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DOHC diesel engine|General > < Replace intercooler

Astra H

Remove and install automatic transmission with torque converter from engine

  Remove

1.   Remove engine
2.   Detach 2x charge air hose
•   From intercooler (1)
– Release clamp
•   From turbocharger (2)
– Release clamp
Object Number: 8231063 Size: DEFAULT


3.   Secure raidator with retaining strap (1) at engine transport shackle (2)
Object Number: 8231062 Size: DEFAULT


4.   Detach 3x coolant hose from radiator
Note:   Place collecting basin underneath.
•   Detach coolant supply hose (3) from radiator
– Release clamp
– Unclip from fan housing bracket
•   Detach coolant return hose (4) from radiator
– Release clamp
•   Unclip coolant hose (1) from fan housing
•   Detach coolant return hose (2) from coolant pipe
– Release clamp
Object Number: 8231064 Size: DEFAULT


5.   Detach 2x transmission fluid line (3) from oil cooler
Note:   Place collecting basin underneath.
•   Unclip 2x protective cap (2)
•   Unscrew 2x retaining clamp (1)
Object Number: 8231065 Size: DEFAULT


6.   Detach compressor wiring harness
•   Disconnect compressor wiring harness plug
•   Unclip from refrigerant line
7.   Detach refrigerant line (1) from condenser
•   Unscrew bolt
•   Unclip from bracket
Object Number: 8231066 Size: DEFAULT


8.   Detach engine cooling module
•   Unclip 2x vacuum line from radiator
•   Remove retaining strap
•   Remove radiator upward from bracket
9.   Detach charge air pipe (5) from turbocharger
•   Unscrew bolt
•   Release clamp
•   Detach hose from cylinder head cover (1)
– Release clamp
10.   Remove oil dipstick guide tube (4)
•   Unscrew bolt (2)
•   Detach from oil pan
– Unscrew bolt
11.   Detach refrigerant line (3) from compressor
•   Unscrew bolt
Object Number: 8231067 Size: DEFAULT


12.   Remove coolant pipe assembly (1)
•   Disconnect wiring harness plug of pre-catalytic converter temperature sensor (2)
•   Unscrew 6x bolts
•   Detach hose from EGR cooler
– Release clamp
•   Detach hose from coolant pipe
– Release clamp
Object Number: 8231068 Size: DEFAULT


13.   Detach exhaust manifold heat shield (3)
•   Unscrew 3x bolts (1)
•   Unscrew 3x nuts (2)
Object Number: 8231069 Size: DEFAULT


14.   Detach exhaust manifold (1)
•   Detach with turbocharger and catalytic converter
•   Detach EGR metal tube (2)
– Release clamp
•   Detach oil feed line from engine block
– Unscrew and remove banjo bolt (arrow)
•   Detach oil return line (3) from engine block
– Unscrew 2x bolts
•   Unclip wiring harness of pre-catalytic converter temperature sensor
•   Detach vacuum line from vacuum unit
•   Release catalytic converter
– Unscrew 2x bolts
•   Unscrew 8x nut
•   Remove seal
Object Number: 2408600 Size: DEFAULT


15.   Attach KM-412-36-2 (1)
•   Exhaust side
•   Tighten 3x bolts
Object Number: 2408601 Size: DEFAULT


16.   Detach oil filter housing with heat exchanger (2)
•   Place collecting basin underneath.
•   Disconnect wiring harness plug for oil pressure switch (arrow)
•   Detach 2x coolant hose (1)
– Undo 2 clamps
•   Unscrew 3 bolts
Object Number: 2408602 Size: DEFAULT


Object Number: 2408156 Size: DEFAULT

17.   Remove starter
•   Release bracket for wiring harness
– Slacken 2x nut (1)
•   Detach 2x wiring harness
– Unscrew 2x nuts (2)
•   Detach earth cable (3)
– Unscrew nut
•   Unscrew stud bolt
•   Unscrew 2x bolts (arrows)

18.   Detach axle shaft on left and right
Note:   2nd mechanic is required.
•   Place collecting basin underneath.
•   Use KM-313 (2) together with KM-902 (1)
– Seal aperture
Object Number: 2411280 Size: DEFAULT


19.   Detach intermediate shaft (1) with its bracket
•   Unscrew 3x intermediate shaft bracket bolt (2) from engine block
•   Unscrew 3x bolt from end shield
Object Number: 8231070 Size: DEFAULT


20.   Attach KM-412-36-1 (1)
•   Intake side
•   Tighten 4x bolts
Object Number: 2408604 Size: DEFAULT


21.   Attach adapter plate KM-883-2
•   3x at engine transport shackle
•   Lock transport hook
•   Suspend from workshop crane
22.   Connect rope to drive unit at KM-883-2
23.   Release rear reaction member
•   Unscrew 3x bolts (1)
•   Detach wiring harness bracket from reaction member
– Unscrew bolt
Object Number: 8231071 Size: DEFAULT


24.   Release front reaction member
•   Unscrew nut (1)
•   Remove bolt
Object Number: 2404855 Size: DEFAULT


25.   Lift drive unit
Note:   2nd mechanic is required.
26.   Attach drive unit to KM-412-A
Note:   2nd mechanic is required
•   Tighten 8x bolts
27.   Detach 3x wiring harness from transmission
•   Disconnect wiring harness plug (1) from selector lever
•   Detach engine management wiring harness bracket (4)
– Unscrew bolt
•   Detach wiring harness bracket (2)
– Unscrew nut
•   Unclip wiring harness from coolant pipe
•   Unclip transmission vent hose (3)
Object Number: 8231072 Size: DEFAULT


28.   Detach charge air pipe (2) from throttle valve module
•   Unscrew 2x bolts (1)
Object Number: 8231073 Size: DEFAULT


29.   Attach transmission to ropes
•   Use KM-2358 (1)
Object Number: 8231074 Size: DEFAULT


30.   Detach torque converter from flywheel
•   Unscrew 6x bolts (1)
– Through exhaust port
Object Number: 8231075 Size: DEFAULT


31.   Undo transmission
•   from oil pan
– Unscrew 2x bolts
•   from engine block
– Unscrew 5x bolts
32.   Remove gearbox
Note:   2nd mechanic is required

  Install

33.   Position transmission
Note:   2nd mechanic is required.
•   Note guide sleeves
•   Screw in bolt
Note:   Do not tighten bolt yet
34.   Secure transmission
•   On cylinder block
– Tighten 5x bolt 60 Nm
•   to oil pan
– Tighten 2x bolt 40 Nm
35.   Detach transmission from ropes
•   Remove KM-2358
36.   Attach torque converter to flywheel
Note:   Through exhaust port
•   Screw in 6x bolt
•   Tighten 6x bolt 30 Nm
37.   Attach charge air pipe
•   Tighten 2x bolts
38.   Attach 3x wiring harness to transmission
•   Clip wiring harness to coolant pipe
•   Attach wiring harness bracket
– Tighten nut
•   Attach engine management wiring harness bracket
– Tighten bolt
•   Connector wiring harness plug of selector lever
•   Clip in transmission vent hose
39.   Attach drive unit to workshop crane with KM-883-2
40.   Detach drive unit from KM-412-A
•   Unscrew 8x bolts
41.   Place drive unit on KM-6001-A
Note:   Note contact points, 2nd mechanic is required.
•   Attach rear reaction member
– Screw in 3x bolts
•   Attach front reaction member
– Insert bolt
42.   Secure front reaction member
•   Tighten screw connection 55 Nm
43.   Fasten rear reaction member to transmission
•   Tighten 3x bolt 80 Nm
44.   Untie ropes from drive unit
•   Remove from workshop crane
45.   Detach adapter plate KM-883-2
•   Release transport shackle
46.   Remove KM-412-36-1
•   Intake side
•   Unscrew 4x bolts
47.   Attach oil filter housing with heat exchanger
•   Replace 2x seal rings
•   Tighten 3x bolt 50 Nm
•   Connect oil pressure switch wiring harness plug
•   Attach 2x hoses
– Attach 2x clamps
48.   Install starter
•   Tighten stud bolt 25 Nm
•   Tighten 2x bolt 25 Nm
•   Install earth cable
– Tighten nut
•   Attach 2x wiring harness
– Tighten 2x nuts
•   Fasten bracket for wiring harness
– Tighten 2x nuts
49.   Detach KM-412-36-2
•   Exhaust side
•   Unscrew 3 bolts
50.   Cleaning Work
•   Clean sealing surface
– Exhaust manifold, cylinder head
51.   Attach exhaust manifold with turbocharger and catalytic converter
•   Replace seal
•   Tighten 8x new nuts 25 Nm
•   Attach EGR metal tube
– Fasten clamp
•   Attach oil feed line
– Replace 2x seal rings
– Tighten banjo bolt 15 Nm
•   Attach oil return line
– Replace seal
– Tighten 2x bolt 25 Nm
•   Clip in wiring harness of pre-catalytic converter temperature sensor
•   Attach vacuum line to vacuum unit
•   Fasten catalytic converter
– Tighten 2x bolts
Note:   Clean thread before re-using and insert bolt with locking compound (red). The maximum installation time including torque check is 10 minutes.
52.   Attach exhaust manifold heat shield
•   Tighten 3x bolt 9 Nm
•   Tighten 3x nuts 9 Nm
53.   Cleaning Work
•   Clean sealing surfaces.
– Coolant pipe, cylinder head
54.   Attach coolant pipe assembly
•   Replace seal
•   Tighten 5x bolts
•   Tighten toothed belt cover bolt to coolant flange
Note:   Clean thread before re-using and insert bolt with locking compound (red). The maximum installation time including torque check is 10 minutes.
•   Attach hose to EGR cooler
– Fasten clamp
•   Attach hose to coolant pipe
– Fasten clamp
•   Connect wiring harness plug of pre-catalytic converter temperature sensor
55.   Attach refrigerant line to compressor
•   Replace 2x seal rings
•   Tighten bolt 20 Nm
56.   Attach dipstick guide tube
•   Attach to oil pan
– Tighten bolt 9 Nm
•   Tighten bolt 9 Nm
57.   Attach charge air pipe to turbocharger
•   Tighten bolt 9 Nm
•   Tighten clamp 3.5 Nm
•   Attach hose to cylinder head cover
– Fasten clamp
58.   Attach intermediate shaft with its bracket
•   Tigthen 3x intermediate shaft bracket bolt to engine block 55 Nm
•   Tighten 3x bolt to end shield 18 Nm
59.   Replace 2x retaining ring, axle shaft on left and right
Object Number: 2417920 Size: DEFAULT


Important:   Retaining ring must engage audibly.
60.   Attach axle shaft on left and right
61.   Attach engine cooling module
•   Insert radiator in bracket from above
•   Secure raidator with retaining strap at engine transport shackle
•   Clip in 2x vacuum line at radiator
62.   Attach refrigerant line to condenser
•   Clip into bracket
•   Tighten bolt 10 Nm
63.   Attach compressor wiring harness
•   Fix wiring harness plug
•   Clip in at refrigerant line
64.   Attach 2x transmission fluid line to oil cooler
•   Install 2x retaining clamp
•   Clip in 2x protective cap
65.   Attach 3x coolant hose to radiator
•   Attach coolant supply hose to radiator
– Fasten clamp
– Clip into fan housing bracket
•   Attach coolant return hose to radiator
– Fasten clamp
•   Clip in coolant hose to fan housing
•   Attach coolant return hose to coolant pipe
– Fasten clamp
66.   Attach 2x charge air hose
•   To intercooler
– Tighten clamp 3.5 Nm
•   To turbocharger
– Tighten clamp 3.5 Nm
67.   Remove retaining strap from radiator
68.   Check transmission fluid level and correct if necessary LUREF_1.gif
69.   Install engine

DOHC diesel engine|General > < Replace intercooler