How to Remove and Install the Engine Opel Omega B

The operation "Engine, Remove and Install" is described for a Y 25 DT engine with manual transmission. Proceed analogously for other equipment versions.

Cable ties which are released / severed for removal must be re-installed in the same position on installation.

Turn steering wheel to straight-ahead position, remove ignition key and allow steering lock to engage.

Remove

1. 1. Drain air-conditioning • see operation "Air-Conditioning, Drain" in group "D".
2. 2. Remove lower engine compartment cover (1).
3. 3. Open coolant drain bolts on cylinder block (3) and radiator (2) • collect escaping coolant • then close coolant drain bolts.

4. 4. Remove starting catalytic converter.
5. 5. Remove visco-fan • see operation "Visco-fan, Remove and Install"
6. 6. Remove air intake manifold • See illustration "Air Ducts"
7. 7. Detach charge air hose from turbocharger • See illustration "Air Ducts" • then cover turbocharger apertures.
8. 8. Disconnect refrigerant lines at the separation points (1) and (2) with KM-917 .

9. 9. Detach coolant hose (3) for exhaust gas recirculation radiator from quick fitting (1) and detach coolant hose (7) with quick fitting from thermostat housing (2).
10. 10. Detach coolant hose (4) with quick fitting from cylinder block coolant flange (5) and lay aside.
11. 11. Detach coolant hose (6) for add-on heater switchover valve.

12. 12. Detach coolant hose (1) from metal pipe (2).
13. 13. Detach coolant hose (3) from coolant pipe and lay aside.
14. 14. Detach vacuum line (4) from brake servo.

15. 15. Detach vacuum line (3) from valve of brake servo vacuum line (2).
16. 16. Detach vacuum line (4) from add-on heater switchover valve (5).
17. 17. Detach vacuum line (1) from T-piece.

18. 18. Unclip fuse carrier (8) out of relay frame cover (7).
19. 19. Detach relay frame cover from relay frame.
20. 20. Detach wiring harness plug (5) from temperature sensor.
21. 21. Pull engine control unit housing (6) out of relay frame.
22. 22. Detach wiring harness plug (4).
23. 23. Unclip fuse socket (3) out of relay frame.
24. 24. Unclip relay (2) with socket out of relay frame.
25. 25. Unclip preheater relay (1) with socket out of relay frame.

26. 26. Detach wiring harness plug (2) from fuel filter housing pressure sensor.
27. 27. Detach positive terminal from battery.
28. 28. Detach cable connection (3) from positive terminal.
29. 29. Detach cable connection (4) from ground terminal.
30. 30. Detach multiplug (1) (turn lock).
31. 31. Set aside complete wiring harness for engine with engine timing unit on the engine.

32. 32. Detach cable connection (3) from positive terminal.
33. 33. Unclip starter wiring harness out of brackets (2) and lay aside with positive and ground terminal on engine.
34. 34. Detach wiring harness plug (1) for AC compressor.

35. 35. Top up brake fluid reservoir completely and close off with dummy plug.
36. 36. Open retaining strap (4) for connecting piece on bulkhead.
37. 37. Detach retaining clip (3) and disconnect clutch actuation pressure line, then re-insert retaining clip.

Important. Important:

38. 38. Fuel escapes. Observe safety regulations and national legislation.
39. 39. Disconnect fuel feed line at separation point (2) using KM-796-A .
40. 40. Detach fuel return line (1) from add-on heater switchover valve – compress quick fitting in direction of arrow.

41. 41. Drain power steering fluid reservoir (1) with suitable suction device.

Note. Alternator must be protected from contamination.

42. 42. Remove hydraulic hose (2) from oil tank - power steering • collect escaping hydraulic oil • Suspend hydraulic hose out of the way.
43. 43. Detach bracket (4) for hydraulic line from power steering pump.
44. 44. Remove hydraulic line (3) from power steering pump • collect escaping hydraulic oil • Suspend hydraulic hose out of the way.
45. 45. Front Wheels, Remove.

46. 46. Detach fastening nuts from tie rods and press left and right tie rods out of steering knuckle with KM-507-C (1).
47. 47. Release idler bracket fastening bolts (2) – do not remove yet.

48. 48. Detach cover cap from steering arm fastening nut (1).
49. 49. Detach steering arm fastening nut.
50. 50. Mark installation position of steering arm.
51. 51. Press out steering arm (2) with KM-146-01 .
52. 52. Remove fastening nuts (4) from idler bracket (3) and remove entire steering linkage.

53. 53. Remove fastening bolts for link rod (1) on both sides of the stabiliser

Note. support with fork wrench against the flattened areas.

54. 54. For vehicles with xenon headlamp: Disconnect wiring harness plug from vehicle level control sensor (2). Remove ball head (3) from vehicle level control sensor.

55. 55. Detach fastening nuts (1) and remove fastening bolts.
56. 56. Pull guide joints (2) downwards out of steering knuckle.
57. 57. Detach propshaft from transmission flange and push to the rear.

58. 58. Remove 4 clips (arrows) from cover (1) on shift outrigger.
59. 59. Push cover forwards.
60. 60. Detach retainer (2) from pin.
61. 61. Pull pin out from shift rod and fork.
62. 62. Detach fastening bolts (3) from shift outrigger.

Important. Important:

63. 63. Before positioning the Centring Mount KM-6190 the split pins of the centring pins (1) and (3) must be pulled out so that the centring pins cannot engage in the corresponding mounts.
64. 64. Install Base Frame KM-904-B with Centring Mount KM-6190 on hydraulic jack and position without play under front axle body – ensure that the centring pins (2) and (4) sit in the corresponding mounts (use hydraulic jack which can be lowered to at least 100 cm).

Important. Important:

65. 65. Removal of the front axle body with an impulse or impact screwdriver is not permissible. Note various lengths of bolts.

66. 66. Unscrew transmission holder from underbody.
67. 67. Remove front fastening bolts (1), centre fastening bolts (2) and rear fastening bolts (3).
68. 68. Carefully lower front axle body with engine and transmission.

Important. Important:

69. 69. Ensure the threads of the captive nuts move freely before installing front axle body and transmission, replace captive nuts if necessary.

Install

Important. Important:

70. 70. Before installing the engine, the centring pins (1) and (3) must be pushed up and secured with the corresponding split pins.
71. 71. Insert drive unit carefully into engine compartment until centring pins (1) and (3) engage in the corresponding recesses in the underbody.

Note. Ensure that no attachments are damaged.

72. 72. Insert new fastening bolts for front axle body to front member and side member.
73. 73. Tighten fastening bolts (1) for the front of the front axle body on the front member • Tightening torque 65 Nm + 30° + 15°
74. 74. Tighten fastening bolts (2) for centre of front axle body on longitudinal member • Tightening torque 150 Nm + 30° + 15°
75. 75. Tighten fastening bolts (3) for the rear of the front axle body on the longitudinal member • Tightening torque 130 Nm + 30° + 15°

76. 76. Attach transmission holder to underbody • Tightening torque 45 Nm / 33.2 lbf. ft. 1) .

Remove

77. 77. Lower hydraulic jack and detach Base Frame KM-904-B and Centring Mount KM-6190 from hydraulic jack.

Install

78. 78. Attach shift outrigger to transmission • Tightening torque 20 Nm
79. 79. Attach shift outrigger to shift lever and attach cover.
80. 80. Attach propshaft to transmission flange • Tightening torque 95 Nm
81. 81. Attach guide joints to steering knuckle • Tightening torque 100 Nm
82. 82. For vehicles with xenon low beam headlamps: Attach ball head and wiring harness plug to vehicle level control sensor.
83. 83. Attach link rods to stabiliser • Tightening torque 65 Nm
84. 84. Attach idler bracket to bodywork • Tightening torque 55 Nm + 75° + 15° 2) .
85. 85. Attach steering arm to steering shaft with new fastening nut • Tightening torque 160 Nm

Note. Note marking

86. 86. Attach cover cap to fastening nut on steering arm.
87. 87. Attach left and right tie rods to steering knuckle with new fastening nuts • Tightening torque 60 Nm
88. 88. Fit front wheels • Tightening torque 110 Nm
89. 89. Attach hydraulic line to power steering pump with new oil seals • Tightening torque 37.5 Nm
90. 90. Attach hydraulic line bracket to power steering pump.
91. 91. Attach hydraulic hose to power steering pump.
92. 92. Attach fuel return line to add-on heater switchover valve.
93. 93. Connect fuel feed line to separation point.
94. 94. Connect clutch actuation pressure line.
95. 95. Connect wiring harness plug to AC compressor.
96. 96. Route starter wiring harness and attach cable connection to positive terminal.
97. 97. Route engine wiring harness.
98. 98. Connect multiplugs (twist lock) – x2.
99. 99. Attach cable connection to ground terminal.
100. 100. Attach cable connection to positive terminal.
101. 101. Detach wiring harness plug at fuel filter housing pressure sensor.
102. 102. Clip preheater relay (1) with socket into relay frame.
103. 103. Clip relay (2) with socket into relay frame.
104. 104. Clip fuse socket (3) into relay frame.
105. 105. Attach wiring harness plug (4).
106. 106. Install engine control unit housing (6) in relay frame.
107. 107. Attach wiring harness plug (5) to temperature sensor.
108. 108. Attach cover (7) for relay frame.
109. 109. Clip fuse carrier (8) into relay frame cover.

110. 110. Attach vacuum line to T-piece.
111. 111. Attach vacuum line to add-on heater switchover valve.
112. 112. Attach vacuum line to valve for vacuum pressure line of brake servo.
113. 113. Connect vacuum hose to brake servo.
114. 114. Attach coolant hose to coolant pipe.
115. 115. Attach coolant hose to metal pipe.
116. 116. Attach coolant hose for add-on heater switchover valve.
117. 117. Attach coolant hose with quick fitting to cylinder block coolant flange.
118. 118. Attach coolant hose with quick fitting to thermostat housing and attach coolant hose for exhaust gas recirculation radiator to quick fitting.
119. 119. Connect refrigerant lines with new gaskets – 2 separation points.
120. 120. Attach charging air hose to turbocharger • See illustration "Air Ducts"
121. 121. Install air intake manifold • See illustration "Air Ducts"
122. 122. Install visco-fan • see operation "Visco-fan, Remove and Install"
123. 123. Install starting catalytic converter.
124. 124. Install lower engine compartment cover. • Tightening torque 5 Nm
125. 125. Vent clutch actuation • see operation "Hydraulic Clutch Actuation, Vent" in group "K".
126. 126. Top up oil tank for power steering • see operation "Hydraulic System, Fill and Bleed" in group "M".
127. 127. Charge air-conditioning system • See operation "Air-Conditioning System, Evacuate and Charge" in group "D"

Inspect

128. 128. Top up cooling system • see operation "Cooling System, Top Up and Bleed" and "Cooling System, Check for Leaks"
129. 129. Check engine oil level and correct if necessary.

1

) Clean thread and insert with bolt locking compound (red).

2

) Use new bolts.