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MTA-Manual Transmission, Remove from Engine and Install > < Engine, Remove and Install

Astra H

Manual Transmission, Remove from Engine and Install

  Remove

1.   Detach cooling module
•   Remove coolant hose (2) from thermostat housing
– Release clamp
•   Remove coolant hose (1) from coolant pump
– Release clamp
•   Remove coolant hose from coolant compensation tank
– Release clamp
•   Lift away from front axle body
Object Number: 3446254 Size: DEFAULT


2.   Detach shift guide
•   Disconnect universal joint
– Remove retaining pin (1)
•   Unscrew 3x bolts (2)
Object Number: 2411024 Size: DEFAULT


3.   Remove drive shafts
•   Knock out with KM-6003-1 in conjunction with KM-313
•   Seal transmission
Object Number: 2411026 Size: DEFAULT


4.   Detach oxygen sensor wiring harness plug
•   Unclip plug from bracket
•   Unclip wiring harness (2) from bracket
5.   Remove engine transport shackles (1)
•   Unscrew 2x bolts
6.   Release heat shield (4)
•   Unscrew 2x bolts (3)
Object Number: 3446265 Size: DEFAULT


7.   Remove oil dipstick guide tube (1)
•   Detach from exhaust manifold (3)
– Unscrew bolt (2)
•   Remove from cylinder block
Object Number: 3446266 Size: DEFAULT


8.   Remove exhaust manifold (2)
•   Unscrew 9x nuts (1)
Object Number: 3446296 Size: DEFAULT


9.   Attach KM-2358
•   to engine transport shackle on the transmission side, exhaust side
10.   Detach front engine damping block bracket (1) from transmission
•   Unscrew 2x bolts (2)
Object Number: 7360873 Size: DEFAULT


11.   Detach rear engine damping block bracket (1) from transmission
•   Unscrew 3x bolts (2)
Object Number: 7360874 Size: DEFAULT


12.   Lift engine with gearbox from front axle body
13.   Release transmission
•   Oil pan
– Unscrew 3x bolts (2)
•   crankshaft bearing bridge
– Unscrew 2x bolts (1)
•   Cylinder block
– Unscrew 3x bolts (3)
•   Remove wiring harness bracket
•   Loosen bolt (4)
Object Number: 2411048 Size: DEFAULT


14.   Detach transmission from engine
Note:   Use a second person
•   Unscrew bolt
15.   Attach engine to KM-412
•   Attach KM-412-18 to engine (1)
– Tighten 4x bolts
•   Attach engine to KM-412-18 (2) with KM-412
– Tighten 8x bolted connections
Object Number: 2399442 Size: DEFAULT


16.   Detach engine from KM-412
•   Detach KM-412-18 from KM-412
– Slacken 8x screwed connections
•   Remove KM-412-18 from engine
– Unscrew 4x bolts

  Install

17.   Attach transmission to engine
Note:   Use a second person
•   Screw in bolt
18.   Fasten transmission to engine
•   On cylinder block
– Tighten 3x bolt 60 Nm
•   To cylinder block base plate
– Tighten 2x bolt 60 Nm
•   To oil pan
– Tighten 3x bolt 40 Nm
19.   Fit engine to front axle body
•   Position engine with transmission on front axle body
•   Attach front engine damping block bracket to transmission
– Screw in 2x bolts!
•   Attach rear engine damping block bracket to transmission
– Screw in 2x new bolts
20.   Fasten engine to front axle body
•   Fasten front engine damping block bracket to transmission
– Tighten 2x bolt 95 Nm
•   Fasten rear engine damping block bracket to transmission
– Tighten 2x bolt 80 Nm + 45° to 60°
21.   Remove KM-2358
•   from engine transport shackle on the transmission side, exhaust side
22.   Insert exhaust manifold gasket
23.   Install exhaust manifold
•   Tighten 9x nut 15 Nm (2 passes)
24.   Install heat shield
•   Screw in 2x bolts
25.   Install dipstick guide tube
•   Use new seal rings
– 2 off
•   Tighten bolt
26.   Fasten heat shield
•   Tighten 2x bolts
27.   Attach engine transport shackle
•   Tighten 2x bolt 20 Nm
28.   Connect oxygen sensor wiring harness plug
•   Clip wiring harness plug into bracket
•   Clip wiring harness into bracket
29.   Attach dipstick guide tube
•   Replace sealing ring
•   Tighten bolt
30.   Install drive shafts
•   Replace 2x retainers
•   Remove 2x transmission seals
•   Insert 2x drive shaft
31.   Install shift guide
•   Connect universal joint
– Install retaining pin
•   Tighten 3x bolts
32.   Attach cooling module
•   Position on front axle body
•   Attach coolant hose to coolant pump
– Fasten clamp
•   Attach coolant hose to thermostat housing.
– Fasten clamp
•   Attach coolant hose to coolant expansion tank
– Fasten clamp

MTA-Manual Transmission, Remove from Engine and Install > < Engine, Remove and Install