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Vauxhall Workshop Service and Repair Manuals

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Remove and install converter (AF13-II) > < Replace winter program pushbutton switch (AF13-II)

Corsa D

Transmission, Remove and Install (AF13-II)

  Remove

1.   Remove front axle body
2.   Drain off transmission fluid
•   Unscrew fluid drain bolt (1)
•   Catch fluid in suitable container
•   Tighten new fluid drain bolt with new seal ring 40 Nm
3.   Detach 2 covers (2) from transmission
Object Number: 10679611 Size: DEFAULT


4.   Remove axle shafts from transmission LUREF_1.gif
•   Attach axle shafts to vehicle underbody
5.   Detach converter from drive disk
•   Lock drive disk with KM-911 (2)
•   Unscrew 3x bolts (1)
Note:   Rotate drive disk another 120°.
Object Number: 10679612 Size: DEFAULT


6.   Remove rear engine damping block bracket (2)
•   Unscrew 3x bolts (1)
Object Number: 10679613 Size: DEFAULT


7.   Control unit - remove electronic gear shifting LUREF_1.gif
8.   Control unit bracket - remove electronic gear shifting LUREF_1.gif
9.   Remove battery tray
10.   Release and disconnect selector lever position switch wiring harness plug (3)
11.   Remove wiring harness bracket
•   Unscrew bolt (4)
•   Unclip wiring harness (1)
12.   Detach selector lever actuation cable (2)
•   Remove actuation cable from counterhold (7)
– Pull sleeve (6) back and remove actuation cable upward from bracket
•   Press lever actuation cable (5) off selector lever position switch
Object Number: 10679614 Size: DEFAULT


13.   Remove engine/transmission control wiring harness
•   Release wiring harness plug (2) and disconnect
•   Unclip wiring harness from bracket (3)
14.   Pull off transmission vent hose (1)
Object Number: 10679615 Size: DEFAULT


15.   Remove coolant expansion tank
•   Unscrew bolt (1)
•   Unclip tank and lay aside
Object Number: 10679627 Size: DEFAULT


16.   Remove oil dipstick
17.   Remove fluid filler tube (2)
•   Unscrew nut (1)
•   Remove fluid filler tube from transmission
•   Remove gasket (3)
Object Number: 10678065 Size: DEFAULT


18.   Detach fluid cooler from transmission
•   Unscrew 2 nuts (1)
•   Unscrew bolt (2)
Object Number: 10678068 Size: DEFAULT


19.   Release transmission at top
•   Remove earthing cable (2)
– Unscrew nut (1)
•   Unscrew 3x bolt (4)
– Remove wiring harness bracket (3)
Object Number: 10679616 Size: DEFAULT


20.   Attach engine hoist
21.   Detach 2 fluid cooler lines from transmission
Note:   Place collecting pan underneath.
•   Pull off 2 protective rings (1)
•   Prise off 2 retaining clamps (2)
Note:   Prise retaining clamp from quick-release connection with a small screwdriver
•   Pull off 2 fluid cooling lines
•   Place fluid cooler with fluid cooling lines aside and secure
Object Number: 10679617 Size: DEFAULT


22.   Remove the engine damping block to the left of the engine damping block retaining base (2)
•   Unscrew 2x bolts (1)
•   Lower engine and transmission by approximately 5 cm using EN 47649
Note:   Ensure that attached parts and wiring harnesses are not damaged.
Object Number: 10679618 Size: DEFAULT


23.   Release transmission at the bottom
•   Detach transmission from oil pan
– Unscrew 3 M10 bolts (1)
•   Unscrew screw connection (2)
Object Number: 10679619 Size: DEFAULT


Object Number: 10679390 Size: DEFAULT

24.   Place transmission fixture DT-47648 on KM-904 and assemble as shown in 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

Rear transmission support with pivot arm

DT-47648-5 right

(3)

F

Support with pivot arm, transmission, front

Important:   Pay strict attention to manufacturer's notice for transmission fixture DT-47648 .
25.   Attach transmission fixture DT-47648 to transmission
Note:   Loosen all screw connections of the pivot arms and supports to the base plate before placing under load. Rotate the supports for the converter housing and transmission housing as far down as possible by way of the spindles.
•   Align the transmission fixture DT-47648 beneath the transmission
•   Attach 2x swivel arm (1) to transmission
•   Tighten screw connections of the pivot arms from the transmission to the base plate
Note:   Align the pivot arms so that as a little lever force as possible is created.
•   Position the supports for the converter housing and transmission housing on the transmission
– Screw the spindles (2) upward
•   Tighten screw connections on the supports
Object Number: 10679620 Size: DEFAULT


Object Number: 10679621 Size: DEFAULT

Important:   Ensure that the converter remains in the transmission
26.   Removing transmission
•   Unscrew 2 M12 bolts (1)
•   Press the engine away from the transmission and slowly lower the hydraulic jack
Note:   Do not damage wiring harnesses and attaching parts

27.   Use KM-6388 (1) to secure torque converter so it does not fall
Object Number: 2406002 Size: DEFAULT


Important:   Do not damage attaching parts when laying transmission down.
28.   If necessary, detach the transmission from the transmission fixture DT-47648
29.   If transmission is being replaced:
•   Drain fluid cooler as much as possible
•   Blow out fluid cooler with air at low pressure
•   Blow out fluid cooling lines at connections in both directions with air at low pressure
•   Convert the attached parts

  Install

30.   If necessary, attach the transmission to the transmission fixture DT-47648
Note:   Pay strict attention to the manufacturer's notice for DT-47648 .

Before installing the transmission: Coat the centring pin (arrow) in the crankshaft thinly with grease. When replacing transmission, ensure that both guide bushings (1) sit in the engine flange.
31.   Check centring pin (3) of converter for frictional rust
•   Clean if necessary
32.   Measure distance between connecting threads of converter and mating surface of transmission housing with calliper gauge (2)
•   Spacing distance of AF13-II approx. 12 mm
33.   Tap 3 threads in converter
34.   Detach KM-6388
Object Number: 2410028 Size: DEFAULT


Object Number: 10679621 Size: DEFAULT

35.   Lift transmission with hydraulic jack and transmission fixture A DT-47648 and align
•   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
36.   Fasten transmission to engine using 2 bolts
•   Tighten 2 M12 bolts (1) 60 Nm
37.   Detach transmission fixture DT-47648 from transmission
•   Unscrew 2x bolts
•   Lower hydraulic jack with transmission fixture DT-47648 and remove

38.   Fasten transmission at the bottom
•   Install transmission on fluid sump
– Tighten 3 M10 bolts (1) 40 Nm
•   Tighten screw connection (2) 40 Nm
Object Number: 10679619 Size: DEFAULT


39.   Attach converter to drive disk
•   Lock drive disk with KM-911 (2)
•   Tighten 3 bolts (1)
Note:   Insert bolts with locking compound.

Rotate drive disk another 120°.
– Step 1: tighten 3 bolts uniformly with 20 Nm
– Step 2: tighten 3 bolts with 45 Nm + 20° + 25°
•   Remove KM-911
40.   Attach 2 covers to transmission
Object Number: 10679612 Size: DEFAULT


41.   Move engine and transmission into installation position with EN 47649
Note:   Do not damage wiring harnesses and attaching parts
42.   Attach the engine damping block on the left to the engine damping block retaining base (2)
•   Tighten 2 bolts (1) 80 Nm 45°
Object Number: 10679618 Size: DEFAULT


43.   Detach engine hoist
44.   Fasten transmission at the top
•   Tighten 3 bolts (4) 60 Nm
– Insert wiring harness bracket (3)
•   Attach earthing cable (2)
– Tighten nut (1)
Object Number: 10679616 Size: DEFAULT


45.   Install fluid filler tube (2)
•   Insert new seal ring (3) into fluid filler pipe with assembly grease
•   Push fluid filler tube into transmission until stop
•   Tighten nut (1) 20 Nm
46.   Insert oil dipstick
Object Number: 10678065 Size: DEFAULT


47.   Attach 2 fluid cooler lines to transmission
Note:   Use new seal rings.
•   Insert 2 retaining clamps (2)
•   Insert 2 fluid cooling lines
Note:   Ensure that the fluid cooling lines engage audibly.
•   Push on 2 protective rings (1)
Object Number: 10679617 Size: DEFAULT


48.   Install 2 axle shafts in transmission LUREF_1.gif
49.   Attach fluid cooler to transmission
•   Tighten 2 nuts (1) 20 Nm
•   Tighten bolt (2) 20 Nm
Object Number: 10678068 Size: DEFAULT


50.   Attach coolant expansion tank
•   Clip in tank
•   Tighten bolt (1)
Object Number: 10679627 Size: DEFAULT


51.   Attach engine/transmission control wiring harness
•   Clip wiring harness into bracket (3)
•   Connect and lock wiring harness plug (2)
52.   Push on transmission vent hose (1)
Object Number: 10679615 Size: DEFAULT


53.   Attach selector actuation cable (2)
•   Attach actuation cable to counterhold (7)
– Pull sleeve (6) back and insert actuation cable from above into bracket
•   Clip lever actuation cable (5) on selector lever position switch
Note:   Ensure that the cable engages audibly.
54.   Install wiring harness bracket
•   Tighten bolt (4)
•   Clip in wiring harness (1)
55.   Connect and lock selector lever position switch wiring harness plug (3)
56.   Adjust selector actuation cable LUREF_1.gif
Object Number: 10679614 Size: DEFAULT


57.   Install battery tray and battery LUREF_1.gif
58.   Control unit bracket - install electronic gear shifting LUREF_1.gif
59.   Control unit - install electronic gear shifting LUREF_1.gif
60.   Attach rear engine damping block bracket (2)
•   Tighten 3 new bolts (1) 80 Nm + 45°
Object Number: 10679613 Size: DEFAULT


61.   Install front axle body
62.   Transmission Fluid Level, Check and Correct LUREF_1.gif
63.   Program volatile memories

Remove and install converter (AF13-II) > < Replace winter program pushbutton switch (AF13-II)