Engine — installation (with manual gearbox) (Opel Ascona C)

1. With the front of the vehicle raised and securely supported, place the engine with the gearbox on the floor under the engine compartment (see photo).

2. Raise the unit on the hoists and turn it slightly so that the right half shaft can be inserted into the main gear housing.

3. Secure the engine to the front mounts.

4. Secure the engine to the rear mounts.

5. All engine mounting bolts and nuts must be hand tightened. The final tightening will be done after the engine rests with all its weight on the mounts. The engine position is adjusted using extended bolt holes on its left front support bracket.

6. Connect the gearbox ground wire.

7. Connect the left half shaft, control arm and anti-roll bar in the reverse order of their disconnection.

8. Control arm support bolt installation details see chapter 10 (extremely important).

9. Install the wheel back in place. The hub nut can be tightened after the car rests its full weight on the wheels.

10. Disconnect the hoists from the engine.

11. Tighten all engine mount bolts and nuts to the specified torque.

12. Check that all suspension, hub and steering bolts and nuts are tightened to the specified torques.

13. Replace the wheels and lower the car to the ground.

14. Connect the speedometer cable to the gearbox.

15. Connect the wiring to the reverse light switch.

16. Connect the clutch cable.

17. Connect the gear shift rod.

18. Check the clutch cable adjustment (see chapter 5) and gear shift mechanism (see chapter 6).

19. Connect the fuel hoses.

20. Connect the wiring to all parts listed in section 18, paragraph 8.



21. Connect the carburetor drive mechanism. On injection models, connect all parts specified in section 16, paragraph 6 and install the injection system components in place (see chapter 3).

22. Connect the vacuum hoses to the brake servo cylinder and distributor.

Material copied from this website: OpelBook

23. Connect the heater and cooling system hoses.

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

25. Replace the hood cover.

26. Fill the engine with oil and coolant.

27. Add oil to the gearbox.

28. Connect the battery.