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Valve Stem Oil Seal and Valve Spring Replacement > < Crankshaft Rear Oil Seal Replacement - Automatic Transmission

Astra J

Engine Replacement (1.4L LUJ - 6T40)

Special Tools

•  CH-904   Underframe
•  CH-49289   Centering Frame
•  CH-49290   Engine Support Tool
•  EN-6015   Closure Plugs
•  EN-34730-91   Pressure Tester

For equivalent regional tools, refer to Special Tools .

Removal Procedure

1. Remove the lower intermediate steering shaft bolt. Refer to Intermediate Steering Shaft Replacement .
2. Open the hood.
3. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .
4. Remove the battery tray. Refer to Battery Tray Replacement .

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5. Remove the windshield washer solvent container filler tube (1).

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6. Remove the front compartment fuse block cover (1).

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7. Loosen the 3 front compartment fuse block bolts (1).
8. Unclip the 4 front compartment fuse block retainer clips (2) and (3) and lift the front compartment fuse block slightly up.

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Note:  The wiring harness plugs should remain in the lower part (4) of the front compartment fuse block.
9. Entirely loosen the 3 front compartment fuse block bolts (1) while lifting the front compartment fuse block until it can be removed from the 3 wiring harness plugs (3), (5) and (6).

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10. Remove the ECM wiring harness plug (1) from the lower part of the front compartment fuse block.
11. Disconnect the ECM wiring harness plug (2) and unclip it from the retainer clip (3).

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12. Remove the 3 ground cable nuts (1) and put the 3 ground cables (2) aside.
13. Unclip the ECM wiring harness from body.
14. Unclip the back up lamp switch wiring harness from body.
15. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .
16. Remove the front bumper fascia. Refer to Front Bumper Fascia Replacement .
17. Remove the front tire and the wheel assembly. Refer to Tire and Wheel Removal and Installation .
18. Drain the cooling system. Refer to Cooling System Draining and Filling .
19. Disconnect the coolant level indicator module wiring harness plug. Refer to Engine Coolant Level Indicator Module Replacement .
20. Unclip the radiator surge tank. Refer to Radiator Surge Tank Replacement .
21. Put the radiator surge tank aside.
22. Disconnect the transmission range selector lever cable from the automatic transmission. Refer to Range Selector Lever Cable Replacement .
23. Remove the heater inlet and outlet hose from the bulkhead. Refer to Heater Inlet Hose Replacement and Heater Outlet Hose Replacement .
24. Place collecting basin underneath the vehicle.

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Warning: Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby.


25. Remove fuel injector rail cap (1).

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26. Relieve fuel pressure. Use EN-34730-91   pressure tester (1).

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27. Remove fuel feed pipe (4) from fuel injector rail.
28. Unclip fuel feed pipe from retainer clip (1).
29. Remove fuel ventilation pipe (2) from evaporative emission canister purge solenoid valve.
30. Unclip fuel ventilation pipe from retainer clip (1).
31. Close the vents with the EN-6015   closure plugs .
32. Disconnect the brake booster vacuum pipe (3) from intake manifold.

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33. Remove the lower condenser hose nut (3).
34. Remove the lower condenser hose (1) and the seal ring (2).

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35. Remove the A/C compressor and the condenser hose nut (1) from the air conditioning evaporator hose.
36. Remove the A/C compressor and the condenser hose (2) and the seal ring (3) from the air conditioning evaporator hose.
37. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
38. Remove the front compartment splash shield. Refer to Front Compartment Splash Shield Replacement .
39. Remove the upper stabilizer shaft link from the absorber on both sides. Refer to Stabilizer Shaft Link Replacement .
40. Remove the steering linkage outer tie rod from the steering knuckle on both sides. Refer to Steering Linkage Outer Tie Rod Replacement .
41. Remove the front lower control arm from the steering knuckle. Refer to Lower Control Arm Replacement .
42. Remove the front wheel shafts from the wheel hubs. Refer to Front Wheel Drive Shaft Replacement - Right Side and Front Wheel Drive Shaft Replacement - Left Side .
43. Disconnect the wheel speed sensors on both sides and unclip it from the suspension frame.
44. Remove the wheel speed sensor wiring harness retainers from the frame.

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45. Disconnect the engine coolant fan wiring harness plug (1) an unclip it from the suspension frame (2).
46. Disconnect the EPS wiring harness plug (3).
47. Disconnect the EPS main wiring harness plug from the EPS unit.

Note:  Do not confuse with three way warm up catalytic converter.
48. Remove the catalytic converter. Refer to Catalytic Converter Replacement .

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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.
49. Assemble the CH-49290   engine support tool (1) according to the details provided in the SPX installation manual.
50. Support the CH-904   base frame on a jack.
51. Support the CH-49290   engine support tool on the CH-904   base frame .

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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.
52. Install the CH-49290   engine support tool (1) according to the details provided in the SPX installation manual.

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53. Remove and DISCARD the 3 engine mount bolts (2) from the engine mount (1) and the engine mount bracket (3).

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54. Remove and DISCARD the 3 transmission mount bolts (2) from the transmission mount (3) and the transmission mount bracket (1).

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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.
55. Assemble the CH-49289   centering frame (1) according to the details provided in the SPX installation manual.
56. Support the CH-904   base frame on a jack.
57. Support the CH-49289   centring frame on the CH-904   base frame .

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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.
58. Install the CH-49289   centering frame (1) according to the details provided in the SPX installation manual.

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Note:  Simplified graphic. The engine/transmission unit is fixed with the engine support tool to the suspension frame. The suspension frame is supported by the centering adapter and the underframe.
59. Remove the frame front bolts (1).
60. Remove the frame rear bolts (2).
61. Remove the frame reinforcements (3).
62. Lower the suspension frame (4) carefully with the engine transmission unit off the vehicle with the hydraulic jack about 7 cm (2.76 in) .
63. Remove the 2 wiring harness bracket bolts from the EPS unit.
64. Remove the 2 wiring harness bracket from the EPS unit.
65. Remove the suspension frame carefully with the engine transmission unit from the vehicle with the hydraulic jack.
66. Drain the transmission fluid.
67. Remove the right wheel drive shaft from the transmission. Refer to Front Wheel Drive Shaft Replacement - Right Side .
68. Remove the left wheel drive shaft from the transmission. Refer to Front Wheel Drive Shaft Replacement - Left Side .

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69. Remove the engine coolant air bleed hose (3) from the water outlet.
70. Remove the heater inlet hose (1) from the water pump.
71. Remove the heater outlet hose (2) from the water outlet.
72. Remove the radiator surge tank (4) in compound with the engine coolant air bleed hose and the 2 heater hoses.
73. Remove the A/C compressor and the condenser hose (9) from the condenser.
74. Remove the radiator coolant feed hose (10) from the engine coolant thermostat housing.
75. Remove the radiator coolant return hose (5) from the water outlet.
76. Remove the charger air cooler inlet air hose (8) from the turbocharger.
77. Remove the charge air cooler outlet air hose (6) from the throttle body. Refer to Charge Air Cooler Outlet Air Hose Replacement .
78. Remove the transmission fluid cooler inlet and outlet pipe from the transmission fluid cooler. Refer to Transmission Fluid Cooler Inlet Pipe Replacement and Transmission Fluid Cooler Outlet Pipe Replacement .
79. Remove the complete radiator assembly (7) from the suspension frame.
80. Install a suitable cable at the 3 engine lift brackets.
81. Install a suitable engine lifting device to the cable.
82. Extend the engine lifting device until the steel cable are slightly tensioned.

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83. Remove the front transmission mount through bolt (1).

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84. Remove the transmission bracket mount to mount through bolt (1).
85. Lower and remove the frame.
86. Remove the 3 torque converter bolts. Refer to Transmission Replacement .
87. Put the engine transmission unit down on a wooden pallet.
88. Loosen the 8 transmission bolts and remove 6 of them. Refer to Transmission Replacement .

Note:  Two mechanics are required.
89. Remove the last 2 transmission bolts and the transmission.
90. Install the engine to a suitable engine stand.
91. Transfer parts as needed. Refer to Off-Vehicle.

Installation Procedure

1. Remove the engine from the engine stand.
2. Put the engine down on a wooden pallet.

Note:  Two mechanics are required.
3. Install the transmission and 2 transmission bolts.
4. Install the 6 transmission bolts.

Caution: Refer to Fastener Caution .
5. Tighten the 8 transmission bolts. Refer to Transmission Replacement .
6. Tighten the 3 torque converter bolts. Refer to Transmission Replacement .
7. Install a suitable cable at the 3 engine lift brackets. Install a suitable engine lifting device to the cable. Raise the engine transmission unit and extend the engine lifting device until the steel cable are slightly tensioned.
8. Raise the CH-904   underframe and CH-49289   centring frame with the hydraulic jack until it contacts the frame.
9. Place the engine transmission unit into the front frame.

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10. Install the rear transmission bracket mount to mount through bolt (1) and tighten to 100 N·m (74 lb ft) .

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11. Install the front transmission mount through bolt (1) and tighten to 100 N·m (74 lb ft) .
12. Remove the cable from the 3 engine lift brackets.
13. Install the complete radiator and condenser assembly to the suspension frame.

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14. Install the complete radiator assembly (7) to the suspension frame.
15. Install the charge air cooler outlet air hose (6) to the throttle body. Refer to Charge Air Cooler Outlet Air Hose Replacement .
16. Install the charger air cooler inlet air hose (8) to the turbocharger.
17. Install the radiator coolant return hose (5) to the water outlet.
18. Install the radiator coolant feed hose (10) to the engine coolant thermostat housing.
19. Install the A/C compressor and the condenser hose (9) to the condenser. Tighten the condenser hose nut to 19 N·m (14 lb ft) .
20. Install the radiator surge tank (4) in compound with the engine coolant air bleed hose and the 2 heater hoses.
21. Install the heater outlet hose (2) to water outlet.
22. Install the heater inlet hose (1) to water pump.
23. Install the engine coolant air bleed hose (3) to the water outlet.
24. Install the transmission fluid cooler inlet and outlet pipe to the transmission fluid cooler. Refer to Transmission Fluid Cooler Inlet Pipe Replacement and Transmission Fluid Cooler Outlet Pipe Replacement .
25. Install the right wheel drive shaft to the transmission. Refer to Front Wheel Drive Shaft Replacement - Right Side .
26. Install the left wheel drive shaft to the transmission. Refer to Front Wheel Drive Shaft Replacement - Left Side .
27. Fill up transmission fluid. Refer to Transmission Fluid Level and Condition Check .

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Note:  Positioning pins (1) of CH-49289   centring frame MUST be extended in order to guide into underbody holes.
28. Move the frame (1) with the engine transmission unit to the vehicle upward until the wiring harness bracket can be fixed to the EPS unit.
29. Install the wiring harness bracket to the EPS unit.
30. Tighten the 2 wiring harness bracket bolts and tighten to 9 N·m (80 lb in) .

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Note:  Simplified graphic. The engine/transmission unit is fixed with the engine support tool to the suspension frame. The suspension frame is supported by centering the adapter and the underframe.
31. Install the frame (4).
32. Install the frame reinforcements (3).
33. Install the frame rear bolts (2). Handtighten ONLY.
34. Install the frame front bolts (3). Handtighten ONLY.
35. Tighten the rear frame bolts (2) and tighten to 160 N·m (118 lb ft) .
36. Tighten the front frame bolts (1) and tighten to 160 N·m (118 lb ft) .

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37. Lower the CH-49289   centring frame (1) with CH-904   base frame and a jack.
38. Remove the CH-49289   centring frame from the CH-904   base frame .

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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.
39. Disassemble the CH-49289   centering frame (1) according to the details provided in the SPX installation manual.

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40. Install the 3 transmission mount bolts (2) to the transmission mount (3) and the transmission mount bracket (1) and tighten to 50 N·m (37 lb ft) + 60° - 70° .

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41. Install the 3 engine mount bolts (2) to the engine mount (1) and the engine mount bracket (3) and tighten to 50 N·m (37 lb ft) + 60° - 70° .

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42. Lower the CH-49290   engine support tool (1) with CH-904   base frame and a jack.
43. Remove the CH-49290   engine support tool from the CH-904   base frame .

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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.
44. Disassemble the CH-49290   engine support tool (1) according to the details provided in the SPX installation manual.
45. Install the catalytic converter. Refer to Catalytic Converter Replacement .

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46. Connect the engine coolant fan wiring harness plug (1) and clip it to the suspension frame (2).
47. Connect the EPS wiring harness plug (3).
48. Connect the EPS main wiring harness to the EPS unit.
49. Install the wheel speed sensor wiring harness retainers from the frame.
50. Connect the wheel speed sensor on both sides.
51. Install the front wheel shafts to the wheel hubs. Refer to Front Wheel Drive Shaft Replacement - Right Side .
52. Install the front lower control arm to the steering knuckle. Refer to Lower Control Arm Replacement .
53. Install the steering linkage outer tie rod to the steering knuckle on both sides. Refer to Steering Linkage Outer Tie Rod Replacement .
54. Install the upper stabilizer shaft link to the absorber on both sides. Refer to Stabilizer Shaft Link Replacement .
55. Install the front compartment splash shield. Refer to Front Compartment Splash Shield Replacement .
56. Lower the vehicle.

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Note:  Use a NEW O-ring seal. Refer to Air Conditioning O-Ring Seal Replacement .
57. Install the A/C compressor and the condenser hose (2) and the seal ring (3) to the air conditioning evaporator hose.
58. Install the A/C compressor and the condenser hose nut (1) to the air conditioning evaporator hose and tighten to 19 N·m (14 lb ft) .

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Note:  Use a NEW O-ring seal. Refer to Air Conditioning O-Ring Seal Replacement .
59. Install the lower condenser hose (1) and the seal ring (2).
60. Install the lower condenser hose nut (3) and tighten to 19 N·m (14 lb ft) .
61. Remove the EN-6015   closure plugs .

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62. Connect fuel feed pipe (4) to the fuel injector rail.
63. Clip the fuel feed pipe to the retainer clip (1).
64. Connect the fuel ventilation pipe (2) to the evaporative emission canister purge solenoid valve.
65. Clip the fuel ventilation pipe to the retainer clip (1).
66. Connect the brake booster vacuum pipe (3) to the intake manifold.

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67. Install the fuel injector rail cap (1).
68. Install the heater inlet and outlet hose to the bulkhead. Refer to Heater Inlet Hose Replacement and Heater Outlet Hose Replacement .
69. Install the transmission range selector lever cable. Refer to Range Selector Lever Cable Replacement .
70. Clip in the radiator surge tank. Refer to Radiator Surge Tank Replacement .
71. Connect the coolant level indicator module wiring harness plug. Refer to Engine Coolant Level Indicator Module Replacement .
72. Fill the cooling system. Refer to Cooling System Draining and Filling .
73. Install the front tire and the wheel assembly. Refer to Tire and Wheel Removal and Installation .
74. Install the front bumper fascia. Refer to Front Bumper Fascia Replacement .
75. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .

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76. Install the ECM wiring harness plug (1) to the lower part of the front compartment fuse block.
77. Connect the ECM wiring harness plug (2) and clip it to the retainer clip (3).

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78. Install the 3 wiring harnesses (2).
79. Install the 3 ground nuts (1) and tighten to 9 N·m (80 lb in) .

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Note:  Ensure that the 3 wiring harness plugs (3), (5) and (6) fit clearly to the front compartment fuse block.
80. Install the front compartment fuse block (2) to the lower part (4) and loosely install the bolts (1).

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81. Clip in the front compartment fuse block to the 4 retainer clips (2) and (3).
82. Tighten the 3 front compartment fuse block bolts (1) to 22 N·m (16 lb ft) .

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83. Install the front compartment fuse block cover (1).

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84. Install the windshield washer solvent container filler tube (1).
85. Install the battery tray. Refer to Battery Tray Replacement .
86. Evacuate and charge the refrigerant system. Refer to Refrigerant Recovery and Recharging .
87. Check the oil level and fill NEW engine oil up if necessary.
88. Close the hood.
89. Install the lower intermediate steering shaft bolt. Refer to Intermediate Steering Shaft Replacement .

Valve Stem Oil Seal and Valve Spring Replacement > < Crankshaft Rear Oil Seal Replacement - Automatic Transmission