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Rear Multifunction Carrier Replacement - 5-Door Hatchback 68 > < Drivetrain and Front Suspension Frame Insulator Replacement

Astra J

Drivetrain and Front Suspension Frame Replacement

Special Tools

•  CH 904   Base Frame
•  CH 49289   Centering Frame
•  EN-45059   Angle Meter

For equivalent regional tools, refer to Special Tools .

Removal Procedure

1. Support the radiator and condenser from above using the condenser tabs on each side.

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Caution: With wheels of the vehicle facing straight ahead, secure the steering wheel utilizing steering column anti-rotation pin, steering column lock, or a strap to prevent rotation. Locking of the steering column will prevent damage and a possible malfunction of the SIR system. The steering wheel must be secured in position before disconnecting the following components:
    •  The steering column
    •  The intermediate shaft(s)
    •  The steering gear
After disconnecting these components, do not rotate the steering wheel or move the front tires and wheels. Failure to follow this procedure may cause the SIR coil assembly to become un-centered and cause possible damage to the SIR coil. If you think the SIR coil has became un-centered, refer to your specific SIR coil's centering procedure to re-center SIR Coil.

2. Remove and DISCARD the lower steering intermediate shaft bolt (1).
3. Detach the steering intermediate shaft from steering gear.
4. Raise the vehicle on a hoist. Refer to Lifting and Jacking the Vehicle .
5. Remove the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation .
6. Remove the exhaust front pipe. Refer to Exhaust Front Pipe Replacement .
7. Remove the front compartment splash shield. Refer to Front Compartment Splash Shield Replacement .
8. Remove the engine shield, if equipped. Refer to Engine Shield Replacement .
9. Remove the front compartment insulator, if equipped. Refer to Front Compartment Insulator Replacement .

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10. Remove the wheel speed sensor wiring harness (2) from the frame on both sides.
  Remove the wiring harness retainers (3) from the frame and the lower control arm.
11. Remove the radiator wiring harness (1) from the frame.
  Remove the wiring harness retainers (4) from the frame.

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12. If equipped with hydraulic power steering, remove the power steering fluid cooling pipe bolt (1), clip out (2) and securing the power steering fluid cooling pipe (3) to the vehicle.
13. Remove the lower ball joints from the steering knuckles. Refer to Lower Control Arm Replacement .

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14. Remove and DISCARD the stabilizer link nut (1) from the strut.
15. Remove the outer tie rods and tie rod nuts from the steering knuckles. Refer to Steering Linkage Outer Tie Rod Replacement .

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16. Remove the front (1) and the rear (2) transmission mount bracket bolts.

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17. If equipped with hydraulic power steering, remove the power steering gear inlet and outlet hose bolts (1). Remove the inlet and outlet hose (2) from the steering gear (3).

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18. If equipped with electronic power steering, carefully disconnect 2 wiring harness plugs (3) from the steering gear with a suitable tool. Use the following procedure to disconnect the 2 wiring harness plugs:
  18.1 Insert a small flat bladed tool into the pocket of the connector retention feature.
  18.2 Gently move the retention feature back and pull on the connector to disconnect the connector.
19. Loosen the front bumper energy absorber bracket bolt.

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Note:  The SPX installation manual is supplied with the special tool and is also available online from SPX directly. Go to www.spxtools-shop.com.
20. Assemble the CH-49289   centering frame (1) according to the details provided in the SPX installation manual.
21. Support the CH-904   base frame on a jack.
22. Support the CH-49289   centring frame on the CH-904   base frame .
23. Install the CH-49289   centring frame according to the details provided in the SPX installation manual.

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Note:  Positioning pins (2, 3) of CH-49289   centring frame MUST stick into holes of drivetrain frame.
24. Check if wheel alignment is required.
  Move out position pins (1) and try to insert into underbody holes.
  If guide pins can NOT be inserted, the Wheel Alignment Measurement is required after installation of the drivetrain frame.

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Note:  Simplified graphic. Suspension frame is supported by centering frame and base frame.
25. Remove the frame front bolts (1).
26. Remove the frame rear bolts (2).
27. Remove the frame reinforcements (3).
28. Remove the frame (4) from the vehicle.
29. Remove the following components if replacing the frame:
  •  The lower control arms-Refer to Lower Control Arm Replacement .
  •  The stabilizer shaft-Refer to Stabilizer Shaft Replacement .
  •  The radiator support brackets.
  •  The steering gear-Refer to Steering Gear Replacement .

Installation Procedure

1. Install the following components on the drivetrain and front suspension frame if removed:
  •  The radiator support brackets.
  •  The stabilizer shaft-Refer to Stabilizer Shaft Replacement .
  •  The lower control arms-Refer to Lower Control Arm Replacement .
  •  The steering gear-Refer to Steering Gear Replacement .

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Note:  Positioning pins (1) of CH-49289   centring frame MUST be extended in order to guide into underbody holes.

Note:  Simplified graphic. Suspension frame is supported by centering frame and base frame.
2. Raise the frame (4) carefully, using CH 49289   centring frame .
3. Install the frame reinforcements (3).

Caution: Refer to Fastener Caution .
4. Install the frame rear bolts (2) and tighten to 160 N·m (118 lb ft) .
5. Install the frame front bolts (1) and tighten to 160 N·m (118 lb ft) .

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Note:  The SPX installation manual is supplied with the special tool and is also available online from SPX directly. Go to www.spxtools-shop.com.
6. Lower the CH-49289   centring frame (1) with CH-904   base frame and a jack.
7. Remove the CH-49289   centring frame from the CH-904   base frame .
8. Disassemble the CH-49289   centering frame (1) according to the details provided in the SPX installation manual.

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9. Install and tighten 2 wiring harness bracket bolts (4) to 9 N·m (80 lb in) .
10. Tighten wiring harness retainer (1) to steering gear.
11. Connect 2 wiring harness plugs (3).
12. Install the front bumper energy absorber bracket bolt.

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13. Install the front transmission mount bolt (1) and tighten to 100 N·m (74 lb ft) .
14. Install the rear transmission mount bracket bolt (2) and tighten to 100 N·m (74 lb ft) .
15. Install the outer tie rods and tie rod nuts to the steering knuckles. Refer to Steering Linkage Outer Tie Rod Replacement .

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16. Install the NEW stabilizer link nut (1). Tighten the steering linkage tie rod nut to 65 N·m (48 lb ft) .
17. Install the lower ball joints to the steering knuckles. Refer to Lower Control Arm Replacement .

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18. If equipped with hydraulic power steering, install the power steering fluid cooling pipe (3) to the frame, install the power steering fluid cooling pipe bolt (1) and clip in (2). Tighten the power steering fluid cooling pipe bolt to 9 N·m (80 lb in) .

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19. Install the wheel speed sensor wiring harness (2) to the frame on both sides.
  Install the wiring harness retainers (3) to the frame and the lower control arm.
20. Install the radiator wiring harness (1) to the frame.
  Install the wiring harness retainers (4) to the frame.

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21. If equipped with hydraulic power steering, install the inlet and outlet hose (2) to the steering gear (3).
22. If equipped with hydraulic power steering, install power steering gear inlet and outlet hose bolts (1) and tighten to 11 N·m (97 lb in) .

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23. Install the NEW lower steering intermediate shaft (1) bolt and tighten a first pass to 25 N·m (18 lb ft) .
24. Tighten the NEW lower intermediate steering shaft bolt a final pass to an additional 180 degrees , using the EN-45059   meter .
25. Remove the support of the radiator and condenser.
26. Install the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation .
27. Install the exhaust front pipe. Refer to Exhaust Front Pipe Replacement .
28. Install the engine shield, if equipped. Refer to Engine Shield Replacement .
29. Install the engine splash shields. Refer to Front Compartment Splash Shield Replacement .
30. Install the front compartment insulator, if equipped. Refer to Front Compartment Insulator Replacement .
31. Lower the vehicle on a hoist.
32. If replacing the frame, check wheel alignment. Refer to Wheel Alignment Measurement .

Rear Multifunction Carrier Replacement - 5-Door Hatchback 68 > < Drivetrain and Front Suspension Frame Insulator Replacement