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Component Locator > < Remove and install transmission (AF40)

Astra H

Seal valve body cover (AF40)

  Remove

1.   Disconnect battery
2.   Remove air filter housing
3.   Detach radiator grille
4.   Drain air conditioning system LUREF_1.gif
Note:   Only for vehicles with air conditioning.
5.   Detach front panelling
6.   Remove lower engine compartment cover
7.   Place collecting pan underneath.
8.   Drain coolant.
•   Open radiator drain bolt (1)
•   Collect coolant
•   Close drain bolt
Object Number: 3446550 Size: DEFAULT


9.   Drain off transmission fluid
Note:   Place collecting pan underneath.
•   Unscrew fluid checking bolt (1)
•   Unscrew rising tube (2)
•   Tighten rising pipe 50 Nm
•   Tighten fluid checking bolt (1) 8 Nm
Object Number: 7360818 Size: DEFAULT


10.   Detach wiring harness from radiator
•   Disconnect wiring harness plug (1) of fan motor
– Detach cable ties
Object Number: 3446561 Size: DEFAULT


Object Number: 9007771 Size: DEFAULT

11.   Detach wiring harness of auxiliary fan motor (3)
Note:   Only for vehicles with air conditioning.
•   Release and disconnect wiring harness plug of auxiliary fan (1)
•   Detach 2 cable ties
•   Unclip 8 clips
•   Unclip 2 relays (2)
•   Release and disconnect wiring harness plug of pressure sensor (5)
•   Release AC compressor wiring harness plug and disconnect
Important:   Seal lines and connections after removal.
12.   Detach 2 refrigerant lines
Note:   Only for vehicles with air conditioning.
•   Remove 2x bolts (4)

13.   Detach refrigerant line (1) from radiator
Note:   Only for vehicles with air conditioning.
•   Open clip (4) and remove
14.   Detach compressor wiring harness (2) from radiator
Note:   Only for vehicles with air conditioning.
•   Release clip
15.   Detach right coolant hose (3) from radiator
•   Release clip
16.   Detach 2 vacuum lines (5) from radiator
•   Unclip from bracket
Object Number: 8125293 Size: DEFAULT


17.   Secure radiator at upper radiator bracket (1)
•   2x insert from rear using suitable tool
Object Number: 3446257 Size: DEFAULT


18.   Remove lower radiator bracket (1)
Note:   Note differing brackets.
•   Unscrew 4x bolt
Object Number: 2415997 Size: DEFAULT


19.   Detach upper fluid cooler line (2) from radiator
•   Pull off protective ring (1)
•   Release retaining clamp (4) with KM-J-41623-B (3)
Note:   Fit KM-J-41623-B on fluid cooler line, slide into connection through simultaneous turning and pressing, turn KM-J-41623-B until the retaining clamp opens.
•   Pull off fluid cooler line when retaining clamp is open
Object Number: 8326687 Size: DEFAULT


20.   Detach lower fluid cooler line (2) from radiator
Note:   Fluid escapes. Place pan underneath.
•   Pull off protective ring (1)
•   Release retaining clamp (4) with KM-J-41623-B (3)
Note:   Fit KM-J-41623-B on fluid cooler line, slide into connection through simultaneous turning and pressing, turn KM-J-41623-B until the retaining clamp opens.
•   Pull off fluid cooler line when retaining clamp is open
Object Number: 8326692 Size: DEFAULT


21.   Remove preheating control unit (1)
•   Pull preheating control unit from bracket in direction of arrow
•   Disconnect wiring harness plug
Object Number: 3446554 Size: DEFAULT


22.   Detach compensation tank coolant hose (2) from radiator
•   Release clip
23.   Detach left coolant hose (1) from radiator
•   Release clip
Object Number: 7360934 Size: DEFAULT


24.   Detach charge air hose (1) from charge air pipe
•   Release clip
Object Number: 7360935 Size: DEFAULT


25.   Detach charge air hose (1) from intercooler
•   Release clip
Object Number: 7360939 Size: DEFAULT


26.   Detach coolant hose (2) from fan housing
•   Unclip from clip (2)
Object Number: 8230480 Size: DEFAULT


27.   Remove cooling module
Note:   2nd mechanic required.
•   Remove 2 retainers from bracket
Object Number: 9007767 Size: DEFAULT

28.   Detach wiring harness bracket of engine control unit (2)
•   Unscrew bolt (1)
29.   Move engine control unit harness (3) up and secure.
30.   Remove fluid cooler line (5)
•   Unscrew nut (4)
•   Remove bracket (7) at front engine damping block
– Unscrew bolt (6)

31.   Undo valve body cover
•   Unscrew 11 bolts (arrows)
32.   Detach valve body cover
Note:   Release valve body cover by gently tapping with a plastic hammer. Be careful not to damage the housing.
Object Number: 9007591 Size: DEFAULT


Important:   The valve body must be removed in order to prevent contamination when cleaning the sealing surfaces.
33.   Remove valve body

  Install

34.   Clean sealing surface (1)
Note:   Completely remove sealing compound and oil residue. Do not damage the sealing surface.
35.   Clean 11 threads (arrows)
Object Number: 9007592 Size: DEFAULT


36.   Install valve body
37.   Attach valve body cover
Note:   Use a new valve body cover. Completely remove oil residue from the sealing surfaces.
•   Apply sealing compound (1) to a new valve body cover
Object Number: 9007593 Size: DEFAULT


38.   Fasten valve body cover
Note:   Do not damage the solenoid valve wiring harness.
•   Tighten 11x new bolts (arrows) 13 Nm
Object Number: 9007591 Size: DEFAULT


Object Number: 9007767 Size: DEFAULT

39.   Attach fluid cooler line (5)
•   Tighten nut (4) 7 Nm
•   Attach bracket (7) at front engine damping block
– Tighten bolt (6)
40.   Position engine control unit wiring harness (3) in its installation position
•   Remove retainer
41.   Attach wiring harness bracket of engine control unit (2)
•   Tighten bolt (1)

42.   Install cooling module
Note:   2nd mechanic required.
•   2x insert retainer in bracket
43.   Attach coolant hose (2) to fan housing
•   Clip into clip (2)
Object Number: 8230480 Size: DEFAULT


44.   Attach charge air hose (1) to intercooler
•   Fasten clamp
Object Number: 7360939 Size: DEFAULT


45.   Attach charge air hose (1) to charge air pipe
•   Fasten clamp
Object Number: 7360935 Size: DEFAULT


46.   Attach compensation tank coolant hose (2) to radiator
•   Fasten clamp
47.   Attach left coolant hose (1) to radiator
•   Fasten clamp
Object Number: 7360934 Size: DEFAULT


48.   Install preheating control unit
•   Insert preheating control unit in bracket
•   Connect wiring harness plug
49.   Attach lower fluid cooler line to radiator
Important:   The retaining clamp (1) must audibly engage. Note seal ring (2) in connection (3).
•   Insert fluid cooler line in connection
•   Fit protective ring (4)
Object Number: 8326693 Size: DEFAULT


50.   Attach upper fluid cooler line to radiator
Important:   The retaining clamp (1) must audibly engage. Note seal ring (2) in connection (3).
•   Insert fluid cooler line in connection
•   Fit protective ring (4)
Object Number: 8326694 Size: DEFAULT


51.   Install lower radiator bracket (1)
Note:   Note differing brackets.
•   Tighten 4x bolt 15 Nm
Object Number: 2415997 Size: DEFAULT


52.   Remove radiator retainer at upper radiator bracket (1)
Object Number: 3446257 Size: DEFAULT


53.   Attach right coolant hose (3) to radiator
•   Fasten clamp
54.   Attach 2 vacuum lines (5) to radiator
•   Clip into bracket
55.   Attach refrigerant line (1) to radiator
Note:   Only for vehicles with air conditioning.
•   Install and engage clip (4)
56.   Connect compressor wiring harness (2) to radiator
Note:   Only for vehicles with air conditioning.
•   Clip in clip
Object Number: 8125293 Size: DEFAULT


Object Number: 9007771 Size: DEFAULT

57.   Attach 2 refrigerant lines
Note:   Only for vehicles with air conditioning.
•   Tighten 2 bolts (4)
58.   Attach wiring harness of auxiliary fan motor (3)
Note:   Only for vehicles with air conditioning.
•   Connect and lock wiring harness plug of auxiliary fan (1)
•   Fasten 2 cable ties
•   Clip in 8 clips
•   Clip in 2 relays (2)
•   Connect and lock wiring harness plug of pressure sensor (5)
•   Connect and lock AC compressor wiring harness plug

59.   Connect wiring harness to radiator
•   Connect wiring harness plug (1) to fan motor
– Fasten cable tie
Object Number: 3446561 Size: DEFAULT


60.   Attach front panelling
61.   Fill air conditioning system LUREF_1.gif
Note:   Only for vehicles with air conditioning.
62.   Attach radiator grille
63.   Install air filter housing
64.   Fill coolant. Adjust level if necessary.
65.   Connect battery
66.   Fill up with transmission fluid
67.   Check and correct transmission fluid level LUREF_1.gif
68.   Install lower engine compartment cover
69.   Program volatile memories

Component Locator > < Remove and install transmission (AF40)