How to Remove and Install the Automatic Transmission from Engine Opel Vectra C

Note. Engine is removed

Remove

1. 1. Place collecting basin underneath.
2. 2. Detach power steering hydraulic line (1) from cooling module • Unscrew 3x bolt (2)

3. 3. Detach power steering pressure line from power steering pump • Unscrew nut (1) • Detach bracket (2) – Remove bolt (3)

4. 4. Detach 2 power steering hydraulic lines from steering gear • Remove bolt (1) • Unclip power steering hydraulic line from front axle body

5. 5. Detach upper coolant hose (1) from coolant drain connection • Release clamp

6. 6. Detach 2 coolant lines (1) from AC compressor • Remove bolt

7. 7. Detach charge air hose (1) from intercooler • Release 2x clamp (2)

8. 8. Detach coolant hose (1) from cooling module • Release clamp

9. 9. Detach charge air hose (2) from turbocharger • Release clamp (1)

10. 10. Remove lower coolant hose (1) from coolant pipe • Release clamp

11. 11. Detach wiring harness (1) from cooling module • Disconnect 4 cable ties • Disconnect wiring harness plug (2)

12. 12. Detach 2x oil-cooling line (1) from transmission • Place collecting pan underneath - oil will run out • Unscrew nut (2) • Detach oil-cooling line • Seal transmission apertures with KM-6326 (green) (3) • Seal oil-cooling lines with KM-6326 (yellow) (4)

13. 13. Remove cooling module

Note. This requires a second person

14. 14. Detach air intake pipe (3) from turbocharger • Release 2x clamp (4) • Pull off charge air control vacuum line (2) • Detach oil dipstick guide tube vent line (1) from air intake pipe – Undo quick-release fitting

15. 15. Remove cooling module • This requires a second person
16. 16. Detach charge air pipe (3) and charge air hose (1) from engine • Unscrew 3x bolt (2)

17. 17. Remove secondary air system pump (4) • Disconnect wiring harness plug (2) • Detach 2 secondary air hoses (1) – Undo 2 quick-release fittings • Unclip coolant hose • Separate cable tie • Unscrew 2x bolt (3)

18. 18. Detach ribbed V-belt from compressor pulley • Tension ribbed V-belt tensioner (1) in direction of arrow

19. 19. Detach AC compressor (2) from bracket • Disconnect wiring harness plug (1) • Unscrew 3x bolt (3)

20. 20. Detach AC compressor bracket (1) from oil pan and engine block • Unscrew 4x bolt (2)

21. 21. Detach wiring trough (1) from transmission • Unscrew nut (2) • Disconnect wiring harness plug, transmission control unit (3) • Unhook wiring trough carefully from above
22. 22. Detach earth cable (1) from bracket • Unscrew nut (4)
23. 23. Detach clamp (2) from bracket • Unscrew nut (3)

24. 24. Disconnect starter from electric supply • Unscrew 2x nut
25. 25. Remove starter • Unscrew 2x bolt (1)

26. 26. Remove oil filter housing • Disconnect oil pressure switch wiring harness plug (1) • Unclip 2x wiring harness • Detach 2 coolant hoses (3) – Release 2x clamp • Detach turbocharger oil feed line – Unscrew banjo bolt (2) • Unscrew 6 bolts (4) and (5)

27. 27. Detach oil dipstick guide tube • Remove bolt
28. 28. Attach KM-412-37-2 (1) to engine • Tighten 3x bolt (2)

29. 29. Remove upper turbocharger heat shield (2) • Unscrew nut (3) • Unscrew 3x bolt (1)

30. 30. Remove exhaust manifold heat shield for cylinders 1, 3 and 5 (2) • Unscrew 5 bolts (1 and 3)

31. 31. Remove lower turbocharger heat shield (1) • Unscrew 2x bolt (2)

32. 32. Detach pre-catalytic converter (1) from turbocharger • Unscrew 3 nuts (2)

33. 33. Detach pre-catalytic converter from cylinder head • Remove bolt (1)

34. 34. Detach 2 pre-catalytic converter brackets (1) • Unscrew 4x bolt

35. 35. Remove pre-catalytic converter
36. 36. Close turbocharger with EN-47983 • Place EN-47983 on one of the stud bolts – Screw in nut (2)

37. 37. Place collecting basin underneath.
38. 38. Remove coolant pipe • Unscrew 2 bolts (1 and 4) • Detach coolant hose (3) • Unclip wiring harness

39. 39. Detach knock sensor heat shield for cylinders 1, 3 and 5 (1) • Unscrew 2x bolt (2) • Unclip cable tie

40. 40. Detach knock sensor for cylinders 1, 3 and 5 • Disconnect wiring harness plug (1) • Remove bolt (2)

41. 41. Attach KM-412-37-1 (1) to engine • Tighten 4x bolt (2)

42. 42. Place collecting basin underneath.
43. 43. Detach left axle shaft from transmission • Use an installing bar to lever it out • Catch the transmission fluid that runs out
44. 44. Detach right axle shaft from intermediate shaft • Use an installing bar to lever it out
45. 45. Detach intermediate shaft flange (3) from main bracket • Unscrew 2x bolt (1) • Catch the transmission fluid that runs out

46. 46. Remove intermediate shaft (5) with bearing from main bracket (3) • Drive intermediate shaft (5) out of main bracket (3) with drift (1, 2)

Important. Set drift (1), (4) on inner ring of bearing or retainer (2)

Note. Transmission fluid runs out

Important. Before fitting MKM-883-2 , read the supplier's instructions

47. 47. Pre-mount MKM-883-2 with fastening spindles and outriggers as shown

Note. Do not tighten the outriggers yet

48. 48. Suspend MKM-883-2 from the engine crane • Attach fastening spindles to engine transport shackles • Tighten outriggers

Note. If necessary, adjust positions of outriggers

49. 49. Detach rear engine damping block main bracket (1) from manual transmission • Unscrew 3x bolt

50. 50. Detach front engine damping block main bracket (1) from manual transmission • Unscrew 2x bolt (2)

51. 51. Lever engine with automatic transmission away from front axle body • This requires a second person
52. 52. Attach engine with automatic transmission to KM-412-A • This requires a second person • Tighten 8x bolted connection
53. 53. Detach MKM-883-2 from perforated plate
54. 54. Detach coolant drain connection (1) from thermostat housing • Unscrew 2 bolts (2 and arrow) • Pull coolant drain connection out of thermostat housing

55. 55. Detach converter from drive disc • Unscrew 6x bolt, converter (1)

Note. Turn torsional vibration dampers 60° further clockwise respectively.

56. 56. Release transmission at the top • Unscrew 2x bolt (1) • Loosen bolt (2)

57. 57. Release transmission at the bottom • Unscrew 4x bolt (1)

Important. Ensure that the converter remains in the transmission

58. 58. Remove transmission flange • Remove bolt • Press transmission away from cylinder block
59. 59. Secure torque converter to prevent it falling out • Attach KM-6388 (1)

Install

60. 60. Attach automatic transmission to engine • Tighten 4x bolt on oil pan 40 Nm • Tighten 5 bolt on cylinder block 60 Nm
61. 61. Attach converter to drive disc • Screw in 6x new bolt (arrow), converter (1), hand-tight • Tighten 6x bolt, converter 30 Nm

Note. Turn belt pulley 60° further clockwise in each case. Note bolt length.

62. 62. Install starter • Tighten 2x bolts 50 Nm
63. 63. Connect up starter • Tighten 2x nut 13 Nm
64. 64. Attach earth cable (1) to bracket • Tighten nut (4)
65. 65. Attach clamp (2) to bracket • Tighten nut (3)

66. 66. Attach wiring trough (1) to transmission • Hook wiring trough in position • Connect wiring harness plug for transmission control unit • Tighten nut (2)
67. 67. Attach coolant pipe to thermostat housing • Tighten 2x bolt

Note. Use new seal ring.

68. 68. Suspend engine from engine crane • Attach cable to MKM-883-2 • Tension the cable
69. 69. Detach engine with automatic transmission from KM-412-A • Detach 8 screwed connections
70. 70. Place engine with automatic transmission on front axle body • This requires a second person • Position engine over front axle body until engine damping block main bracket can be attached to manual transmission at front and rear • Attach engine damping block main bracket to manual transmission at rear – Tighten 3x bolt 80 Nm • Attach engine damping block main bracket to manual transmission at front – Tighten 2x bolt 80 Nm • Lower engine with manual transmission onto front axle body
71. 71. Detach engine crane from MKM-883-2
72. 72. Detach MKM-883-2 from engine • Detach 3 hooks from engine transport shackles
73. 73. Attach intermediate shaft with flange to transmission and main bracket • Insert KM-6332 (1) in transmission

Note. Use KM-6332 so as not to damage the transmission seal ring

74. 74. Insert intermediate shaft with flange in main bracket and KM-6332 on transmission • Insert the intermediate shaft all the way into the transmission • Attach the flange to the main bracket – Tighten 2x bolt 18 Nm

Note. When the splines on the intermediate shaft (1) have passed through the KM-6332 tool, remove the tool KM-6332 (2) by pulling it downwards.

75. 75. Renew 2 retainers on the inner axle shaft joint (1) • Remove the retainer with a screwdriver • Insert a new retainer in the groove on the axle shaft

76. 76. Attach right axle shaft to intermediate shaft • Push axle shaft into intermediate shaft until retainer engages
77. 77. Insert left axle shaft (1) in KM-6332 on transmission • Push left axle shaft into transmission

Note. When the splines on the axle shaft (1) have passed through the KM-6332 tool, remove the tool KM-6332 (2) by pulling it downwards.

Note. If necessary, drive axle shaft into transmission with plastic hammer on joint housing until retainer engages

78. 78. Remove KM-412-37-1 from engine • Unscrew 3x bolt
79. 79. Attach knock sensor for cylinders 1, 3 and 5 • Tighten bolt 23 Nm • Connect wiring harness plug
80. 80. Attach knock sensor heat shield for cylinders 1, 3 and 5 • Tighten 2x bolt 8 Nm • Clip in cable ties
81. 81. Fit coolant pipe. • Use new seal ring. • Tighten 2x bolt • Clip starter wiring harness onto coolant pipe
82. 82. Attach lower turbocharger heat shield • Tighten 2x bolt 12 Nm
83. 83. Attach exhaust manifold heat shield for cylinders 1, 3 and 5 • Tighten 5x bolt 10 Nm
84. 84. Attach pre-catalytic converter • Attach pre-catalytic converter to turbocharger – Tighten 3 new nuts 23 Nm • Attach pre-catalytic converter to bracket – Tighten bolt 40 Nm • Tighten 2x bolt in oil pan 23 Nm • Connect catalytic converter control oxygen sensor wiring harness plug and lay wiring harness
85. 85. Attach upper turbocharger heat shield • Tighten 3x bolt 8 Nm • Tighten nuts 3 Nm
86. 86. Clip power steering oil line into bracket on front axle body
87. 87. Install oil dipstick guide tube • Use new seal ring. • Tighten bolt 10 Nm
88. 88. Attach compressor bracket • Tighten 4x bolt 38 Nm
89. 89. Attach oil filter housing with new seal • Tighten 4x bolt on cylinder head 12 Nm • Tighten 2x bolt on cylinder block 22 Nm • Attach turbocharger oil feed line – Tighten banjo bolt with new seal rings 30 Nm • Attach coolant hose. – Fasten clamp • Disconnect oil pressure switch wiring harness plug • Attach wiring harness

Note. Note dissimilar bolt lengths

90. 90. Attach compressor • Tighten 3x bolt 22 Nm • Connect wiring harness plug
91. 91. Install ribbed V-belt. • Tighten ribbed V-belt tensioner.
92. 92. Install secondary air system pump with air pipes • Tighten 2x bolt 8 Nm • Clip in coolant line • Connect upper pipe for secondary air system – Connect quick-release fitting – Tighten bolt • Connect wiring harness plug
93. 93. Attach charge air pipe and charge air hose to engine • Tighten 3x bolt 8 Nm
94. 94. Set cooling module on front axle body • This requires a second person
95. 95. Attach 2x oil-cooling line (1) to transmission • Place collecting pan underneath - oil will run out • Remove KM-6326 (3) and (4) from oil cooling line and transmission • Insert oil-cooling line in transmission connection • Tighten nut (2) 7 Nm

96. 96. Attach cooling module wiring harness to cooling module • Attach 3 cable ties • Connect wiring harness plug • Attach air intake pipe to turbocharger – Attach oil dipstick guide tube bleed line – Attach vacuum line – Tighten clamp 3.5 Nm
97. 97. Attach lower curved radiator hose to coolant pipe • Fasten clamp
98. 98. Attach charge air hose to turbocharger • Tighten clamp 3.5 Nm
99. 99. Attach charge air hose to intercooler • Tighten clamp 3.5 Nm
100. 100. Attach 2 coolant lines to AC compressor with new seals • Tighten bolt 20 Nm
101. 101. Attach upper coolant hose to coolant drain connection • Fasten clamp
102. 102. Attach 2 hydraulic lines for power steering • Attach power steering hydraulic line to cooling module – Tighten 3x bolt • Attach power steering pressure line to power steering pump – Tighten nuts – Attach bracket • Attach 2 power steering hydraulic lines to steering gear – Tighten bolt 11 Nm • Clip power steering hydraulic line on to front axle body