How to Remove and Install the Engine Opel Calibra I

Engine, Remove and Install

Disconnect ground cable from battery.

Ground cable (1) from battery terminal, positive cable (2) from battery terminal.

Disconnect positive cable from battery and remove battery.

Disconnect engine wiring harness plug.

Disconnect wiring harness plug (1) for knock sensor.

Wiring harness plug (2) from hot film mass air flow meter.

Wiring harness plug (3) from intake air temperature sensor.

Detach idle speed adjuster hose (1) from air intake hose.

Air intake hose (3) from throttle body and remove with upper part of air cleaner housing (2).

Remove lower part of air cleaner housing.

MT version:

Fastening bolt (1) from torque strut bracket.

Bracket (2) with torque strut from toothed belt tension roller or guide roller bracket.

Note different bolt lengths.

Remove upper engine cover (1) and air duct (2) for alternator cooling fan.

Remove Bowden cable (1) from ball head and from bracket.

Brake servo vacuum line (2) from intake plenum.

1 Wiring harness plug, knock sensor

2 Wiring harness plug, camshaft sensor

3 Wiring harness plug, crankshaft pulse pick-up

4 Wiring harness plug, tank vent valve

5 Wiring harness plug, coolant temperature sender

6 Wiring harness plug, coolant temperature sensor

7 Wiring harness plug, oxygen sensor

8 Wiring harness plug, dual spark ignition coil

9 Ground cable

Disconnect or remove wiring harness plugs 1 to 9.

Release wiring harness plug retainer with screwdriver in direction of arrow.

Wiring harness plug (1) from wiring trough.

Remove fastening bolts (1).

Lay wiring trough aside to rear.

Wiring harness plug from alternator cooling fan.

Lower coolant hose from radiator - collect coolant.

Coolant hoses (1) from coolant bridge.

Coolant hoses (2) from intake port.

Detach coolant hose (1) from coolant compensation tank.

Detach upper coolant hose from radiator and coolant pipe.

Fuel lines (1) from fuel distributor pipe - counterhold on fuel distributor pipe (2).

Fuel escapes, observe safety measures and national regulations.

Reduce fuel pressure via test connection with Fuel Pressure

Gauge KM-J-34730-91 - collect escaping fuel in suitable container.

Detach all connections (shift linkage, Bowden cables, wiring harness plugs etc.) from transmission - see operation "Transmission, Remove and Install" in group "K".

Version with AC:

Evacuate AC - see group "D".

Detach fluid lines (1) from power steering hydraulic pump.

Version with AC:

Remove fastening bolt (2) from AC compressor.

Attach engine to Engine Holder KM-263-B.

Separate front exhaust pipe (1) from both exhaust manifolds and from catalytic converter flange.

Remove front axle body - see operation

"Front Axle Body, Remove and Install" in group "E".

Version with AC:

Separate refrigerant lines from AC compressor at specified cutting point and remove.

Wiring harness plug (1) from AC compressor.

Remove drive shafts from transmission or from intermediate shaft and suspend at suitable point - see group "K"

Place hydraulic engine lifter with holder frame under engine and transmission and raise engine slightly.

Engine damping blocks from side member.

Remove Engine Holder KM-263-B.

Lower engine with transmission downwards.

Guide engine with transmission from below into engine compartment.

Attach engine to Engine Holder KM-263-B.

Engine damping blocks to side member -

65 Nm/48 lbf. ft. 1).

1) Recut thread and insert bolts with

Locking Compound 15 10 177 (90 167 347).

Attach drive shafts to transmission or intermediate shaft - see group "K".

Version with AC:

Wiring harness plug (1) to AC compressor.

Bolt refrigerant lines to AC compressor.

Install front axle body - see operation

"Front Axle Body, Remove and Install" in group "E".

Attach front exhaust pipe (1) to both exhaust manifolds and to catalytic converter flange -

25 Nm/18 lbf. ft.

Detach engine from Engine Holder KM-263-B.

Version with AC:

Attach fastening bolt (2) with refrigerant lines to

AC compressor.

Attach fluid lines (1) to power steering hydraulic pump.

Attach all connections (shift linkage, Bowden cables, wiring harness plugs etc.) to transmission - see operation "Transmission, Remove and Install"

in group "K".

Fuel lines (1) from fuel distributor pipe - counterhold on fuel distributor pipe (2).

Attach upper coolant hose to radiator and coolant pipe.

Attach coolant hose (1) to coolant compensation tank.

Coolant hoses (2) to intake port.

Coolant hoses (1) to coolant bridge.

Lower coolant hose to radiator.

Wiring harness plug to alternator cooling fan.

Attach wiring trough with fastening bolts (1) to intake plenum.

Connect wiring harness plug (1) on wiring trough and engage wiring harness plug retainer downwards

(in direction of arrow).

1 Wiring harness plug, knock sensor

2 Wiring harness plug, camshaft sensor

3 Wiring harness plug, crankshaft pulse pick-up

4 Wiring harness plug, tank vent valve

5 Wiring harness plug, coolant temperature sender

6 Wiring harness plug, coolant temperature sensor

7 Wiring harness plug, oxygen sensor

8 Wiring harness plug, dual spark ignition coil

9 Ground cable

Connect or attach wiring harness plugs 1 to 9.

Brake servo vacuum line (2) to intake plenum.

Fasten Bowden cable (1) in bracket and to ball head.

Install upper engine cover (1) and air duct (2) for alternator cooling fan.

MT version:

Bracket (2) with torque strut to toothed belt tension roller or guide roller bracket - 60 Nm/44 lbf. ft.

Note different bolt lengths.

Fastening bolt (1) to torque strut bracket -

60 Nm/44 lbf. ft.

Install lower part of air cleaner housing.

Attach air intake hose (3) to throttle body and upper part of air cleaner housing (2).

Idle speed adjuster hose (1) to air intake hose.

Connect wiring harness plug (1) for knock sensor.

Wiring harness plug (2) to hot film mass air flow meter.

Wiring harness plug (3) to intake air temperature sensor.

Connect engine wiring harness plug.

Install battery.

Connect positive cable to battery.

Positive cable (2) to battery terminal.

Ground cable (1) to battery terminal.

Connect ground cable to battery.

Version with AC:

Charge AC - see group "D"

Top up and bleed power steering hydraulic system - see group "M".

Top up cooling system - see operation

"Cooling System, Top up and Bleed" and

"Cooling System, Check for Leaks".