Remove and Install Automatic Transmission with Torque Converter from Engine Opel Astra H

Spezialwerkzeugliste:

KM-2358 KM-313 KM-412 KM-412-27-1 KM-6312 KM-883-2 KM-902

Remove

1. 1. Remove engine

Note. Remove engine

2. 2. Detach upper radiator hose elbow from radiator • Release clamp
3. 3. Detach lower radiator hose elbow from radiator • Release clamp • Unclip coolant hose from bracket
4. 4. Detach coolant expansion tank coolant hose (1) from radiator • Release clamp
5. 5. Place collecting basin underneath.
6. 6. Detach upper automatic transmission fluid line (2) • Unscrew bolt

7. 7. Detach lower automatic transmission fluid line (2) • Unscrew bolt (1)

8. 8. Remove cooling module
9. 9. Detach exhaust manifold heat shield (1) • Detach wiring harness plug for mixture regulator oxygen sensor (4) • Detach heat shield – Unscrew nut (3) – Unscrew 2x stud bolt (2) – Unscrew bolt (5) • Fit engine transport shackle – Tighten stud bolt – Tighten nut

10. 10. Detach exhaust manifold • Unscrew 10x nut • Remove gasket

11. 11. Detach right axle shaft (1) • Use a suitable tool (2)

Note. 2nd mechanic is required. Press off using installing bar.

12. 12. Remove intermediate shaft (3) • Unscrew 3 bolts

13. 13. Detach intermediate shaft bearing support (1) • Unscrew 3x bolts (2)

14. 14. Detach left-hand axle shaft • Use KM-313 together with KM-902 (1)

Note. 2nd mechanic is required.

15. 15. Insert KM-412-27-1 • Tighten 2x bolts

16. 16. Remove oil dipstick guide tube (1) • Detach knock sensor wiring harness plug • Unclip wiring harness • Unscrew bolt (2)

17. 17. Detach engine control unit • Detach wiring harness bracket – Unscrew 2x nuts (1) • Release and unplug 2x wiring harness plug (2) • Release and disconnect throttle valve module wiring harness plug (5) • Unclip wiring harness • Detach earth cable (3) – Unscrew bolt • Detach engine control unit – Unscrew 3 bolts

18. 18. Detach engine management wiring harness (I) • Alternator – Disconnect wiring harness plug (1) – Unscrew nut (2) • Starter – Unscrew 2x nuts • Disconnect wiring harness plug – Dynamic oil level check • Detach earth cable – Unscrew bolt • Detach automatic transmission combination plug (3) • Unclip wiring harness • Disconnect supply unit wiring harness – Ground distribution, positive distribution

19. 19. Remove knock sensor (3) • Unscrew bolt (2) • Release and unplug wiring harness plug (1)

20. 20. Remove wiring harness for engine management • Disconnect wiring harness plug – Crankshaft pulse pick-up, oil pressure switch, throttle valve module • Disconnect ground distribution – Unscrew bolt – Cylinder block • Unclip wiring harness
21. 21. Detach tank vent valve • Disconnect wiring harness plug • Detach tank vent line • Unclip tank vent line
22. 22. Detach intake manifold • Detach wiring harness plug for intake pipe pressure sensor • Remove engine cover bracket – Unscrew 2x nuts • Unscrew 5x bolts (1) • Unscrew 2x nut (arrows)

23. 23. Insert KM-412-27-1 • Tighten 3x bolts
24. 24. Attach adapter plate KM-883-2 • to engine transport shackles • Lock transport shackles • Suspend from workshop crane

25. 25. Release front reaction member • Unscrew nut (arrow) • Remove bolt (1)

26. 26. Release rear reaction member • Unscrew bolt (1)

27. 27. Lift drive unit

Note. 2nd mechanic is required.

28. 28. Attach drive unit • Use KM-412 – Tighten 8x bolts • Untie ropes from drive unit

Note. 2nd mechanic is required.

29. 29. Detach starter • Unscrew 2x bolts (1)

30. 30. Undo torque converter • Turn crankshaft in the direction of engine rotation at the bolt on the ribbed V-belt pulley • Unscrew 3 bolts

31. 31. Undo automatic transmission • Oil pan – Unscrew 2x bolts (2) • Cylinder block – Unscrew 4x bolt (1 and 4)

Note. Leave one bolt (3) as a retainer

32. 32. Rope up automatic transmission • Use KM-2358 • To workshop crane
33. 33. Lift off automatic transmission • Unscrew bolt

Note. 2nd mechanic is required.

Important. Note torque converter.

34. 34. Detach automatic transmission • Put down automatic transmission • Remove KM-2358

Important. Check centring journal of converter for friction corrosion, clean if necessary and coat thinly with special grease. Note correct seating of converter. Measure the distance between the connecting threads of the converter and the connecting surface of the transmission housing using a calliper gauge: distance approx. 16 mm.

35. 35. Check centring journal
36. 36. Clean the thread

Note. Recut 3x thread in converter

Install

37. 37. Attach automatic transmission • Detach KM-2358 • Lift automatic transmission
38. 38. Position automatic transmission • Screw in bolt

Note. 2nd mechanic is required.

39. 39. Untie ropes from automatic transmission • Remove KM-2358
40. 40. Fasten automatic transmission • Tighten 5x bolt 60 Nm – On cylinder block • Tighten 2x bolt 40 Nm – To oil pan
41. 41. Attach torque converter • Replace 3x bolt • Screw in 3x bolts – Use screw locking compound (red)

Note. Screw in bolts to stop

42. 42. Tighten torque converter • Replace 3x bolt • Tighten 3x bolt 60 Nm
43. 43. Fit starter • Tighten 2x bolt 40 Nm
44. 44. Remove drive unit • Suspend workshop crane • Unscrew 8x bolts

Note. 2nd mechanic is required.

45. 45. Position drive unit • Position on KM-6312 • Attach rear reaction member – Screw in bolt • Attach front reaction member – Insert bolt – Screw in nut

Note. 2nd mechanic is required.

Note. Note locating points

46. 46. Secure rear reaction member • Tighten bolt – Tightening torque 80 Nm
47. 47. Secure front reaction member • Tighten nut 80 Nm
48. 48. Untie ropes from drive unit
49. 49. Detach 2x KM-412-27-1
50. 50. Install intake manifold • Tighten 2x nut 6 Nm • Tighten 5x bolt 9 Nm • Attach engine cover bracket – Tighten 2x nuts • Connect wiring harness plug for intake pipe pressure sensor
51. 51. Attach tank vent valve • Clip in tank vent valve • Connect tank vent line • Fit wiring harness plug
52. 52. Attach engine control unit • Tighten 3x bolt 9 Nm • Connect and lock wiring harness plug
53. 53. Attach wiring harness for engine management • Attach wiring harness • Attach ground distribution – Tighten bolt – Cylinder block, engine control unit • Connect and lock 3x wiring harness plug – Crankshaft pulse pick-up, oil pressure switch, throttle valve module
54. 54. Attach knock sensor • Tighten bolt 23 Nm • Connect and lock wiring harness plug
55. 55. Attach wiring harness for engine management • Attach supply unit wiring harness (I) – Ground distribution, positive distribution • Automatic transmission combination plug • Attach wiring harness • Install earth cable – Tighten bolt • Connect and lock wiring harness plug – Dynamic oil level check • Starter – Tighten 2x nuts • Alternator – Fit wiring harness plug – Tighten nut • Engine control unit – Connect and lock wiring harness plug, combination plug
56. 56. Install dipstick guide tube • Tighten bolt 9 Nm • Connect and lock knock sensor wiring harness plug • Attach wiring harness
57. 57. Replace 2x axle shaft retaining ring (1)

Important. Retaining ring must engage.

58. 58. Install left-hand axle body
59. 59. Attach intermediate shaft bearing support • Tighten 3x bolt 55 Nm • Attach 2 retaining clamps
60. 60. Install intermediate shaft • Tighten 3x bolts 18 Nm

Important. Retaining ring must engage.

61. 61. Fit right-hand axle body
62. 62. Attach exhaust manifold • Replace gasket
63. 63. Detach exhaust manifold heat shield • Detach engine transport shackle – Unscrew stud bolt • Attach heat shield – Tighten 2 stud bolts 23 Nm – Tighten bolt – Tighten nut 25 Nm • Connect and lock oxygen sensor wiring harness plug, mixture regulation
64. 64. Attach engine cooling module • Attach automatic transmission fluid cooler lines – Tighten 2x bolt 25 Nm • Attach lower coolant hose • Attach upper radiator hose
65. 65. Install engine

Note. Install engine