Engine — installation (manual gearbox remained on the car) (Opel Ascona C)

1. If you have disassembled the clutch, you must center the driven clutch disc before connecting the engine to the gearbox, otherwise the drive shaft of the gearbox will not pass through the hub to the driven disc.

2. To center the disc, install it on the flywheel so that the protruding hub of the disc faces away from the flywheel.

3. Install the flywheel housing cover in place, aligning the marks made during disassembly, and secure it with bolts, tightening them by hand.

4. Now you will need a centering tool, which must be passed through the driven disk hub and inserted into the bearing at the end of the crankshaft. If you don't have a special tool, you can use a variable cross-section rod.

5. Once the driven disk is centered, tighten the cover bolts to the required torque and remove the tool.

6. Lower the engine into the engine compartment at an angle such that it can be connected to the flywheel housing.

7. Screw in the upper connecting bolts.

8. Replace the clutch cover.

9. Now that the engine and gearbox are supported together by hoists, remove the jack that was propping up the gearbox.

10. Install the generator and its support bracket.

11. Secure the engine to the right rear mount.

12. Secure the engine to the right front mount and to both left mounts.

13. Disconnect the hoists.

14. Install the crankshaft pulley in place and (on engines 1.6 and 1.8) torsional vibration damper. Tighten the locking bolt(s) to the specified torque while holding the crankshaft by the ring gear with a large screwdriver inserted through the starter hole.



15. Install the starter and generator in place.

16. Connect the drive shaft to the driven clutch disc and flywheel in the reverse order of its disconnection (see section 18, paragraphs 9-13).

17. Connect the exhaust downpipe to the manifold and the rear section of the exhaust system.

18. Lower the front of the car.

19. Connect the fuel supply and return hoses.

20. Install the drive belt and tighten it (see chapter 2).

21. Connect the wiring to the terminals indicated in section 18, paragraph 8.

22. Connect the carburetor drive mechanism. On injection models, connect the electrical plugs and other components as specified in section 18, paragraph 6.

23. Install the radiator.

24. Connect the heater and cooling system hoses.

25. Connect the distributor and brake servo cylinder vacuum hoses.

26. Install the air cleaner and air intake duct (carburetor models). On injection models, connect the air intake duct.

27. Replace the hood cover.

28. Fill with coolant (see chapter 2).

29. Fill the engine and gearbox with oil.

30. Connect the battery.