Vauxhall Workshop Service and Repair Manuals

Remove and install automatic transmission with torque converter from engine

Note:   Engine with automatic transmission removed

  Remove

1.   Detach coolant return hose, throttle valve pre-heating (1) from coolant expansion tank •   Release clamp •   Unclip from bracket

2.   Detach upper radiator hose (1) from thermostat (2) •   Release clamp

4.   Detach refrigerant lines (1) from compressor •   Unscrew bolt (2)

5.   Disconnect 3x wiring harness plugs •   Compressor (1) •   Manometric switch, condenser (2) – Unclip wiring harness •   Temperature sensor, radiator (3)

6.   Detach 2x transmission fluid line (1) from automatic transmission •   Lever off 2x retaining clamp (2) from quick coupling

7.   Detach cooling module (1) •   Remove from lower radiator brackets

9.   Remove right-hand axle body •   Remove axle body with KM-460-B (1) from differential gear •   Seal opening in differential with sealing plug

10.   Remove left-hand axle body •   Remove axle body with KM-313 and KM-6003-1 (1) from differential gear •   Seal opening in differential with sealing plug

11.   Remove oil dipstick guide tube (2) •   Unscrew bolt (1) •   Remove oil dipstick guide tube upward

13.   Remove ribbed V-belt •   Apply tension to ribbed V-belt tensioner in the direction of the arrow at the projection (1) and lock with KM-6349 (2) – Remove ribbed-V-belt

15.   Detach bracket for catalytic converter (1) from cylinder block •   Unscrew 2x bolts (2) and (3)

16.   Remove exhaust manifold •   Unscrew 9x nuts (1)

17.   Remove compressor •   Unscrew 3x bolts (1)

18.   Remove coolant pipe (1) between thermostat housing and oil filter housing •   Unscrew 2x bolts (2) •   Draw out of oil filter housing

19.   Detach coolant pipe (1) from coolant pump •   Unscrew 2x bolts (2) •   Push coolant pipe into oil filter housing

20.   Remove oil filter housing (3) •   Release coolant pipe (1) and push into oil filter housing – Unscrew bolt (2) •   Unscrew 4x bolts (4)

21.   Detach intake manifold support (2) •   Disconnect wiring harness plug of catalytic converter control oxygen sensor •   Unclip wiring harness plug (1) from bracket •   Unscrew 2x bolts (3)

22.   Disconnect alternator from power supply •   Disconnect alternator from power supply – Unscrew 2x nuts (1) and (2) 23.   Remove alternator •   Unscrew 2x bolts (3) and (4)

24.   Detach earth cable (1) from starter •   Unscrew nut 25.   Detach 2x positive cable (2) starter •   Unscrew 2x nuts

26.   Detach starter •   Unclip wiring harness plug for oxygen sensor of catalytic converter control from bracket •   Unscrew 2x bolts (1) and (2)

27.   Attach KM-412-31-1 (1) •   Tighten 3x bolt (2)

28.   Attach KM-412-31-2 (1) •   Tighten 3x bolts

30.   Remove front engine damping block •   Detach screwed connection (1) 31.   Remove rear engine damping block •   Detach screwed connection (2)

34.   Detach gearshift cable bracket (1) from transmission •   Unscrew 2x bolts (2)

35.   Remove torque converter from drive disc •   Remove 2x sealing plug •   Turn engine towards torsional vibration damper until the relevant screw is accessible •   Unscrew 3 bolts Note:   Lock torque converter with appropriate counterstay (1)

36.   Detach transmission (1) from engine •   Unscrew 7x bolts Note:   One bolt remains as a retaining device

  Install

38.   Measure resistance, torque converter in the transmission •   Measure with measuring device (1) – Distance: approx. 12 mm

39.   Coat centring seat (arrow) for torque converter in the crankshaft with grease 40.   Check correct seating of 2x guide bush (1) in engine flange

41.   Cut thread (arrows) in the torque converter

67.   Install left-hand axle body •   Attach new circlip (1) to axle body •   Lubricate teeth and bearing points with engine oil •   Push axle body into gearbox until circlip engages

70.   Attach oil cooling lines to transmission Note:   Observe correct assignment. •   Use 2x new O ring (1)

76.	Check and correct transmission fluid level