How to Remove and Install the Engine Opel Zafira B

Note. The operation "Engine, Remove and Install" is described for a Z 20 LET engine with AC and left hand drive. Proceed analogously for other equipment versions,

Cable ties detached for removal of the engine must be reattached at the same location on installation.

Caution

For vehicles with airbag: Turn steering to straight ahead position, remove ignition key and engage steering lock.

Remove

1. 1. Remove clamping bolt (1) on steering column intermediate spindle (interior).
2. 2. Drain air conditioning – see operation "Air Conditioning, Drain" in group "D",

3. 3. Detach ground cable (3) from ground terminal (4) and ground terminal from battery.
4. 4. Detach positive cable (2) from positive terminal (1) and positive terminal from battery.
5. 5. Remove battery.
6. 6. Detach battery support (5) from body,

7. 7. Unclip coolant hose from battery support and unclip wiring harness,
8. 8. Remove battery support,
9. 9. Detach engine compartment seal (2),
10. 10. Remove water deflector cover (1),
11. 11. Remove fastening bolts (3) and fastening nuts (4),
12. 12. Remove bulkhead cover plate insulation (5),

13. 13. Unclip tank vent valve from air cleaner housing,
14. 14. Disconnect wiring harness plug from tank vent valve,
15. 15. Remove air filter housing with charge air pipe (4) and charge air hose (3) – see illustration "Air Duct",
16. 16. Reduce fuel pressure with Pressure Gauge KM-J-34730-91 via test connection – collect escaping fuel in suitable container – observe safety regulations and national legislation,
17. 17. Disconnect fuel lines (1) and (2) from fuel pressure regulator and fuel distributor pipe,

18. 18. Disconnect wiring harness plug (3) from engine control unit and remove cable duct from body (arrow) – expose wiring duct,
19. 19. Disconnect wiring harness plug (2) (grey),
20. 20. Detach multiplug (1) (turn lock).

21. 21. Remove front panelling – see operation "Front Panelling, Remove and Install " in group "A",
22. 22. Remove lower engine splash guard.
23. 23. Open coolant drain bolt – collect escaping coolant.
24. 24. Close coolant drain bolt.
25. 25. Disconnect wiring harness plug of catalytic converter control oxygen sensor.
26. 26. Expose catalytic converter control oxygen sensor wiring harness – see operation "Catalytic Converter Control Oxygen Sensor, Remove and Install",
27. 27. Remove front exhaust pipe – see operation "Front Exhaust Pipe, Remove and Install" in group "L",
28. 28. Remove wiring harness plug (1) from auxiliary coolant pump – expose wiring harness,

29. 29. Disconnect reversing lamps switch wiring harness plug from reversing lamps switch,
30. 30. Unlock wiring harness plug (1) in direction of arrow and detach from cooling module control unit,
31. 31. Detach ground cable (3) from body

Note. The drive unit must be aligned to the front axle body using KM-6173 and KM-6001-A in order to ensure correct alignment of the drive unit after releasing the fastening bolts for the right and left engine damping blocks. The attachment of KM-6173 and KM-6001-A is described below,

Remove

32. 32. KM-6173 (3) to front axle body – screw up support bearing (2) until pins are seated flush in mount (1) on cylinder block,

33. 33. Release fastening bolts (arrows) for adjustment rails on KM-6001-A (1),
34. 34. KM-6001-A insert as illustrated – pins (2) and (5) must seat in guide holes of front axle body,
35. 35. Tighten fastening bolts for adjustment rails.
36. 36. Front support bearing (4) and rear support bearing (3) up to contact surface of front and rear engine damping block guide pins – the guide pins must be seated in the support bearings without play,

37. 37. Remove coolant hoses (1) and (4) from coolant compensation tank,
38. 38. Detach retaining clip (2) from coolant compensation tank,
39. 39. Retrieve coolant compensation tank,

40. 40. Withdraw fuse (2) from fuse carrier (1) and withdraw fuse carrier from fuse carrier bracket,
41. 41. Detach ground cable (3) from body
42. 42. Remove wiring harness plug (4) and expose steering wiring harness,

43. 43. Detach delivery line with connector (1) from central equipment delivery line at clutch housing – to do this, release clamp (2) with screwdriver and remove; then bend clamp together slightly and re-insert in connector. Caution During disassembly of the cables, ensure that ball socket bearing journals are not bent from being tilted when levered off. As a result of this, easy shifting is no longer possible after reinstallation, The cables must not be turned, twisted or kinked,

Remove

44. 44. Disconnect shift cables (1) from shift guide lever assembly using KM-6042 ,
45. 45. Unclip shift cables from holder and lay aside,

46. 46. Release coolant hoses (2) in direction of arrow and detach from heater core, Detach brake servo vacuum line (1) from intake manifold.

47. 47. Detach tank vent valve line from intake manifold,
48. 48. Detach wastegate vacuum hose from wastegate and separation point,
49. 49. Detach left engine damping block bracket (2) from engine damping block support,
50. 50. Detach right engine damping block bracket (1) from engine damping block support,
51. 51. Front Wheels, Remove.

52. 52. Detach swing arm (1) on both sides from spring strut support tube – counterhold with open-ended spanner at the two flattened surfaces.

53. 53. Withdraw axle shafts on both sides from wheel hub (do not remove from transmission) – see operation "Axle Shaft, Remove and Install" in group "E".
54. 54. Install Base Frame KM-904 with Centring Device KM-6000 on hydraulic jack and position free of play under front axle body (use hydraulic jack which can be lowered at least 100 cm), Caution Dismantling of front axle body using an impulse or impact screwdriver is not permissible. Note dissimilar bolt lengths.

Note. For a clearer representation, the illustration shows the front axle body without hydraulic jack and centring device.

Remove

56. 56. Remove six rear fastening bolts (4) on left and right side,
57. 57. Remove front fastening bolts on right (1) and left (3) side,
58. 58. Remove centre fastening bolts (2),
59. 59. Carefully lower front axle body with entire drive unit, steering gear and radiator – thereby ensuring that no attaching parts are damaged, Caution Ensure the threads of the captive nuts move freely before installing front axle body with drive unit, steering gear and radiator, replace captive nuts if necessary,

Install

60. 60. Carefully guide front axle body with entire drive unit, steering gear and radiator into engine compartment and position free of play on chassis – thereby ensuring that no attaching parts are damaged.
61. 61. Attach front axle body to vehicle underbody with new fastening bolts (1 – 4) – Tightening torque 90 Nm / 66 lbf. ft.+ 45° + 15° , Caution Installing the front axle body using an impulse or impact screwdriver is not permissible. Note dissimilar bolt lengths,

62. 62. Install axle shafts – see operation "Axle Shaft, Remove and Install" in group "E",
63. 63. Attach swing arms on both sides to spring strut support tube with new fastening nuts – counterhold with open-ended spanner at two flattened surfaces – Tightening torque 65 Nm / 48 lbf. ft ,
64. 64. Attach front wheels – Tightening torque 110 Nm / 81 lbf. ft ,
65. 65. Attach engine damping block bracket to right side of engine damping block support – Tightening torque 55 Nm / 41 lbf. ft ,
66. 66. Attach engine damping block bracket to left side of engine damping block support – Tightening torque 55 Nm / 41 lbf. ft ,
67. 67. Attach wastegate vacuum hose to wastegate and separation point,
68. 68. Attach tank vent valve line to intake manifold,
69. 69. Connect brake servo vacuum line to intake manifold.
70. 70. Connect coolant hoses to heat exchanger – ensure proper fit,
71. 71. Clip shift cables into holder and attach to shift guide lever assembly,
72. 72. Attach pressure connection for hydraulic clutch actuator to manual transmission,
73. 73. Route steering wiring harness, clip fuse carrier into bracket, connect wiring harness plug and ground cable to body,
74. 74. Insert coolant compensation tank and fasten with retaining clip,
75. 75. Connect coolant hoses to coolant compensation tank – ensure proper seating,
76. 76. Remove Mount KM-6001-A and Engine Mount KM-6173 ,
77. 77. Route cooling module control unit wiring harness and connect cooling module control unit wiring harness plug,
78. 78. Attach ground cable to body.
79. 79. Connect reversing lamps switch wiring harness plug to reversing lamps switch,
80. 80. Connect auxiliary coolant pump wiring harness plug to auxiliary coolant pump,
81. 81. Install front exhaust pipe – see operation "Front Exhaust Pipe, Remove and Install" in group "L",
82. 82. Attach front exhaust pipe to start-up catalytic converter using gasket – Tightening torque 35 Nm / 26 lbf. ft ,
83. 83. Install lower engine splash guard.
84. 84. Connect catalytic converter control oxygen sensor wiring harness plug and route catalytic converter control oxygen sensor wiring harness, attach cable ties,
85. 85. Install front panelling – see operation "Front Panelling, Remove and Install" in group "A".
86. 86. Connect multiplug (twist lock) and wiring harness (grey),
87. 87. Attach cable trough to body and wiring harness plug to engine control unit.
88. 88. Attach fuel lines to fuel distributor pipe and to fuel pressure regulator – Tightening torque 15 Nm / 11.1 lbf. ft ,
89. 89. Install charge air hose – see illustration "Air Duct",
90. 90. Install air cleaner housing with charge air pipe – see illustration "Air Duct",
91. 91. Connect tank vent valve wiring harness plug to tank vent valve and attach tank vent valve to air cleaner housing,
92. 92. Install bulkhead cover plate insulation,
93. 93. Clip coolant hose to battery support and attach battery support to body – Tightening torque 15 Nm / 11.1 lbf. ft ,
94. 94. Install battery.
95. 95. Attach positive terminal to battery and positive lead to positive terminal.
96. 96. Attach ground lead to battery and ground lead to ground terminal,
97. 97. Coat new clamping bolt with screw locking compound (red) and attach steering column intermediate shaft to steering gear – Tightening torque 22 Nm / 16 lbf. ft ,
98. 98. Charge air conditioning – see operation "Air Conditioning, Evacuate and Charge" in group "D".
99. 99. Bleed clutch hydraulic system – see operation "Hydraulic Clutch Actuator, Bleed (F13/F17/F23)" in group "K",

Inspect

100. 100. Charge cooling system – see operations "Cooling System, Charge and Bleed" and "Cooling System, Check for Leaks".