Workshop Repair Manuals

Vauxhall Workshop Manuals

[PREV PAGE] [NEXT PAGE]

vauxhall Workshop Repair Guides


Astra H

J Engine and Engine Aggregates > DOHC Petrol Engine > General > Repair Instructions > Remove and install automatic transmission with torque converter from engine

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
Object Number: 9007924  Size: DEFAULT


2.   Detach upper radiator hose (1) from thermostat (2)
•   Release clamp
Object Number: 9007922  Size: DEFAULT


3.   Detach lower radiator hose from coolant pump
•   Release clamp
•   Unclip from bracket
4.   Detach refrigerant lines (1) from compressor
•   Unscrew bolt (2)
Object Number: 9007923  Size: DEFAULT


5.   Disconnect 3x wiring harness plugs
•   Compressor (1)
•   Manometric switch, condenser (2)
Unclip wiring harness
•   Temperature sensor, radiator (3)
Object Number: 9007921  Size: DEFAULT


6.   Detach 2x transmission fluid line (1) from automatic transmission
•   Lever off 2x retaining clamp (2) from quick coupling
Object Number: 7361207  Size: DEFAULT


Object Number: 7360872  Size: DEFAULT

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

8.   Place collecting basin underneath.
9.   Remove right-hand axle body
•   Remove axle body with KM-460-B (1) from differential gear
•   Seal opening in differential with sealing plug
Object Number: 2416469  Size: DEFAULT


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
Object Number: 2417912  Size: DEFAULT


11.   Remove oil dipstick guide tube (2)
•   Unscrew bolt (1)
•   Remove oil dipstick guide tube upward
Object Number: 8230998  Size: DEFAULT


12.   Detach wiring harness plug of catalytic converter control oxygen sensor
•   Disconnect wiring harness connector.
•   Unclip from bracket
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
Object Number: 9007697  Size: DEFAULT


14.   Detach exhaust manifold heat shield
•   Unscrew 3x bolts
Object Number: 9007925  Size: DEFAULT

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

16.   Remove exhaust manifold
•   Unscrew 9x nuts (1)
Object Number: 9007876  Size: DEFAULT


17.   Remove compressor
•   Unscrew 3x bolts (1)
Object Number: 9007873  Size: DEFAULT


18.   Remove coolant pipe (1) between thermostat housing and oil filter housing
•   Unscrew 2x bolts (2)
•   Draw out of oil filter housing
Object Number: 9007898  Size: DEFAULT


19.   Detach coolant pipe (1) from coolant pump
•   Unscrew 2x bolts (2)
•   Push coolant pipe into oil filter housing
Object Number: 9007906  Size: DEFAULT


20.   Remove oil filter housing (3)
•   Release coolant pipe (1) and push into oil filter housing
Unscrew bolt (2)
•   Unscrew 4x bolts (4)
Object Number: 9007907  Size: DEFAULT


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)
Object Number: 9007877  Size: DEFAULT


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)
Object Number: 2412800  Size: DEFAULT


24.   Detach earth cable (1) from starter
•   Unscrew nut
25.   Detach 2x positive cable (2) starter
•   Unscrew 2x nuts
Object Number: 9007889  Size: DEFAULT


26.   Detach starter
•   Unclip wiring harness plug for oxygen sensor of catalytic converter control from bracket
•   Unscrew 2x bolts (1) and (2)
Object Number: 9007890  Size: DEFAULT


27.   Attach KM-412-31-1 (1)
•   Tighten 3x bolt (2)
Object Number: 9007926  Size: DEFAULT


28.   Attach KM-412-31-2 (1)
•   Tighten 3x bolts
Object Number: 2412905  Size: DEFAULT


29.   Hitch engine up to workshop crane.
•   Attach holding ropes to engine transport shackles
30.   Remove front engine damping block
•   Detach screwed connection (1)
31.   Remove rear engine damping block
•   Detach screwed connection (2)
Object Number: 2417913  Size: DEFAULT


32.   Lift motor away from front axle body
33.   Install engine on engine overhaul stand KM-412-A
Note:   2 mechanics required
•   Remove holding ropes from engine transport shackles
34.   Detach gearshift cable bracket (1) from transmission
•   Unscrew 2x bolts (2)
Object Number: 10679255  Size: DEFAULT


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)
Object Number: 10679256  Size: DEFAULT


Object Number: 2415294  Size: DEFAULT

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

Important:   Torque converter must remain in the transmission
37.   Remove gearbox
•   Attach holding ropes
•   Hitch gearbox up to workshop crane
•   Unscrew bolt
Note:   Ensure that attached parts and wiring harnesses are undamaged

  Install

38.   Measure resistance, torque converter in the transmission
•   Measure with measuring device (1)
Distance: approx. 12 mm
Object Number: 2395887  Size: DEFAULT


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
Object Number: 3447282  Size: DEFAULT


41.   Cut thread (arrows) in the torque converter
Object Number: 2397627  Size: DEFAULT


42.   Install gearbox
•   Hitch gearbox up to workshop crane
•   Attach transmission to engine
•   Screw in bolt
•   Unhitch workshop crane
•   Remove holding ropes
43.   Attach transmission to engine
•   Attach transmission to cylinder block
Tighten 4 bolts 60 Nm
•   Attach transmission to oil pan
Tighten 3x bolt 40 Nm
44.   Attach torque converter to drive disc
•   Tighten 3x bolts
Note:   Insert bolts with locking compound

Insert bolts in two stages
20 Nm
45 Nm + 30°
•   Install covers
45.   Hitch engine up to workshop crane.
•   Attach holding ropes to engine transport shackles
46.   Detach engine from engine overhaul stand KM-412-A
Note:   2 mechanics required
•   Raise engine carefully
47.   Attach rear engine damping block, front axle body
•   Tighten screwed joint 55 Nm
Use new nuts
48.   Attach front engine damping block to front axle body
•   Tighten screwed joint 55 Nm
Use new nuts
49.   Detach KM-412-31-1 and KM-412-31-2 from cylinder block
•   Unscrew 6x bolts
50.   Attach alternator
•   Tighten 2x bolt 35 Nm
51.   Fit starter
•   Tighten 2x bolt 25 Nm
•   Clip in wiring harness plug for oxygen sensor of catalytic converter control to bracket
52.   Attach starter wiring harness
•   Tighten 2x nuts
•   Install earth cable
Tighten nut, clip in 2x
53.   Connect alternator wiring harness
•   Tighten 2x nuts
54.   Attach intake manifold bracket
•   Tighten 2x bolt 8 Nm
•   Clip wiring harness plug into bracket
•   Connect wiring harness plug for catalytic converter control oxygen sensor
55.   Clean sealing surface
56.   Replace 4x coolant pipe seal ring
•   Remove 2x coolant pipe from oil filter housing
•   Insert 2x coolant pipe in oil filter housing
57.   Attach oil filter housing
•   Tighten 4x bolt 25 Nm
•   Insert 3x new gasket
•   O-rings with silicone grease
58.   Attach coolant pipe to coolant module
•   Draw coolant pipe out of oil filter housing
•   Attach coolant pipe to oil filter housing
Tighten bolt 25 Nm
59.   Attach coolant pipe to coolant module
•   Draw coolant pipe out of oil pump housing
•   Tighten 2x bolts
60.   Detach coolant pipe, oil filter housing to thermostat housing
•   Replace 2x gaskets
•   Push into oil filter housing
•   Attach to thermostat housing
Tighten 2x bolt 8 Nm
61.   Attach compressor
•   Tighten 3x bolt 22 Nm
62.   Clean sealing surface
63.   Attach exhaust manifold with catalytic converter
•   Use new gasket
•   Tighten 9x new nut 20 Nm
•   Attach bracket to cylinder block
Tighten 2x bolt 20 Nm
64.   Attach heat shield
•   Tighten 3x bolt 8 Nm
65.   Attach wiring harness plug of catalytic converter control oxygen sensor
•   Fix wiring harness plug
•   Clip in
Note:   Be careful of wiring harness bracket
66.   Attach dipstick guide tube
•   Use new gasket
•   Insert guide tube into oil pan
•   Tighten bolt 8 Nm
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
Object Number: 2417920  Size: DEFAULT


68.   Fit right-hand axle body
•   Attach new circlip to axle body
•   Lubricate teeth and bearing points with engine oil
•   Push axle body into gearbox until circlip engages
69.   Place cooling module in position
70.   Attach oil cooling lines to transmission
Note:   Observe correct assignment.
•   Use 2x new O ring (1)
Object Number: 2397605  Size: DEFAULT


71.   Connect 3x wiring harness plugs
•   Temperature sensor, radiator
•   Compressor
•   Manometric switch, condenser
Attach wiring harness
72.   Attach refrigerant line to compressor
•   Use new gasket
•   Tighten bolt 20 Nm
73.   Attach lower radiator hose to radiator
•   Fasten clamp
Clip into bracket
74.   Attach upper radiator hose to thermostat
•   Fasten clamp
75.   Attach coolant return hose, throttle valve pre-heating to coolant expansion tank
•   Fasten clamp
•   Clip into bracket
76.   Check and correct transmission fluid level LUREF_1.gif

J Engine and Engine Aggregates > DOHC Petrol Engine > General > Repair Instructions > Remove and install automatic transmission with torque converter from engine

[PREV PAGE] [NEXT PAGE]