How to Replace the Motor with Replacement Motor Opel Zafira B

Remove

Remove engine - see operation "Engine, Remove and Install (X 20 DTL, Y 20 DTH up to MY 2003)" or "Engine, Remove and Install (Y 20 DTH from MY 2003, Y 22 DTR)".

Attach engine to engine assembly stands (KM-412) – see operation "Engine to Engine Assembly Stands (KM-412), Attach",

Detach cable connections (3) from starter and cable connections (2) from alternator. Detach cable ties (4) from starter and remove wiring trough,

Detach heat shields for turbocharger (x3) (1) from exhaust manifold and turbocharger,

Mark running direction of ribbed V-belt. Tension ribbed V-belt tensioner in direction of arrow (anticlockwise) using hex lug (3) and remove ribbed V-belt.

Detach alternator (4) from coolant connection/alternator bracket (6) and timing case,

Detach heating coolant hoses (5) from coolant connection/alternator bracket,

Detach engine damping block bracket (1) from timing case or cylinder block,

Detach ribbed V-belt tensioner (2) from auxiliary aggregate support,

Detach AC compressor (4) from AC compressor support,

Detach AC compressor support from cylinder block,

Remove oil dipstick guide tube (3),

Detach fuel lines (1) from fuel injection pump,

Detach fuel lines bracket (2) from engine transport shackles and remove with fuel lines,

Detach bracket for crankshaft pulse pick-up (2) from upper part of intake manifold,

Detach heat exchanger coolant hose (1) from thermostat housing and heat exchanger coolant hose (4) from coolant connection.

Detach oil filter housing with heat exchanger (3) from cylinder block and remove,

Remove crankshaft pulse pick-up (5) from cylinder block,

Detach clutch with thrust plate (1) from flywheel. Lock flywheel (2) with KM-652 and remove from crankshaft. Detach coolant pump belt pulley (3) from coolant pump. Detach torsional vibration damper (4) from crankshaft,

Suspend engine on workshop crane and detach from engine assembly stands (KM-412),

Detach Adapters KM-412-16 and KM-412-8-A from cylinder block,

Install

Suspend replacement engine on workshop crane. Attach engine with Adapters KM-412-16 and KM-412-8-1 to engine assembly stands,

Attach torsional vibration damper with new fastening bolt to crankshaft – tightening torque 150 Nm / 111 lbf. ft. + 45° + 15°,

Attach coolant pump belt pulley to coolant pump – tightening torque 20 Nm / 15 lbf. ft,

Install

Attach flywheel to crankshaft with new fastening bolts – lock flywheel with KM-652 – tightening torque 45 Nm / 33 lbf. ft. + 30° + 15°,

Note. Before installing the clutch, check that a guide bushing is present in the crankshaft. If it is not, drive in a guide bushing flush (available from "Aftersales"). This is used to guide the centring drift,

Install

Attach thrust plate and clutch thrust washer to flywheel with Centring Drift KM-735. Lock flywheel with KM-652 and attach thrust plate to flywheel with new fastening bolts – tighten fastening bolts evenly alternating crosswise – tightening torque 15 Nm / 11 lbf. ft,

Remove

Remove Centring Drift KM-735,

Install

Attach crankshaft pulse pick-up to cylinder block with new seal ring – tightening torque 8 Nm / 6 lbf. ft,

Attach oil filter housing/heat exchanger with new gasket to cylinder block – tightening torque 20 Nm / 15 lbf. ft,

Attach heat exchanger coolant hose to thermostat housing and coolant connection. Attach bracket for crankshaft pulse pick-up to upper part of intake manifold,

Insert fuel lines with brackets and attach fuel lines bracket to engine transport shackles. Attach fuel lines to injection pump - tightening torque 15 Nm. Insert oil dipstick and attach to cylinder block.

Attach AC compressor support to cylinder block. Attach AC compressor to AC compressor support,

Attach ribbed V-belt tensioner to auxiliary aggregates support – tightening torque 42 Nm / 31 lbf. ft. Attach damper for ribbed V-belt tensioner to auxiliary aggregates support – tightening torque 23 Nm / 17 lbf. ft,

Attach bracket for engine damping block to timing case or cylinder block – tightening torque 50 Nm / 37 lbf. ft,

Attach heating coolant hoses to coolant connection/alternator support,

Attach alternator to coolant connection/alternator bracket and timing case- tightening torque 35 Nm / 26 lbf. ft,

Tension ribbed V-belt tensioner via hex lug - anti-clockwise - and place ribbed V-belt in position - note running direction and installed position of the ribbed V-belt:

Attach turbocharger heat shields (x3) to turbocharger and exhaust manifold,

Insert wiring trough. Attach cable connections to starter and alternator- note cable routing,

Remove

Detach engine from Engine Assembly Stands (KM-412) – see operation "Engine from Engine Assembly Stands (KM-412), Detach",

Install

Install engine - see operation "Engine, Remove and Install (X 20 DTL, Y 20 DTH up to MY 2003)" or "Engine, Remove and Install (Y 20 DTH from MY 2003, Y 22 DTR)".