Astra L4-1.8L (2009)
2. Raise the front frame with hydraulic jack, KM-904 and KM-6390 .
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution).
Note:
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Ensure that the guide pins of KM-6390 are seated in the guide holes in the vehicle underbody.
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Ensure that the engine damping blocks front and rear are positioned perfectly.
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Be careful of the wiring harness for steering. Installing the front frame with an impulse screwdriver or impact screwdriver is not permitted.
Note the bolt lengths and washers. Tighten bolts evenly at all fastening points.
3. Align the front frame and tighten the 4 new bolts to 90 Nm (67 lb ft) plus 45 degrees plus 15 degrees.
4. Install the triangular plates and tighten the 6 new bolts to 90 Nm (67 lb ft) plus 45 degrees plus 15 degrees.
5. Detach the hydraulic jack, KM-904 and KM-6390 .
Note: Clean the thread and insert bolts with locking compound.
6. Install the bracket for rear engine damping block to the transmission and tighten to 80 Nm (59 lb ft).
7. Install front engine damping block to the front frame and tighten to 55 Nm (40 lb ft).
1. Insert the bolt.
2. Install the new nut.
8. In vehicles with manual transmission, install the shift guide to shift rod.
1. Slide onto the shift rod.
2. Install the clamping screw loosely.
3. Place rocker onto the shift guide bracket.
4. Secure using new retaining clip.
9. Install the front exhaust pipe, catalytic converter and center muffler. Refer to Mid Muffler Replacement (See: Engine, Cooling and
Exhaust/Exhaust System/Muffler/Service and Repair).
10. If present, install the lower engine compartment cover.
11. Connect the guide joint to the steering knuckle on the right and left side and tighten the 2 new nuts to 50 Nm (37 lb ft).
12. Connect the tie rod end to the steering knuckle. Refer to Steering Linkage Outer Tie Rod Replacement (See: Steering/Tie Rod/Service and
Repair/Steering Linkage Outer Tie Rod Replacement).
13. Install the swing arm to the spring strut support tube on the right and left side and tighten to 55 Nm (40 lb ft).
1. Use 2 new nuts.
2. Counterhold at the two flattened areas with open-ended wrench.
14. Install the right lower wheelhouse paneling and tighten to 5 Nm (44 lb in).
15. Install the front paneling. Refer to Front Bumper Fascia Replacement (See: Body and Frame/Bumper/Front Bumper/Front Bumper Cover /
Fascia/Service and Repair/Front Bumper Fascia Replacement).
16. Install the right and left engine splash guards.
17. Install the front wheels and tighten to 110 Nm (81 lb ft).
18. Disconnect MKM-883-1 and MKM-883-2 from the engine.
19. Connect the steering wiring harness.
20. Connect the ground connection to insulated ground terminal.
21. Connect the steering wiring harness plug.
22. Install the coolant expansion tank to bracket.
23. Install the upper engine cover.
1. Remove the oil filler cap.
2. Install the upper engine cover.
3. Install the 2 bolts and tighten to 8 Nm (71 lb in).
4. Install the oil filler cap.
