Removal and installation of a diesel engine together with a gearbox (Opel Vectra B)

Removal

1. Remove the hood.

2. Remove the battery and battery tray.

3. Block the rear wheels, raise the front of the car and secure it on stands.

4. If the engine is to be disassembled, drain the engine oil and remove the oil filter. Drain the coolant from the cooling system.

5. Remove the air cleaner housing, remove the exhaust pipe, disconnect the fuel supply and return hoses from the fuel pump, disconnect the vacuum hose from the brake booster and the hoses from the intake and exhaust manifolds, disconnect the electrical connectors from the intake and exhaust manifold electrical components, on 1.7L engines, disconnect the accelerator cable.



6. Loosen the clamps and disconnect the coolant supply hoses (indicated by arrows) to the engine cylinder head and block.

7. On models with air conditioning, remove the compressor mounting bolt and move it away from the engine.

8. Release the air conditioning hoses from the mounting brackets and move them away from the engine.



9. Disconnect the electrical wires from the starter (B), generator (A), oil pressure, level and temperature sensors.





10. Unscrew the mounting bolt (indicated by the arrow) grounding buses from the gearbox.

11. Remove the power steering pump mounting bolt and move the pump to the side without disconnecting the hoses from it.

12. Drain the transmission oil. Disconnect the electrical connector from the reverse light switch. Disconnect the gear shift rod from the transmission. Disconnect the clutch cable.



13. Hook the lifting mechanism's hooks onto the power unit and lift until the weight of the power unit is supported by the lifting mechanism.

14. Remove the front suspension lower frame.

15. Remove the inner drive shaft joints from the transmission. Using soft wire, tie the inner ends of the drive shafts to the car body.



16. Ensure that any items that may prevent engine removal are removed or disabled.

17. Unscrew the nuts and remove the right powertrain mount.



18. Place a trolley under the engine compartment of the vehicle. Lower the power unit onto the trolley and remove it from under the vehicle.

Separating the gearbox from the engine

Cm. subsection 3.5.3

Installation

1. Check that the guide pins are installed in the engine or gearbox.

(Source is on this resource OpelBook.ru)

2. Install the gearbox to the engine on the guide pins. Install and tighten the gearbox to engine mounting bolts to the specified torque.

3. Install the starter and tighten the bolts.

4. Move the power unit under the engine compartment of the vehicle, hook it with the lifting mechanism clamp and install the power unit in the engine compartment. When installing the power unit, tilt and rotate it if necessary so that it is installed in place without causing damage.

5. Align the engine with the right support and tighten the mounting nuts by hand.

6. Replace the drive shaft oil seals and install the drive shafts into the transmission.

7. Install the front suspension lower frame.



8. Tighten the right powertrain mount nuts to the specified torque.

9. Further installation is carried out in the reverse order of removal.

10. Fill the gearbox with oil.

11. Fill the engine with motor oil and the cooling system with coolant.