Astra H M32 Z19DTL Z19DT Z19DTH Gearbox — OPEL / VAUXHALL

🧭 Before you start

Fits: platform codes 1.9, CDTI, 16V, |, 8V

• Timing position: the crankshaft or camshaft is set and locked during this job
• Special tools named: locking pin

Don't miss

• Remove the coolant reservoir, but do not disconnect

🔧 Engine codes this applies to

📐 41 workshop diagrams for Z19DT

Real factory drawings for this job — timing marks, bolt locations and routing. Locked in the free view.

📋 Procedure

Preparation and removal

1. Stage 1:
2. Stage 2:
3. Proceed as follows:
4. Remove the EGR cooler
5. The gear-shift lever should be locked

6. Remove the upper bolts from the gearbox
7. Disconnect the reversing light switch
8. Remove the coolant reservoir, but do not disconnect
9. Remove the headlight(s)
10. Protect the radiator
11. Disconnect the power steering wiring loom
12. Use a hoist to support the engine
13. Rear engine support
14. Note: Connect to the lifting eye
15. Remove both front wheels
16. Remove the wheel arch cover lining
17. Remove the bumper front panel
18. Remove the stabiliser link upper bolt
19. Disconnect the tie rods
20. Disconnect the steering arm ball joints from the wheel bearing housings
21. Fit the special tool and apply pressure
22. Disconnect the lower ball joints from the wheel bearing housing
23. Use the special tool
24. Remove the front exhaust pipe with catalytic converter
25. Disconnect the gearbox operating linkage
26. Disconnect the gearbox support bracket at the back of the engine/gearbox
27. Disconnect the front engine support from the subframe
28. Use the special tool to support the subframe
29. Fit a lifting jack
30. Remove the subframe bolts
31. Lower the subframe
32. Remove the drive shaft locking pin and locking nut
33. Remove the drive shafts
34. Collect the escaping fluid in a container
35. Plug the holes
36. Remove the intermediate drive shaft
37. Remove the left engine support bolt
38. Lower the engine/gearbox slightly
39. Disconnect the starter motor electrical connections
40. Remove the front engine support
41. Remove the rear engine support
42. Fit the special tool to support the gearbox
43. Remove the engine to gearbox bolts
44. Remove the gearbox

Installation and checks

45. Reconnect the gear-shift cable
46. Remove the special tool
47. Turn the steering wheel to the straight-ahead position
48. Stage 1:
49. Lock the steering wheel in centre position
50. Stage 3:
51. Check for correct operation
52. Reset volatile memories after reconnecting the battery cables

Other OPEL / VAUXHALL procedures

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• Opel Astra G 2003 2.0 DTI Y20DTH timing chain replacement
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