Note: Depending on the engine, the appearance, location and number of attachment points of the right support and its attachment bracket to the cylinder block may differ from those described below and shown in the accompanying illustrations. These design features of the engines practically do not affect the order in which this procedure is performed.
7. Due to the design features of the front suspension and the layout of the units in the engine compartment for removal / replacement, toothed belt / timing chain (on some models and multirib belt), as well as for the dismantling of some units, the removal of the right engine mount is required. For this, it is possible to dismantle the right support without removing the engine.
8. Before proceeding with this operation, it is necessary to unload the right support. This will require a lifting device (hoist) with appropriate devices for lifting the engine, or a universal set of tools from Opel for holding the engine on the front subframe of the car during removal / replacement of the support. In some cases, a jack can be used to support the engine by placing a suitable size block of wood between the jack head and the engine. All work with the removal of engine mounts is recommended to be performed in a service station.
9. At specialized Opel service stations, when removing the right support, a special set of tools KM-6169 is used to prevent changes in the position of the engine.
Note: For models starting from 2004, instead of the KM-6169-1 fixture, the KM-6394 fixture is used. The procedure for performing the operation is completely identical.
10. Disconnect the wire from the negative terminal of the battery (see chapter 5) and remove the air cleaner (see chapter 4).
11. Jack up and place the car on stands or raise it on a lift. Remove the multi-ribbed belt cover or crankcase guard (see above).
12. Install the tool Opel-KM-6169-2 (see resist. illustration) on the gearbox and tighten the fixing bolts to 95 Nm.
5.12. Installing the tool Opel KM-6169-2
13. Install tool Opel-KM-6169 (see resist. illustration) first on the left side of the subframe (I), and then to the right (II). The guide pins of the tool must fit into the holes in the subframe. Tighten the mounting bolts.
5.13. Installing the tool Opel-KM-6169 (1) on the stretcher
14. Install the 3 fixture legs and adjust their height (see resist. illustration), first on the gearbox side (IN) - the supports must fit snugly against the guide pins, then on the timing side (A) - the support must fit into the hole on the engine block, if necessary, to align the support trunnion with the hole, adjust the position of the support base on the fixture. Unscrew the supports up until they rest against the support points of the power unit - the device should be firmly fixed, without play, on the subframe. Tighten the supports.
5.14. Installing and adjusting the supports of the Opel-KM-6169 fixture: 1. Fixing nut of the support on the timing side; 2. Support base; 3. Supports on the gearbox side
15. Turn out the bottom bolt of an arm of fastening of the right support to the block of the engine (see illustration 5.15a). Lower the car, unscrew the bolts of the support to the side member and the upper bolts of the bracket (see illustrations 5.15b), - remove the engine support together with the bracket.
5.15a. bottom bolt (1) fastening of an arm of the right support of the engine | 5.15b. The right engine mount - the arrows show the upper bolts of the bracket of the right pore to the cylinder block |
16. If necessary, the engine support can be dismantled without removing the bracket. In this case, it is necessary to unscrew the 2 bolts securing the right support to the bracket (see illustration 5.15b).
17. When installing the support, first install the lower bracket mounting bolt and tighten it by hand. Torque tighten (see specs) bolts securing the support to the spar, then the upper mounting bolts of the bracket and finally the lower bolt. If the bracket was not removed, first tighten the bolts securing the support to the side member and then to the bracket. Dismantling of the device is carried out in the reverse order.
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