Replace Alternator Support Opel Astra H

Remove

1. 1. Open bonnet
2. 2. Detach engine cover (1) • Unclip engine vent hose from bracket (2) • Unscrew 2x bolts (4) • Unscrew oil filler cap (5) • Remove engine cover • Screw on oil filler cap

Note. Re-attach any retaining rubbers (3) to the engine cover which may have become detached

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

4. 4. Raise vehicle by its full height
5. 5. Detach the lower engine cover and right engine splash guard
6. 6. Fit and adjust KM-6397 • Adjust KM-6397 – Screw in 2x adjusting bolts (4)

Note. Support plate (5) must lie flat against oil pan

7. 7. 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.

8. 8. Remove ribbed V-belt (1) • Mark rotational direction of ribbed V-belt • Tension ribbed V-belt tensioner in direction of arrow • Insert KM-6349 (2)

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

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

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

11. 11. Lower vehicle by its full height
12. 12. Remove right engine damping block (1) • Detach from engine damping block adapter – Unscrew 3x bolts (2) • Detach from side member – Unscrew 3x bolts (3)

13. 13. Remove toothed belt cover • Unscrew 6x bolt (arrows) • 4x unclip camshaft sensor wiring harness

14. 14. Remove engine damping block adapter (1) • Unscrew 5x bolts

Note. Note dissimilar bolt lengths

15. 15. Set cylinder no. 1 to TDC of combustion stroke • The mark on the camshaft sprocket (1) must align with the mark on the camshaft housing cover (2).

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

Note. Mark direction of rotation

17. 17. Disconnect battery • Detach ground connection from ground terminal – Slacken nut
18. 18. Detach wiring harness • Unscrew 4x bolts (1) • Disconnect 4x wiring harness plugs from injector (2)

19. 19. Detach 4x oil leak line (2) from injectors • Release 4x retaining clamps (3) at injector – Pull off oil leak line • Unclip 2x oil leak line from bracket (1)

Note. The oil leak line must not be detached from the fuel return damping case. It if is detached, it must be replaced.

Note. Seal 4x injectors with suitable blanking plugs

20. 20. Disconnect 2x wiring harness plugs • From exhaust gas recirculation (1) • From boost pressure sensor (2)

21. 21. Remove fuel return damping case (1) with oil leak line • Unscrew 2x bolts • Detach return line with KM-796-A – Unclip line – Seal with KM-6015 • Detach 2x hoses – Undo 2 clamps

Note. Open fuel connections must be sealed with suitable blanking plugs

22. 22. Detach accumulator high pressure line (1) to high pressure pump • Unscrew 2x union nuts

Important. When releasing the retaining nut on the high pressure pump, counterhold with open-ended wrench.

Note. Fuel connections that have been opened must be sealed with suitable plugs from the kit (45 06 154).

23. 23. Detach 4x high pressure line - accumulator to injector • Unscrew 8x union nut (1)

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

Note. Open fuel connections must be sealed with suitable blanking plugs

24. 24. Remove accumulator (1) • Unscrew 2x nut (arrows) • Disconnect 2x wiring harness plugs

25. 25. Detach vacuum reservoir and retaining plate • Unscrew 3 bolts

Note. If present

26. 26. Detach fuel line of high-pressure pump (1) • Release clamp • Open fuel connections must be sealed with suitable blanking plugs
27. 27. Disconnect high-pressure pump wiring harness plug (2)

28. 28. Release high-pressure pump drive gear • Counterhold with KM-6347 (1) in combination with KM-956-1 (2)

29. 29. Remove 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)

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

31. 31. Remove wiring harness bracket • Unscrew 2x bolts
32. 32. Remove ribbed V-belt tension roller • Unscrew bolt
33. 33. Detach alternator • Unscrew 3x bolts, remove upper bracket • Set alternator on its side

Note. Note dissimilar bolt lengths

34. 34. Remove alternator support • Unscrew 6x bolts • Screw in spacer

Note. Note dissimilar bolt lengths

35. 35. Clamp support in vice
36. 36. Remove attaching parts • Detach engine transport shackle – Unscrew bolt • Unscrew engine cover bracket • Unscrew • Unscrew 2x stud bolt

Install

37. 37. Fit attaching parts • Fit engine transport shackle – Tighten bolt • Tighten engine cover bracket • Screw in spacer
38. 38. Remove support from vice
39. 39. Install alternator bracket • Tighten 5x bolt 25 Nm • Screw in spacer as far as stop – Tighten bolt 25 Nm

Note. Place 2x on centring sleeve

Note. Note dissimilar bolt lengths

40. 40. Attach alternator • Insert top bracket and secure with 3x bolts 60Nm

Note. Note dissimilar bolt lengths

41. 41. Install ribbed V-belt tension roller • Tighten bolt 50 Nm

Note. Lug of tensioning device must be lodged in guide on generator support.

42. 42. Install wiring harness bracket • Tighten 2x bolts
43. 43. Install high pressure pump • Tighten 3x nut 25 Nm
44. 44. Fit high pressure pump wheel • Tighten nut 50 Nm • Counterhold with KM-6347 in conjunction with KM-956-1
45. 45. Connect high-pressure pump wiring harness plugs
46. 46. Attach fuel line to high-pressure pump • Remove closure plugs • Fasten clamp
47. 47. Attach vacuum reservoir and retaining plate • Tighten 3x bolt 25 Nm

Note. If present

48. 48. Install accumulator • Tighten 2x nuts 25 Nm • Connect 2x wiring harness plugs
49. 49. Install 4x new high-pressure line, accumulator to injector • Remove closure plugs • Tighten 4x union nut (M14) 23 Nm • Tighten 4x union nut (M12) 23 Nm

Important. Pressure lines must not be installed more than once. When fastening the retaining nut counterhold against the injector with an open-ended wrench.

50. 50. Attach new high pressure line - accumulator to high pressure pump • Remove closure plugs • Tighten union nut (M14) 23 Nm • Tighten union nut (M12) 23 Nm

Important. Pressure lines must not be installed more than once. When fastening the union nut to the high-pressure pump, counterhold against it with an open-ended wrench.

51. 51. 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 • Attach return line – Clip in line
52. 52. Connect 2x wiring harness plugs • To exhaust gas recirculation • To boost pressure sensor
53. 53. Attach wiring harness • Tighten 4x bolts • Connect 4x wiring harness plugs to injector
54. 54. Attach 4x oil leak line to injectors • Remove closure plugs • Clip 4x oil leak line to injector • Clip 2x oil leak line in bracket
55. 55. Remove toothed belt tightening roller • Unscrew bolt
56. 56. Clean the thread
57. 57. Fit toothed belt tightening roll • Insert tension roller in guide • Screw in bolt

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

58. 58. Set cylinder no. 1 to TDC of combustion stroke • The mark on the camshaft sprocket (1) must align with the mark on the camshaft housing cover (2).

59. 59. Install toothed belt • Position toothed belt

Note. Observe direction of rotation

Important. Tightened end (1) must be taut

60. 60. Raise vehicle by its full height
61. 61. Tension the toothed belt (1) • Screw in bolt (6) • Tension the toothed belt • Tighten bolt, toothed belt tension roller (3) 25 Nm

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

62. 62. Check crankshaft setting with EN-46788 • Unscrew bolt (arrow) • Tighten stud bolt (1) EN-46788 • Attach positioning disk (4) EN-46788 – Screw in bolt (3) – Screw in nut (2) • Remove positioning disk EN-46788

Note. If EN-46788 cannot be fitted, repeat the toothed belt positioning procedure.

63. 63. Lower vehicle by its full height
64. 64. Timing, Check • Turn crankshaft 720° in the direction of rotation of the engine • Check camshaft position – The mark on the camshaft sprocket must align with the mark on the camshaft housing cover.
65. 65. Raise vehicle by its full height
66. 66. 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) • Remove positioning disk EN-46788

67. 67. Lower vehicle by its full height
68. 68. Install engine damping block adapter • Tighten 3x bolt (M10) 50 Nm • Tighten 2x bolt (M8) 25 Nm

Note. Note dissimilar bolt lengths

69. 69. Install toothed belt cover • Tighten 4x bolt (M6) 9 Nm • Tighten 2x bolt (M8) 25 Nm • 4x clip in camshaft sensor wiring harness
70. 70. Install right engine damping block • Attach engine damping block to adapter – Tighten 3x bolt 55 Nm • to side member – Tighten 3x bolt 35 Nm
71. 71. Raise vehicle by its full height
72. 72. Remove KM-6001-A
73. 73. Remove KM-6397
74. 74. Install upper ribbed V-belt guide roller • Tighten bolt 50 Nm
75. 75. Install torsional vibration damper • Tighten 4x bolt 25 Nm

Note. Observe correct fitting position

Note. Counterhold toothed belt drive gear at bolt.

76. 76. Insert ribbed V-belt • Position ribbed V-belt – I Route of ribbed V-belt with air conditioning – II Route of ribbed V-belt without air conditioning • Remove KM-6349

Note. Note direction of travel

77. 77. Detach the lower engine cover and right engine splash guard
78. 78. Lower vehicle by its full height
79. 79. Install air cleaner housing • Tighten bolt • Attach to air intake pipe – Tighten clamp 3.5 Nm • Connect mass air flow sensor wiring harness – Clip wiring harness into bracket
80. 80. Connect battery • Attach ground connection to ground terminal – Tighten nut
81. 81. Attach engine cover • Unscrew oil filler cap • Position engine cover • Screw on oil filler cap • Tighten 2x bolt 9 Nm • Clip engine vent hose into bracket
82. 82. Program volatile memories
83. 83. Close bonnet