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Wheel Well > < Rear Frame Side Member, Right Side, Replace (Model L 08, L 48)

Astra H

Replace Front Complete

  Remove

Important:   Disconnect battery and wait 1 minute for the capacitor to discharge.
1.   Disconnect the battery
2.   Detach bonnet
3.   Detach radiator grille
4.   Remove front panelling
5.   Detach headlamps
6.   Detach impact absorber
7.   Remove washing water container
•   Disconnect windscreen washer pump wiring harness plug (1)
•   Detach windscreen wash system (2) from pump
•   Detach rear window wash system (3) from pump
•   Unclip 2x hose from guide
•   Unscrew 2x bolt (4) and (5)
Object Number: 3446910 Size: DEFAULT


8.   For vehicles with high-pressure headlamp wash system: disconnect pump wiring harness plug
9.   Detach impact absorber
10.   Detach right and left airbag sensors
•   Slacken 4x bolt (1)
•   Disconnect wiring harness plug.
•   Release cable tie
Object Number: 3446845 Size: DEFAULT


11.   Detach right and left radiator brackets
•   Unscrew 2x bolt (1)
Object Number: 3446911 Size: DEFAULT


12.   Remove small components from top right front
•   Remove 2x headlamp nut
•   Remove 2x bonnet buffer
13.   Remove bonnet closure (lock mechanism) LUREF_1.gif
14.   Detach air filter housing assembly
  • Z 14 XEL, Z 14 XEP
  • Z 16 XEP
  • Z 18 XE
  • Z 20 LEL
  • Z 17 DTL, Z 17 DTH
15.   Slacken resonator
•   Unscrew bolt
•   Pull tube from centre top front guide
16.   Remove top front
•   Unscrew 6x bolt (1) and (2) from centre top front
•   Remove resonator
•   Drill out 2x spot weld (I) and (II) at right top front
•   Unscrew 4 bolts (3) and (4) at right and left top front
Object Number: 3446914 Size: DEFAULT


  Install

17.   Install top front right and left
Note:   During production the top front is spot welded to the front frame longitudinal member and the wheel housing. These welds are not included in service repairs.
•   Unscrew 4x top bolt
18.   Fasten radiator bracket
•   Tighten 2x bolt
19.   Place resonator on radiator
20.   Attach centre top front
•   Screw in 6x bolt
21.   Adjust top front
Note:   Observe body dimension chart.
22.   Drill holes (1) at right and left side top front
Note:   Drill each hole through the wheel housing, side front and side member closure plate. Deburr and prime the holes.
•   Diameter - 8.5 mm
Object Number: 3446706 Size: DEFAULT


23.   Insert bolt (1) 90 568 791 into side top front on right and left and screw on nut (2) 90 538 128
Object Number: 3447564 Size: DEFAULT


24.   Tighten top front
•   Tighten 4x bolt for upper front on left and right of body 20 Nm
•   Tighten 2x bolt with 2x nut on upper front to the left and right sides 20 Nm
•   Tighten 6x bolt upper front centre 20 Nm
25.   Seal cavity
Note:   Observe corrosion protection measures for protective wax. Apply cavity sealing / protective wax to the mounting surfaces and connecting flanges.
26.   Fasten resonator
•   Slide tube into top front centre guide
•   Tighten bolt
27.   Install air filter housing assembly
  • Z 14 XEL, Z 14 XEP
  • Z 16 XEP
  • Z 18 XE
  • Z 20 LEL
  • Z 17 DTL, Z 17 DTH
28.   Install bonnet closure (lock mechanism) LUREF_1.gif
29.   Install top front right and left small components
•   Install 2x bonnet buffer
•   Install 2x headlamp nut
30.   Install right and left airbag sensors
•   Connect wiring harness plug
•   Fasten cable tie
•   Tighten 4x bolt
31.   Attach impact absorber
32.   Install wash water container
•   Tighten 2x bolt
•   Clip 2x hose into guide
•   Attach rear window wash system hose to pump
•   Attach front window wash system hose to pump
•   Connect windscreen washer pump wiring harness plug
33.   For vehicles with high-pressure headlamp wash system: connect pump wiring harness plug
34.   Attach impact absorber
35.   Install headlamps
36.   Attach front panelling
37.   Install radiator grille
Note:   For radiator grilles up to MY 07.5, speed nuts must be used on the front at the top and the radiator grille must be fastened with 4x bolts instead of 4x body-bound rivets.
38.   Attach bonnet
39.   Connect the battery
40.   Program volatile memory

Wheel Well > < Rear Frame Side Member, Right Side, Replace (Model L 08, L 48)