Engine Overhaul — Disassembly Procedure (Opel Astra G)

1. It is recommended to disassemble the engine on a special stand; if there is no stand, then secure the engine on a level surface.

2. If you purchase a reconditioned engine, you must remove all attachments and install them in exactly the same order as if you were doing a major overhaul yourself. These attachments include:

1) Intake and exhaust manifolds.
2) Generator/A/C compressor brackets (depending on the configuration).
3) Coolant pump.
4) Parts for the fuel injection system.
5) All sensors and solenoid valves with wiring.
6) Flywheel/drive disk of the torque converter.

Before removing attachments, mark gaskets, seals and other parts to facilitate assembly.

3. If an incomplete cylinder block is to be installed (i.e. a cylinder block with a selected and installed crank mechanism and piston group), then you should also remove the cylinder head, oil pan, oil pump and camshaft belt.

5. If a major overhaul is planned, the engine should be disassembled in the following order

1) Intake and exhaust manifolds.
2) Cylinder head.
3) Flywheel/drive disk of the torque converter.
4) Oil pan.
5) Balance mechanism (on 2.0 l engines).
6) Oil pump.
7) Connecting rod and piston group.
8) Crankshaft.