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Repair Instructions - Off Vehicle > < Engine Oil Level Sensor Replacement

Astra J

Engine Replacement (Manual Transmission)

Special Tools

•  CH-904  Base Frame
•  CH–49289  Centering Frame
•  CH–49290  Engine Support Tool
•  EN–6015  Closure Plugs
•  EN–45059  Angle Meter

For equivalent regional tools, refer to Special Tools .

Removal Procedure

1. Position the vehicle on a lift and remove the key. The wheels should be in the straight-ahead position and the steering wheel should be locked in a straight ahead position.
2. Remove the lower intermediate steering shaft bolt. Refer to Intermediate Steering Shaft Replacement .
3. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .
4. Remove the engine control module. Refer to Engine Control Module Replacement .
5. Remove the battery tray. Refer to Battery Tray Replacement .
6. Remove the engine sight shield. Refer to Engine Sight Shield Replacement .
7. Remove the charge air cooler inlet and outlet air hose. Refer to Charge Air Cooler Inlet Air Hose Replacement and Charge Air Cooler Outlet Air Hose Replacement .

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8. Remove the windshield washer solvent container filler tube (1).

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9. Remove the front compartment fuse block cover (1).

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10. Remove the 3 front compartment fuse block bolts (1).
11. Remove the front compartment fuse block (2).

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12. Unclip the 3 wiring harness plugs (3).
13. Disconnect the wiring harness plug from the front compartment fuse block.

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14. Remove the 3 ground nuts (1) and put the 4 wiring harness (2) aside.

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15. Disconnect the 2 wiring harness plugs (1, 2).
16. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement .
17. Disconnect the air conditioning compressor and condenser hose from the air conditioning evaporator hose assembly. Refer to Air Conditioning Compressor and Condenser Hose Replacement .
18. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
19. Drain the transmission. Refer to Transmission Fluid Drain and Fill .
20. Remove both front wheels. Refer to Tire and Wheel Removal and Installation .
21. Remove the front bumper fascia. Refer to Front Bumper Fascia Replacement .
22. Remove the front compartment insulator. Refer to Front Compartment Insulator Replacement .
23. Remove the exhaust front pipe. Refer to Exhaust Front Pipe Replacement .
24. Drain the cooling system. Refer to Cooling System Draining and Filling .

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25. Remove the lower and upper condenser hose nuts and the lower and upper condenser hoses (1, 2).
26. Remove the upper stabilizer shaft link from the absorber on both sides. Refer to Stabilizer Shaft Link Replacement .
27. Remove the steering linkage outer tie rod from the steering knuckle on both sides. Refer to Steering Linkage Outer Tie Rod Replacement .
28. Remove the front lower control arm from the steering knuckle. Refer to Lower Control Arm Replacement .
29. Remove the front wheel shafts from the wheel hubs. Refer to Front Wheel Drive Shaft Replacement - Right Side and Front Wheel Drive Shaft Replacement - Left Side .

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30. Remove the wheel speed sensor wiring harness (2) from the frame on both sides.
31. Remove the wiring harness retainers (3) from the frame and the lower control arm.

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32. Remove the engine coolant air bleed hose (1) and the radiator surge tank engine hose (2) from the surge tank.
33. Unclip the transmission vent hose from the radiator surge tank.
34. Remove the heater inlet hose from the bulkhead. Refer to Heater Inlet Hose Replacement .
35. Remove the heater outlet hose from the bulkhead. Refer to Heater Outlet Hose Replacement .

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Warning: Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby.


Caution: Clean all fuel pipe connections and surrounding areas before disconnecting the fuel pipes to avoid contamination of the fuel system.

36. Disconnect the fuel feed pipe (2) from the fuel pump.
37. Disconnect the fuel return pipe (1).
38. Close all connections with EN-6015  plugs.
39. Remove the turbocharger wastegate actuator vacuum control solenoid valve hose from the solenoid valve. Refer to Turbocharger Wastegate Actuator Vacuum Control Solenoid Valve Hose Replacement .
40. Disconnect the turbocharger wastegate actuator vacuum control solenoid valve wiring harness plug.
41. Disconnect the negative pressure pipe from the power brake booster pump.
42. Remove the shift lever and the selector lever cable from the transmission. Refer to Manual Transmission Shift Lever and Selector Lever Cable Replacement .
43. Raise the vehicle. Refer to Lifting and Jacking the Vehicle .
44. Disconnect the 2 wiring harness plugs from the engine cooling fan.
45. Raise the vehicle.
46. Install the CH-49290  support tool. For the assembly use attached installation manual.
47. Remove the engine mount. Refer to Engine Mount Replacement .
48. Remove the transmission mount-left side. Refer to Transmission Mount Replacement - Left Side .

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Note:  The SPX installation manual is supplied with the special tool and is also available online from SPX directly. Go to www.spxtools-shop.com.
49. Assemble the CH-49290  support tool (1) according to the details provided in the SPX installation manual.
50. Support the CH-904  base frame on a jack.
51. Support the CH-49290  support tool on the CH-904  base frame.

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Note:  The SPX installation manual is supplied with the special tool and is also available online from SPX directly. Go to www.spxtools-shop.com.
52. Install the CH-49290  engine support tool (1) according to the details provided in the SPX installation manual.

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53. Remove and DISCARD the 3 engine mount bolts (2) from the engine mount (1) and the engine mount bracket (3).

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54. Remove and DISCARD the 3 transmission mount bolts (2) from the transmission mount (3) and the transmission mount bracket (1).

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Note:  The SPX installation manual is supplied with the special tool and is also available online from SPX directly. Go to www.spxtools-shop.com.
55. Assemble the CH-49289  centering frame (1) according to the details provided in the SPX installation manual.
56. Support the CH-904  base frame on a jack.
57. Support the CH-49289  centring frame on the CH-904  base frame.

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Note:  The SPX installation manual is supplied with the special tool and is also available online from SPX directly. Go to www.spxtools-shop.com.
58. Install the CH-49289  centering frame (1) according to the details provided in the SPX installation manual.

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Note:  Simplified graphic. Engine/transmission unit is fixed with engine support tool to suspension frame. Suspension frame is supported by centering adapter and underframe.
59. Remove the frame front bolts (1).
60. Remove the 2 rear frame bolts (3).
61. Remove the frame reinforcements (4).
62. Lower the frame (1) with the engine transmission unit from the vehicle.
63. Remove the right wheel drive shaft from the transmission. Refer to Front Wheel Drive Shaft Replacement - Right Side .
64. Remove the left wheel drive shaft from the transmission. Refer to Front Wheel Drive Shaft Replacement - Left Side .

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65. Loosen the radiator outlet hose clamp (1) and remove the radiator outlet hose (2) from the engine.

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66. Remove the radiator inlet hose clamp (3).
67. Remove the radiator inlet hose (2) from the radiator (1).
68. Remove the cooling module (1) from the frame.
69. Install suitable cable at the 3 engine lift brackets.
70. Install a suitable engine lifting device to the cable.
71. Extend the engine lifting device until the steel cables are slightly tensioned.
72. Remove the transmission front mount trough bolt. Refer to Transmission Front Mount Replacement .
73. Remove the transmission rear bracket mount to mount trough bolt. Refer to Transmission Mount Bracket Replacement - Rear
74. Put the engine transmission unit down on a wooden pallet.
75. Loosen the 8 transmission bolts and remove 6 of them. Refer to Transmission Replacement .

Note:  A second technician is required.
76. Remove the 2 remaining transmission bolts and the transmission.
77. Install the engine to a suitable engine stand.
78. Transfer parts as needed.

Installation Procedure

1. Remove the engine from the engine stand.
2. Put the engine down on a wooden pallet.

Note:  A second technician is required.
3. Install the transmission and hand tighten 2 transmission bolts.
4. Install and hand tighten 6 transmission bolts.
5. Tighten the 8 transmission bolts. Refer to Transmission Replacement .
6. Place the engine transmission unit into the front frame.
7. Install the transmission rear bracket mount to mount trough bolt. Refer to Transmission Mount Bracket Replacement - Rear .
8. Install the transmission front mount trough bolt. Refer to Transmission Front Mount Replacement .

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9. Remove the cable from the 3 engine lift brackets.
10. Install the cooling module (1) to the frame and fix it with safety belts.
11. Install the radiator inlet hose (2) to the radiator (1).
12. Reposition the radiator inlet hose clamp (3).

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13. Install the radiator outlet hose (2) to the engine and tighten the radiator outlet hose clamp (1).
14. Remove the safety belts from the engine cooling module.
15. Install the left wheel drive shaft to the transmission. Refer to Front Wheel Drive Shaft Replacement - Left Side .
16. Install the right wheel drive shaft to the transmission. Refer to Front Wheel Drive Shaft Replacement - Right Side .

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Note:  Positioning pins (1) of CH-49289  adapter MUST be extended in order to guide into underbody holes.

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Note:  A second technician is required.
18. Raise the frame (1) with the engine transmission unit to the vehicle.
19. Install the frame reinforcements (4).
20. Install the 2 front frame bolts (2). Hand tighten ONLY.
21. Install the 2 reinforcement bolts. Hand tighten ONLY.

Caution: Refer to Fastener Caution .
22. Tighten the rear frame bolts (3) to 160 N·m (118 lb ft) .
23. Tighten the front frame bolts (2) to 160 N·m (118 lb ft) .

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24. Lower the CH-49289  centring frame (1) with CH-904  base frame and a jack.
25. Remove the CH-49289  centring frame from the CH-904  base frame.

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Note:  The SPX installation manual is supplied with the special tool and is also available online from SPX directly. Go to www.spxtools-shop.com.
26. Disassemble the CH-49289  centering frame (1) according to the details provided in the SPX installation manual.

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27. Install the 3 NEW transmission mount bolts (2) to the transmission mount (3) and the transmission mount bracket (1) and tighten in a first pass to 50 N·m (46 lb ft) .
28. Tighten the transmission mount bolts a final pass to an additional 60 - 75 degree , using the EN–45059  meter.

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29. Install the 3 engine mount bolts (2) to the engine mount (1) and the engine mount bracket (3) and tighten in a first pass to 50 N·m (46 lb ft) .
30. Tighten the engine mount bolts a final pass to an additional 60 - 75 degrees , using the EN–45059  meter.

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31. Lower the CH-49290  support tool (1) with CH-904  base frame and a jack.
32. Remove the CH-49290  support tool from the CH-904  base frame.

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Note:  The SPX installation manual is supplied with the special tool and is also available online from SPX directly. Go to www.spxtools-shop.com.
33. Disassemble the CH-49290  support tool (1) according to the details provided in the SPX installation manual.
34. Connect the 2 wiring harness plugs to the engine cooling fan.
35. Lower the vehicle by its half height. Refer to Lifting and Jacking the Vehicle .
36. Install the transmission shift lever and the selector lever cable. Refer to Manual Transmission Shift Lever and Selector Lever Cable Replacement .
37. Connect the negative pressure pipe to the power brake booster pump.
38. Connect the turbocharger wastegate actuator vacuum control solenoid valve wiring harness plug.
39. Install the turbocharger wastegate actuator vacuum control solenoid valve hose to the solenoid valve. Refer to Turbocharger Wastegate Actuator Vacuum Control Solenoid Valve Hose Replacement .

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Warning: Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby.


Caution: Clean all fuel pipe connections and surrounding areas before disconnecting the fuel pipes to avoid contamination of the fuel system.

40. Remove the EN-6015  plugs from all connections.
41. Connect the fuel feed pipe (2) to the fuel pump.
42. Connect the fuel return pipe (1).
43. Install the heater outlet hose to the bulkhead. Refer to Heater Outlet Hose Replacement .
44. Install the heater inlet hose to the bulkhead. Refer to Heater Inlet Hose Replacement .

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45. Clip the transmission vent hose into the radiator surge tank.
46. Install the engine coolant air bleed hose (1) and the radiator surge tank engine hose (2) to the surge tank.

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47. Install the wiring harness retainers (3) to the frame and the lower control arm.
48. Install the wheel speed sensor wiring harness (2) to the frame on both sides.
49. Install the front wheel shafts to the wheel hubs. Refer to Front Wheel Drive Shaft Replacement - Right Side and Front Wheel Drive Shaft Replacement - Left Side .
50. Install the front lower control arm to the steering knuckle. Refer to Lower Control Arm Replacement .
51. Install the steering linkage outer tie rod to the steering knuckle on both sides. Refer to Steering Linkage Outer Tie Rod Replacement .
52. Install the upper stabilizer shaft link to the absorber on both sides. Refer to Stabilizer Shaft Link Replacement .

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Note:  Use a NEW O-ring seal.
53. Install the lower and upper condenser hoses (1, 2).
54. Install the lower and upper condenser hose nut and tighten to 19 N·m (14 lb ft) .
55. Install the exhaust front pipe. Refer to Exhaust Front Pipe Replacement .
56. Install the front compartment insulator. Refer to Front Compartment Insulator Replacement .
57. Install the front bumper fascia. Refer to Front Bumper Fascia Replacement .
58. Install both front wheels. Refer to Tire and Wheel Removal and Installation .
59. Lower the vehicle.
60. Connect the air conditioning compressor and condenser hose to the air conditioning evaporator hose assembly. Refer to Air Conditioning Compressor and Condenser Hose Replacement .
61. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement .

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62. Connect the 2 wiring harness plugs (1, 2).

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63. Instal the 4 wiring harness (2) and tighten the 3 ground nuts to 9 N·m (80 lb in) .

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64. Connect the wiring harness plugs to the front compartment fuse block.
65. Clip in the 3 wiring harness plugs (3).

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66. Install the front compartment fuse block (2).
  Install the 3 front compartment fuse block bolts (1) and tighten to 22 N·m (16 lb ft) .

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67. Install the front compartment fuse block cover (1).

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68. Remove the windshield washer solvent container filler tube (1).
69. Install the charge air cooler inlet and outlet air hose. Refer to Charge Air Cooler Inlet Air Hose Replacement and Charge Air Cooler Outlet Air Hose Replacement .
70. Install the engine sight shield. Refer to Engine Sight Shield Replacement .
71. Fill the transmission. Refer to Transmission Fluid Drain and Fill .
72. Install the battery tray. Refer to Battery Tray Replacement .
73. Install engine control module. Refer to Engine Control Module Replacement .
74. Recharge the refrigerant. Refer to Refrigerant Recovery and Recharging .
75. Install the lower intermediate steering shaft bolt. Refer to Intermediate Steering Shaft Replacement .
76. Refill the cooling system. Refer to Cooling System Draining and Filling .

Repair Instructions - Off Vehicle > < Engine Oil Level Sensor Replacement