vauxhall Workshop Repair Guides

Vauxhall Workshop Service and Repair Manuals

ABOUT US
Remove and install automatic transmission with torque converter from engine > < Check engine for leaks

Astra H

Engine, Remove and Install

  Remove

1.   Open bonnet
Important:   Move steering wheel to straight-ahead position
2.   Remove steering column interim spindle
•   Engage steering wheel lock
•   Unscrew bolt (1)
Object Number: 3446122 Size: DEFAULT


3.   Disconnect battery
•   Detach ground connection from ground terminal
– Slacken nut
4.   Remove engine cover
5.   Detach radiator grille (2)
•   Detach 4x body-bound rivets (1)
•   Release 6x lugs from front panelling
Object Number: 8230656 Size: DEFAULT


6.   Detach front panelling at top
•   Unscrew 2x bolts (1)
•   Remove 2x body-bound rivets (2)
•   Disconnect wiring harness connector.
Object Number: 8230657 Size: DEFAULT


7.   Empty climate control system
•   Connect service station
•   Blue hose to low-pressure service connection with small diameter
•   Red hose to high-pressure service connection with large diameter
Note:   Read Service Station operating instructions carefully
•   Determine quantity of condenser extracted at the oil separator of the Service Station
Object Number: 3446584 Size: DEFAULT


8.   Undo 2x front wheels
•   Slacken 10x wheel bolts
9.   Raise vehicle by half its height
10.   Remove 2x front wheels
•   Unscrew 10x wheel bolts
11.   Remove front panelling
•   Remove 6x body-bound rivets (2)
•   Unscrew 4x bolts (1)
Object Number: 8230658 Size: DEFAULT


12.   Remove front panelling
Note:   Use a second person
•   Push front panelling upwards at side and pull out of bracket
•   Detach front panelling from bracket
– Unclip 4x clips
•   Unclip outside temperature sensor
13.   Raise vehicle by half its height
14.   Detach the lower engine cover and right engine splash guard
15.   Place collecting basin underneath.
16.   Drain coolant
•   Open drain bolt on radiator (1)
•   Collect coolant
•   Close drain bolt
Object Number: 3446550 Size: DEFAULT


Important:   Protect the exhaust pipe from uncontrolled sagging as deflection as little as 5-10 degrees from the prescribed installation position could damage the flex pipe housed within it.
17.   Remove front exhaust pipe (1)
•   Detach from particle filter flange
– Unscrew 3x nut
•   Detach from pre-catalytic converter
– Unscrew 3x nut
•   Detach from oil pan
– Unscrew 2x nuts
Object Number: 8230474 Size: DEFAULT


18.   Fit and adjust KM-6397
•   Fit KM-6397
– Insert upper bracket (2) with support plate below lower oil pan
– Attach lower bracket (3)
– Tighten 2x bolts (1)
•   Adjust KM-6397
– Screw in 2x adjusting bolts (4)
Note:   Support plate (5) must lie flat against oil pan
Object Number: 7360962 Size: DEFAULT


Object Number: 7361595 Size: DEFAULT

19.   Fit KM-6001-A
Note:   Attaching KM-6001-A guarantees perfect alignment of the drive unit with the front axle body
•   Detach front right bracket (1)
•   Insert KM-6001-A
•   Attach front right bracket
•   Insert journals (4) and (5) in guide holes in front axle body
•   Tighten 2x guide rails
– Tighten 3x bolted connections
•   Adjust support bearings (2) and (3)
Note:   The guide journals must be seated free from play in the support bearings

20.   Lower vehicle by its full height
21.   Remove battery
•   Detach positive terminal (3) from positive pole
– Slacken nut
•   Remove bracket 1)
– Unscrew bolt (2)
•   Remove battery insulation
Object Number: 7360933 Size: DEFAULT


22.   Remove battery support.
•   Remove pre-glow system control unit (4)
•   Unclip coolant hose bracket (5)
•   Detach wiring harness
– Undo cable tie (1)
– Unclip 2x brackets
•   Unscrew 3x bolts (2)
Object Number: 3446570 Size: DEFAULT


23.   Detach 3x coolant hose (1) from coolant expansion tank
•   Undo 3x clamps
Object Number: 3446572 Size: DEFAULT


24.   Remove coolant expansion tank (1)
•   Pull from bracket in direction of arrow
Object Number: 3446575 Size: DEFAULT


25.   Disconnect steering wiring harness
•   Remove fuse carrier cover (1)
•   Detach positive cable (2) from fuse carrier
Note:   Mark installation position
– Unscrew nut
•   Disconnect wiring harness connector (3)
•   Detach earth cable from negative battery terminal
– Unscrew bolt
•   Expose wiring harness and put aside on drive unit
– Detach 2x cable ties
Object Number: 3446576 Size: DEFAULT


26.   Disconnect upper engine timing wiring harness
•   Detach positive cable (1) from fuse carrier
Note:   Mark installation position
– Unscrew nut
•   Release and unplug wiring harness plug (2)
•   Unclip wiring harness
•   Put engine timing wiring harness with pre-heating system control unit (3) aside on drive unit
Object Number: 3446577 Size: DEFAULT


27.   Disconnect starter wiring harness (1)
•   Disconnect wiring harness connector (3)
•   Detach wiring harness from positive terminal
– Unscrew bolt
•   Detach earth connection wiring harness from body
– Unscrew nut (2)
•   Put wiring harness aside onto drive unit
Object Number: 7361596 Size: DEFAULT


28.   Detach selector lever actuation cable
•   Lever out head (3) from selector lever with KM-569-A (2)
•   Unclip cable (1) upward
Object Number: 8230651 Size: DEFAULT


29.   Disconnect 2x coolant hose (1) from heater core
•   Release 2x coolant hoses in direction of arrow
Note:   Mark affiliation
Object Number: 7361597 Size: DEFAULT


30.   Remove brake servo vacuum line
•   Disconnect quick-release fitting (2)
•   Unclip 2x line (1)
Object Number: 8230704 Size: DEFAULT


31.   Detach 2x fuel line from fuel return damping case
Note:   Open fuel connections must be sealed with appropriate plugs
•   Detach fuel return line (2) with KM-796-A
– Unclip fuel line from bracket
•   Detach fuel supply line (1) from high-pressure pump
– Release clamp
Object Number: 8231051 Size: DEFAULT


32.   Remove air cleaner housing
33.   Disconnect air conditioning low pressure line (1)
•   Unscrew bolt (2)
•   Unclip wiring harness of turbocharger solenoid valve from low pressure line
Object Number: 7361599 Size: DEFAULT


34.   Detach right engine damping block from engine damping block adapter
•   Unscrew 3x bolts (1)
Object Number: 7361601 Size: DEFAULT


35.   Detach left engine damping block from transmission
•   Unscrew 3x bolts (1)
Object Number: 8231052 Size: DEFAULT


36.   Raise vehicle by half its height
37.   Detach AC high pressure line (1) from pressure sensor
•   Unscrew bolt (2)
Object Number: 8231053 Size: DEFAULT


38.   Disconnect turbocharger solenoid valve (2)
•   Disconnect 2x vacuum lines (3)
Note:   Mark vacuum line
•   Disconnect wiring harness plug (1)
Object Number: 7360943 Size: DEFAULT


39.   Detach cooling module wiring harness
•   Unscrew nut (1)
•   Disconnect wiring harness plug (2)
•   Unfasten 3x cable ties
Object Number: 3446578 Size: DEFAULT


40.   Detach wiring harness from engine control unit
•   Release and unplug wiring harness plug (1) from engine control unit
•   Unclip wiring harness from bracket
•   Unclip 2x wiring harness from body
Object Number: 3446579 Size: DEFAULT


41.   Detach 2x swing arms (2)
•   Unscrew 2x nuts
– Use spanner (1) to hold against flat surface
42.   Detach 2x tie rods
•   2x nuts
– Use KM-161-B (3) to press out of steering knuckle
43.   Detach 2x steering knuckle pins
•   Detach 2x screw connections
•   Spread steering knuckle pins with KM-915 (4) and draw guiding joint out of steering knuckle
Object Number: 8230980 Size: DEFAULT


44.   Detach 2x axle shafts
•   Unscrew 2x nuts
– Counterhold at wheel hub with KM-468-B (1)
– Use 2x wheel bolts
Object Number: 2418002 Size: DEFAULT


45.   Raise vehicle by half its height
46.   Unplug wiring harness plug of particle filter temperature sensor (1)
•   Unclip wiring harness plug from bracket
•   Undo cable tie
•   Unclip wiring harness from front axle body bracket
Object Number: 8230692 Size: DEFAULT


47.   Release and unplug bulkhead wiring harness plug (1)
•   Unclip wiring harness
Object Number: 8231057 Size: DEFAULT


48.   Remove 2x underbody closure plug (1)
Object Number: 8231056 Size: DEFAULT


Object Number: 3446252 Size: DEFAULT

49.   Fit KM-904 in conjunction with KM-6390
•   Attach to hydraulic lifter
Note:   Use hydraulic jack that can be lowered to a height of at least 100 cm
•   Lower centring pins (1)
– Remove 2x splines
•   Place under front axle body, ensure there is no play
– Centring pins (2) must engage in the relevant holes in the front axle body

Object Number: 2397674 Size: DEFAULT

Important:   Do not use an impact screwdriver!
50.   Remove front axle body
•   Unscrew 10x bolts (1...4)
Note:   Note different bolt lengths

Important:   Ensure that no attached parts are damaged.
51.   Move out front axle body with engine
Note:   Use a second person
52.   Check thread
•   Check ease of movement of 10x cage nuts, replacing if necessary
Important:   Ensure that no attached parts are damaged.
53.   Raise and align front axle body
Note:   Use a second person
•   Insert centring pins in underbody

  Install

Important:   Do not use an impact screwdriver!
54.   Fit front axle body
•   Tighten 10x new bolt 90 Nm + 45° + 15°
Note:   Note different bolt lengths
55.   Detach KM-904 together with KM-6390
•   Lower hydraulic lifter
56.   Install 2x underbody closure plug
57.   Lower vehicle by its full height
58.   Attach right engine damping block to engine damping block adapter
•   Tighten 3x bolt 55 Nm
59.   Attach left engine damping block to transmission
•   Tighten 3x bolt 55 Nm
60.   Connect air conditioning low pressure line
•   Replace seal
•   Tighten bolt 22 Nm
•   Clip wiring harness of turbocharger solenoid valve to low pressure line
61.   Install air cleaner housing LUREF_1.gif
62.   Attach 2x fuel line to fuel return damping case
•   Remove closure plug
•   Attach fuel return line to high-pressure pump
– Fasten clamp
•   Attach fuel supply line
– Clip in line
Warning:   Connection must audibly engage
63.   Connect brake servo vacuum line
•   Clip in 2x lines
64.   Attach 2x coolant hoses to heater core
•   Slide 2x quick release fitting locking mechanisms in direction of arrow as far as they will go
– The plastic rings (blue) are hidden
•   Fit 2x quick release fittings onto heater core connecting piece (1) as far as they will go
Note:   Pay attention to coloured markings!
•   Slide 2x quick release fitting locking mechanisms (3) in direction of arrow as far as they will go
– The plastic rings (blue) must be visible
•   Check that quick release fittings are correctly seated and that plastic rings (arrows) are visible
Object Number: 3446293 Size: DEFAULT


Important:   Shift cables must not be stretched, twisted or kinked.
65.   Attach selector lever actuation cable
•   Clip in cable from above
•   Clip head into selector lever
66.   Connect starter wiring harness
•   Connect and lock wiring harness plug
•   Attach earth connection wiring harness to body
– Tighten nut
•   Attach wiring harness to positive terminal
– Tighten bolt 10 Nm
67.   Connect engine timing wiring harness (top)
•   Attach positive cable to fuse carrier
Note:   Pay attention to installation position.
– Tighten nut 4.5 Nm
•   Connect and lock wiring harness plug
•   Attach wiring harness
68.   Connect steering wiring harness
•   Clip in 2x cable ties
•   Fix wiring harness plug
•   Attach positive cable to fuse carrier
Note:   Pay attention to installation position
– Tighten nut 4.5 Nm
•   Attach earth cable to negative battery terminal
– Tighten bolt 10 Nm
•   Install fuse carrier cover
69.   Install coolant expansion tank
•   Insert into bracket
70.   Attach 3x coolant hose to coolant expansion tank
•   Attach 3x clamps
71.   Raise vehicle by half its height
72.   Install 2x axle shafts into wheel hub
•   Insert guiding joint into steering knuckle
•   Tighten 2x nut 150 Nm , slacken 45° , then tighten to 250 Nm
– Use new nuts
•   Counterhold at wheel hub with KM-468-B
– Use 2x wheel bolts
73.   Attach 2x guide joints to steering knuckle
•   Tighten 2x new screwed joint 50 Nm
74.   Attach 2x tie rods to steering knuckle
•   Tighten 2x new nut 30 Nm + 90° + 15°
75.   Attach 2x swing arms to spring strut support tube
Note:   Use spanner to counterhold against flat surface
•   Tighten 2x new nut 55 Nm
76.   Attach wiring harness to engine control unit
•   Connect wiring harness plug to control unit
•   Clip wiring harness into bracket
•   Clip in 2x wiring harness to body
77.   Attach cooling module wiring harness
•   Connect and lock wiring harness plug
•   Clip in 3x wiring harness brackets
•   Install ground cable
– Tighten nut
78.   Connect charge air control solenoid valve
•   Connect 2x vacuum lines
Note:   Pay attention to marks.
•   Fix wiring harness plug
79.   Attach AC high pressure line to pressure sensor
•   Use new seal
•   Tighten bolt 22 Nm
80.   Raise vehicle by half its height
81.   Remove KM-6001-A
82.   Remove KM-6397
83.   Connect wiring harness plug of particle filter temperature sensor
•   Clip wiring harness plug into bracket
•   Connect cable ties
•   Clip wiring harness into front axle body bracket
84.   Connect and lock bulkhead wiring harness plug
•   Attach wiring harness
85.   Install front exhaust pipe
Important:   Prevent exhaust system from sagging in an uncontrolled manner. Even flex pipe bending of 5 - 10 degrees from intended installation position can cause damage that may result in total failure of the flex pipe
•   Replace 2x seals
•   Attach to particle filter flange
– Tighten 3x new nut 20 Nm
•   Attach to pre-catalytic converter
– Tighten 3x new nut 20 Nm
•   Attach to oil pan
– Apply assembly paste (white)
– Tighten 2x new nuts
86.   Install lower engine cover and right engine splash guard
87.   Lower vehicle by half its height
88.   Install front panelling
Note:   Use a second person
•   Clip in outside temperature sensor
•   Attach front panelling to bracket
– Clip in 4x clips
•   Clip in the front panelling on the side
89.   Attach front panelling at bottom
•   Install 6x body-bound rivets
•   Tighten 4 bolts 2.5 Nm
90.   Fit 2x front wheels
•   Screw in 10x wheel bolts
91.   Lower vehicle by half its height
92.   Fasten 2x front wheels
•   Tighten 10x wheel bolt 110 Nm
93.   Attach front panelling at top
•   Fasten 2x body-bound rivets
•   Tighten 2x bolt 2.5 Nm
94.   Install battery holder
•   Tighten 3x bolt 15 Nm
•   Attach wiring harness
– Connect cable ties
– Clip on 2x brackets
•   Attach pre-glow system control device
•   Clip on coolant hose bracket
95.   Install battery
•   Install bracket
– Tighten bolt 7 Nm
•   Insert battery insulation
•   Attach positive connection to positive terminal
– Tighten nut
96.   Evacuate and charge air conditioning system
•   Connect service station
•   Connect blue hose to low pressure service connection with small diameter
•   Connect red hose to high pressure service connection with large diameter
Note:   Read Service Station operating instructions carefully.
•   Use the Service Station to insert the quantity of new compressor lubricant into the climate control system that was extracted when it was emptied.
– Fill air conditioning system with R 134a refrigerant
Object Number: 3446584 Size: DEFAULT


97.   Connect battery
•   Attach ground connection to ground terminal
•   Tighten nut
98.   Attach engine cover
99.   Install radiator grille
•   6x clip in front panelling
•   Install 4x body-bound rivets
100.   Install steering column intermediate shaft clamp bolt
•   Tighten new bolt 22 Nm
Note:   Clean thread before re-using and insert bolt with locking compound (blue). The maximum installation time including torque check is 10 minutes.
101.   Top up coolant or ensure correct quantity is present. LUREF_1.gif
102.   Program volatile memories
103.   Close bonnet

Remove and install automatic transmission with torque converter from engine > < Check engine for leaks