping block • Unscrew bolt

Install

17. 17. Attach engine damping block bracket to engine damping block • Tighten bolt 55 Nm
18. 18. Install right engine damping block • Fit engine damping block to longitudinal beam – Tighten 3x bolt 35 Nm • Attach engine damping block bracket to engine damping block support – Tighten 3x bolt 55 Nm
19. 19. Raise vehicle by its full height
20. 20. Remove KM-6001-A • Undo 3x bolts
21. 21. Remove KM-6173 • Unscrew 2x bolts
22. 22. Attach right drive shaft to intermediate shaft
23. 23. Attach right guide joint to steering knuckle • Tighten new screw connection 50 Nm
24. 24. Install lower engine compartment cover • Tighten 4x bolts • Install 2x body-bound rivets
25. 25. Lower vehicle by half its height
26. 26. Attach tie rod end to steering knuckle • Attach CH-47658 – Position CH-47658 with suitable sleeve – Fasten CH-47658 to hexagonal section • Tighten new tie rod end nut 30 Nm + 90° + 15° • Detach CH-47658 – Release at hex

Note. In order to centre CH-47658 , CH-47658 must be used with the appropriate socket wrench groove. Insert fastening nut of tie rod end in socket wrench groove

27. 27. Attach front right wheel
28. 28. Lower vehicle by half its height
29. 29. Tighten front right wheel 110 Nm
30. 30. Install air cleaner housing with air intake hose • Attach air cleaner housing to wheelhouse – Tighten bolt • Attach air intake hose to throttle valve part – Fasten clamp • Connect and lock wiring harness plug of mass air flow meter – Attach wiring harness • Clip in bonnet contact switch • Attach air intake pipe
31. 31. Close bonnet