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Frame and Underbody: Component Locations Saturn Astra I

Frames, Subframes & Crossmembers 2 illustrations ~725 words

Special Tools

  1. KM-904 Base Frame. See «Special Tools»(ref-302303-S29374387322008102100000) .
  2. KM-6390 Centering Equipment
  3. MKM-883-1 Engine Bridge. See «Special Tools»(ref-302303-S29374387322008102100000) .
  4. MKM-883-2 Retaining Tool

Scheme 2

Scheme 2: Removal Procedure
Scheme 2: Removal Procedure
  1. Lock the steering wheel. Turn the steering wheel and front wheels to the straight-ahead position. Remove the ignition key. Engage the steering wheel lock.
  2. Remove the intermediate spindle from steering gear. Remove the intermediate spindle clamping screw (1). Pull the intermediate spindle from steering gear spindle.
  3. Disconnect the battery.
  4. Remove the battery shield (2). Remove the bolt (3). Remove the 2 shields (1) from battery carrier.
  5. Remove the battery holder (1). Remove the bolt.
  6. Remove the battery.
  7. Remove the battery carrier. Cut the 2 cable ties (1). Remove the 3 bolts (2).
  8. Disconnect the coolant expansion tank. Disconnect the wiring harness plug. Place coolant expansion tank to one side.
  9. Disconnect the 2 oxygen sensor wiring harness plugs.
  10. Remove the headlamps. Refer to «Headlamp Replacement - Left Side»(ref-302302-S30820209252008102100000) and «Headlamp Replacement - Right Side»(ref-302302-S14609313922008102100000) or «Headlamp Replacement (with Dipped Beam)»(ref-302302-S15650409052008102100000) or «Headlamp Replacement (without Dipped Beam)»(ref-302302-S26447553122008102100000) .
  11. Secure the radiator. Insert a suitable wire bar into the bracket (1) at right and left.
  12. Loosen the steering wiring harness. Detach the cover from positive distribution. Disconnect the wiring harness from the fuse (1). Disconnect the steering wiring harness (2). Disconnect the steering wiring harness ground cable (3) from ground terminal. IMPORTANT: Pay attention to cable routing. Expose the steering wiring harness, access required from below. Remove the cable ties. Remove the wiring harness from the bracket.
  13. Prepare for attachment of MKM-883-1 and MKM-883-2 . See «Special Tools»(ref-302303-S29374387322008102100000) . MKM-883-2 Retaining spindle (1) Outrigger (3 off) (2) Retaining spindle (3 off) (3) Hex drives (2 off) (4) Support spindles (2 off) (5) Tensioning nuts (6 off) (6) Ring nuts (3 off) (7) First of all the alignment and attachment of MKM-883-2 will be described below on an engine-specific basis.
  14. Attach MKM-883-2 , for U18 XER.
  15. Remove the upper engine cover. Remove the oil filler cap. Install the oil filler cap.
  16. Preassemble MKM-883-2 with fastening spindles, arms and supporting spindle as shown. Ensure that the hexagon drives point forwards.
  17. Place MKM-883-2 on engine and attach fastening spindles to engine transport shackles.
  18. Attach MKM-883-1 . See «Special Tools»(ref-302303-S29374387322008102100000) . MKM-883-1 Hoist (1) MKM-883-1 (2) Safety hook (3) Retaining spindle (4)
  19. Position MKM-883-1 . See «Special Tools»(ref-302303-S29374387322008102100000) .
  20. Attach chain hook to the two outer eye nuts of MKM-883-2 .
  21. Rotate the 2 tensioning chain drives until tensioning chains are under slight amount of pretension.
  22. Align MKM-883-2 . Evenly tension the fastening spindles by rotating the knurled nuts.
  23. Install the retaining spindles to the center ring nut.
  24. Apply slight tension to the retaining spindle.
  25. Remove the 2 front wheels.
  26. Remove the right engine splash guard. Remove the 4 bolts. Remove the 2 body-bound rivets.
  27. Remove the right and left swing arms (2) from spring strut support tube. Counterhold at flattened areas with open-ended wrench (1).
  28. Release the tie rod ends from the steering knuckle. Refer to «Rack and Pinion Outer Tie Rod End Replacement»(ref-302308-S14293351942008102100000) .
  29. Remove the guide joint from the steering knuckle. Remove the guide joint bolt at both sides. Pull the guide joint out of steering knuckle.
  30. If present, remove lower engine compartment cover.
  31. Remove the front exhaust pipe with catalytic converter and center muffler. Refer to «Mid Muffler Replacement»(ref-302311-S23419456572008102100000) .
  32. Detach the shift guide from shift rod transmission. Remove the shift rod clamp. Detach the shift guide from shift rod.
  33. Remove the engine damping block rear bracket (1) from the transmission. Remove the 3 bolts.
  34. Detach the front engine damping block from the front frame. Remove the nut. Remove the bolt (2).
  35. Attach KM-904 and KM-6390 to hydraulic jack. See «Special Tools»(ref-302303-S29374387322008102100000) .
  36. Place the hydraulic jack beneath the frame body (no clearance).
  37. Detach the front frame from the front frame. Remove the 6 bolts (2). Remove the triangular plates. Remove the 2 bolts (1), right and left. IMPORTANT: Ensure that no attaching parts are damaged. Pay attention to steering wiring harness. Remove the 2 bolts (3).
  38. Carefully lower front frame using hydraulic jack.
  39. Replace the front frame. Refer to «Front Frame Replacement (Replacement)»(ref-302303-S17522976952008102100000) or «Front Frame Replacement (Removal)»(ref-302303-S01377642962008102100000) .

KM-907 Control Arm Bushing Remover/Installer. See Special Tools .

Illustration Tool Number/ Description KM-904 Base Frame KM-907 Control Arm Bushing Remover/Installer MKM-883-1 Engine Bridge SA9211T-2/KM-161-B and KM-161-2

Scheme 3

Scheme 3: Special Tools
Scheme 3: Special Tools

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