Engine assembly procedure (Opel Astra G)

Contents: Petrol engines ⬇ Diesel engines ⬇

Before you begin assembling the engine, make sure you have all the necessary parts, materials and tools, which include the following:

Standard set of locksmith tools;
Torque wrench with 1/2-inch drive;
Piston ring tool;
Piston Ring Crimping Tool;
Short sections of fuel hose for fitting onto connecting rod bearing cap studs;
Plastigage Measuring Kit;
Blade type feeler gauge set;
Fine tooth file;
Fresh engine oil;
Assembly engine or molybdenum-containing grease;
Gasket sealant;
Sealant for fixing threaded connections.

At this stage, all components to be installed must be absolutely clean and dry. For convenience, lay out the parts on a clean surface in the order of installation.

To save time and minimize the number of problems that may arise, assemble the engine in the following order:

Petrol engines

1. Piston rings;

2. Crankshaft and main bearings;

3. Connecting rod and piston assemblies;

4. Oil pump with oil intake pipe (see SOHC Gasoline Engine Repair Procedures Without Removing Them From The Vehicle or Repair procedures for DOHC gasoline engines without removing them from the vehicle);

5. Balancing assembly/main bearing bridge (depending on the configuration, if provided)

6. Oil pan (including oil deflector plate, if provided) (cm. SOHC Gasoline Engine Repair Procedures Without Removing Them From The Vehicle or Repair procedures for DOHC gasoline engines without removing them from the vehicle);

7. Flywheel/drive disc (see SOHC Gasoline Engine Repair Procedures Without Removing Them From The Vehicle);

8. Cylinder head with camshaft and valve drive components (see SOHC Gasoline Engine Repair Procedures Without Removing Them From The Vehicle or Repair procedures for DOHC gasoline engines without removing them from the vehicle);

9. The timing case and its cover (see SOHC Gasoline Engine Repair Procedures Without Removing Them From The Vehicle or Repair procedures for DOHC gasoline engines without removing them from the vehicle);

10. Water pump (see Chapter Cooling and heating systems);

11. Rear timing belt cover (see SOHC Gasoline Engine Repair Procedures Without Removing Them From The Vehicle or Repair procedures for DOHC gasoline engines without removing them from the vehicle);

12. Timing drive components (see SOHC Gasoline Engine Repair Procedures Without Removing Them From The Vehicle or Repair procedures for DOHC gasoline engines without removing them from the vehicle);

13. Front timing belt covers (see SOHC Gasoline Engine Repair Procedures Without Removing Them From The Vehicle or Repair procedures for DOHC gasoline engines without removing them from the vehicle);

14. Intake manifold and exhaust manifold (see Chapter Power and exhaust systems);

15. Mounted units;

16. Engine protective cover (with appropriate equipment).

(Text copied from an online resource: «www.opelbook.ru»)

Diesel engines

1. Piston rings;

2. Crankshaft and main bearings;

3. Connecting rod and piston assemblies;

4. Timing drive components with rear cover- 2.0L engines (cm. Repair procedures for 1.7L and 2.0L diesel engines without removing them from the vehicle);