Mta Manual Transmission from Engine, Detach and Attach Opel Combo C

Note. Engine removed

Remove

1. 1. Rope drive unit • To engine transport shackles – Use KM-2358
2. 2. Detach upper coolant hose (1) • From thermostat housing
3. 3. Detach lower coolant hose (3) • From heat exchanger/oil cooler
4. 4. Remove charge air hose (2) • From charge air pipe at intercooler
5. 5. Remove charge air hose • From turbocharger • Open quick-release fitting
6. 6. Detach air conditioning line • Remove bolt (arrow)
7. 7. Disconnect wiring harness plug of AC compressor (4)

8. 8. Remove cooling module

9. 9. Remove compressor • Unscrew 3x bolts (1...3)

10. 10. Detach compressor support (1) • Unscrew 4 bolts (2)
11. 11. Detach exhaust manifold heat shield • Unscrew 3 nuts • Remove engine transport shackle
12. 12. Remove turbocharger/catalytic converter (3) • Detach oil feed line at oil cooler – Unscrew banjo bolt (1) • Detach oil return line at cylinder block – Unscrew 2 bolts (2) • Remove charge air pipe at turbocharger • Remove bolt – Catalytic converter bracket at cylinder block • Unscrew 3x nuts (arrows)

13. 13. Detach alternator • Unscrew 3 bolts (2) • Electrically disconnect alternator – Unscrew 2 nuts (1)
14. 14. Detach ground cable (3) • From cylinder block • Remove bolt

15. 15. Detach alternator support • Unscrew 5 bolts
16. 16. Fit 2x KM-412-32 • Tighten 6 bolts

17. 17. Attach engine transport shackle. • To exhaust manifold
18. 18. Remove 2 axle shafts • Use KM-313 (2) • Use KM-902 (1) – Seal openings

19. 19. Detach charge air pipe (1) from intake manifold • Unscrew 4 bolts (arrows)

20. 20. Detach rear reaction member • Remove bolt (arrow)

21. 21. Remove front reaction member • Undo bolted connection (arrow)

22. 22. Raise drive unit • From front axle unit
23. 23. Attach drive unit to KM-412-A • Tighten 8 bolts • Remove ropes from drive unit
24. 24. Remove transmission • From oil pan – Unscrew 2 bolts • From cylinder block – Unscrew 3 bolts – Loosen bolt

Note. Note differing bolts

25. 25. Remove transmission • Remove bolt

Note. Second person required

Install

26. 26. Insert transmission • Screw in 6x bolt

Note. Second person required

27. 27. Attach transmission • To oil pan – Tighten 2 bolts 40 Nm – 4x transmission at cylinder block 60 Nm • At cylinder block – Tighten 4 bolts 60 Nm
28. 28. Remove drive unit • Rope drive unit • Unscrew 8 bolts
29. 29. Insert drive unit • On front axle unit • Screw in 2x bolt – In reaction member

Note. Second person required

30. 30. Attach front reaction member • Tighten bolted connection 60 Nm
31. 31. Attach rear reaction member • Tighten bolt 80 Nm
32. 32. Remove 2x KM-412-32 • Undo 6 bolts
33. 33. Replace 2 axle shaft retaining rings
34. 34. Install 2 axle shafts
35. 35. Fit charge air pipe at intake manifold • Replace seal ring • Tighten 4 bolts
36. 36. Connect ground cable. • At cylinder block
37. 37. Attach alternator support • Tighten 5 bolts 25 Nm
38. 38. Attach alternator • Tighten 3 bolts 25 Nm • Electrically connect alternator – Tighten 2 nuts
39. 39. Install turbocharger/catalytic converter • Fit turbocharger • Tighten 3x nuts 25 Nm • Fit charge air pipe at turbocharger • Catalytic converter bracket at cylinder block • Attach oil return line at cylinder block – Tighten 2 bolts 15 Nm – Replace gasket • Attach oil feed line at oil cooler – Tighten banjo bolt 12 Nm – Replace 2x seal ring
40. 40. Attach exhaust manifold heat shield • Detach engine transport shackle • Tighten 3x nuts 9 Nm • Insert engine transport shackle
41. 41. Attach compressor support • Tighten 4 bolts 20 Nm
42. 42. Fit compressor • Tighten 3 bolts 22 Nm
43. 43. Insert cooling module
44. 44. Connect air conditioning compressor wiring harness plug
45. 45. Connect air conditioning line • Replace 2x seal ring • Tighten bolt 20 Nm
46. 46. Attach charge air hose. • To turbocharger • Close quick-release fitting
47. 47. Attach charge air hose. • To upper charge air pipe • Tighten clamp 3.5 Nm
48. 48. Connect lower coolant hose • To heat exchanger/oil cooler
49. 49. Attach upper coolant hose • To thermostat housing
50. 50. Remove ropes from drive unit
51. 51. Check transmission fluid level, top up if necessary