Vauxhall Workshop Service and Repair Manuals

Transmission, Remove and Install (Z18XER/A18XER - AF17)

Note:   In order to ensure that the drive unit is correctly aligned when the bolts for the left engine damping block are slackened, the drive unit must be aligned with the front axle body using KM-6001-B . Instructions for attaching KM-6001-B are given in the following.

  Remove

1.	Remove battery and battery support

2.	Remove lower engine compartment cover Note:   If present.

4.   Attach KM-6001-B to front axle body •   Release 2x bolt (arrows) for adjustment rails on KM-6001-B (1) •   Insert KM-6001-B as shown Note:   2x journals (2) and (5) must sit flush in the guide holes of the front axle body. •   Tighten 2x bolt for adjustment rails •   Twist up front support bearing (4) – as far as the stop on the guide pin of the front engine damping block Note:   The guide pins must sit in the support bearings with no play. •   Twist up rear support bearing (3) – as far as the stop on the guide pin of the rear engine damping block bracket Note:   The guide pins must sit in the support bearings with no play.

5.   Release and disconnect wiring harness plug for selector lever position switch (2) •   Open lock in the direction of the arrow 6.   Release and disconnect wiring harness plug (3) for transmission wiring harness •   Open lock in the direction of the arrow 7.   Clip selector actuation cable from counterhold •   Open retaining clamp (1) •   Detach selector actuation cable (4) from actuation lever.

8.   Detach selector actuation cable bracket •   Unscrew 2x bolt (1) 9.   Remove fluid filler tube (2) with dipstick •   Unscrew nut

10.   Release transmission at top •   Unscrew 3x bolt (1)

12.	Remove 2x axle shaft from transmission Note:   Place collecting pan underneath - transmission fluid escapes. Axle shafts remain in the wheel hubs. Attach axle shafts to underbody. •   Seal 2x apertures in transmission with plugs

13.   Detach converter from drive disc •   Remove 2x sealing plugs •   Lock drive disc with KM-911 (2) •   Unscrew 3x bolt (1) Note:   Turn drive disc by a further 120° each time.

14.   Detach 2x fluid cooler line (1) from transmission Note:   Place collecting pan underneath - transmission fluid will escape Note allocation of the fluid cooler lines. •   Detach 2x retaining clamp (2) •   Seal apertures in transmission with KM-924 15.   Detach front engine damping block •   Unscrew 2x bolt (3)

16.   Detach wiring harness bracket •   Unscrew bolt (1) 17.   Detach rear engine damping block •   Unscrew 3x bolt (2)

19.   Detach left engine damping block from engine damping block bracket •   Unscrew 3x bolt (1)

21.   Detach transmission from oil pan •   Unscrew 3x M10 bolts (1) •   Unscrew M10 bolt connection (2)

22.   Place transmission holder DT-47648 on KM-904 and preinstall as shown in the illustration: Component Position on base plate Designation DT-47648-2 (4) 2 Converter housing support DT-47648-3 (2) 14 Transmission housing support DT-47648-5 left (1) A Support with rear transmission swivel arm DT-47648-5 right (3) F Support with front transmission swivel arm

Important:   It is essential to follow the manufacturer's instructions for transmission holder DT-47648 . 23.   Attach transmission holder DT-47648 to transmission Note:   Before placing in position slacken all bolt connections of the swivel arms and supports as far as the base plate. Adjust the supports for the converter housing and transmission housing using the spindles until they are as low as possible. •   Align transmission holder DT-47648 under transmission •   Attach 2x swivel arms (1) to transmission •   Tighten the bolt connections of the swivel arms, starting from the transmission and going as far as the base plate Note:   Align the swivel arms so that as little leverage as possible is created. •   Position supports for converter housing and transmission housing on transmission – Twist up the spindles (2) •   Tighten bolt connections of the supports

Important:   Ensure that the converter remains in the transmission. Do not damage wiring harnesses and attaching parts 24.   Remove transmission •   Unscrew 2x M12 bolts (1) •   Press transmission off engine and slowly lower the hydraulic jack

25.   Secure torque converter so it does not fall out •   Attach KM-6388 (1)

  Install

28.   If required: attach transmission to transmission holder DT-47648 Note:   It is important that the manufacturer's instructions for DT-47648 are followed. Before installing the transmission: thinly coat the centring seat (arrow) for the converter in the crankshaft with grease. When replacing the transmission, ensure that the two guide bushings (1) sit in the engine flange. 29.   Check converter centring journal (3) for fretting •   Clean if necessary 30.   Measure the distance between the converter connecting threads and the mating surface of the transmission housing with a calliper gauge (2) •   Distance: approx 12 mm

31.   Recut thread (arrows) in converter

33.   Raise transmission with hydraulic jack and transmission holder DT-47648 and align it •   Place transmission so that it is in even contact with the engine Note:   Ensure it is seated perfectly. Do not damage wiring harnesses and attaching parts 34.   Fasten transmission to engine with 2x bolts •   Tighten 2x M12 bolts (1) 60 Nm 35.   Detach transmission holder DT-47648 from transmission •   Unscrew 2x bolt •   Lower hydraulic jack with transmission holder DT-47648 and extend

36.   Fasten transmission at the bottom •   Install transmission on fluid sump – Tighten 3x M10 bolts (1) 40 Nm •   Tighten bolt connection (2) 40 Nm

37.   Attach converter to drive disc •   Lock drive disc with KM-911 (2) •   Tighten 3x bolt (1) Note:   Insert bolts with retaining compound Turn drive disc by a further 120° each time. – Stage 1: tighten 3x bolts evenly to 20 Nm – Stage 2: Tighten 3x bolts to 45 Nm +20° +25° •   Remove KM-911 38.   Attach 2x covers to transmission

39.   Attach engine damping block to transmission at front •   Tighten 2x bolt (1) 80 Nm

40.   Attach rear engine damping block to transmission •   Tighten 3x bolt (2) 80 Nm 41.   Attach wiring harness bracket •   Tighten bolt (1)

42.	Install axle shafts in transmission

43.   Attach oil cooler lines to transmission Note:   Note allocations. •   Use 2x new O-ring (1) Note:   Fluid cooler lines must be heard to engage.

45.   Attach left engine damping block to engine damping block bracket •   Screw in 3x bolt (1) Note:   Do not tighten the 3 bolts yet. Important:   When installing the front axle body, ensure that the support bearings with KM-6001-B sit properly in the guide pin of the front engine damping block and the rear engine damping block bracket. If necessary: correct installation position of engine and transmission using MKM-883-1 . 46.   Install front axle body Note:   Do not yet install front exhaust pipe, catalytic converter, centre muffler, battery support and battery. 47.   Fasten left engine damping block •   Tighten 3x bolt (1) 55 Nm

48.   Fasten transmission at top •   Tighten 3x bolt (1) 60 Nm

49.   Attach selector actuation cable bracket •   Tighten 2x bolt (1) 20 Nm 50.   Install fluid filler tube (2) with dipstick Note:   Use new seal ring •   Tighten nut

51.   Connect transmission venting hose (3) Note:   Check that the bleeder hose is correctly routed and clipped in (1). The free end of the bleeder hose (2) must be laid at least 10 cm lower.

55.	Install battery support and battery

58.	Attach lower engine compartment cover Note:   If present.

59.	Check transmission fluid level

60.	Adjust selector actuation cable