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Home/Saturn/Astra/Saturn Astra I (2008-2009)/Repair manual/Frames, Subframes & Crossmembers/Frame and Underbody: Removal & Installation
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Frame and Underbody: Removal & Installation Saturn Astra I

Frames, Subframes & Crossmembers 1 illustration ~1168 words

Removal Procedure

  1. Remove the front frame. Refer to «Front Frame Replacement (Replacement)»(ref-302303-S17522976952008102100000) or «Front Frame Replacement (Removal)»(ref-302303-S01377642962008102100000) .
  2. Detach the 2 radiator brackets (1) from the front frame.
  3. Detach the stabilizer (4) from the front frame. Refer to «Stabilizer Shaft Replacement»(ref-302306-S03005974082008102100000) .
  4. Detach the rear engine damping block bracket (2) from engine damping block.
  5. Detach the rear engine damping block (5) from front frame.
  6. For the vehicles with manual transmission, detach the shift guide bracket (3) from the front frame.
  7. Detach the electrohydraulic supply unit from the front frame. Refer to «Electronic Brake Control Module Replacement (MK70)»(ref-302307-S21832616372008102100000) or «Electronic Brake Control Module Replacement (MK60)»(ref-302307-S03128347172008102100000) .
  8. Detach the steering gear from front frame. Refer to «Steering Gear Replacement (ZF)»(ref-302308-S28651334002008102100000) or «Steering Gear Replacement (TRW without NR1, NS1, NS2)»(ref-302308-S18337508882008102100000) .
  9. Detach the left and right control arms from the front frame. Refer to «Lower Control Arm Replacement»(ref-302306-S08330152382008102100000) .

Installation Procedure

  1. Install a new damping bushings in front frame. Refer to «Front Frame Cushion or Insulator Replacement»(ref-302303-S32345958542008102100000) .
  2. Connect the left and right control arms to front frame. Use the 4 new bolts. Install the 4 new nuts.
  3. Attach the rear engine damping block (4) to the front frame. Install the 2 new nuts (2, 5). Tighten: Tighten to 55 N.m (40 lb ft).
  4. Install the steering gear to the front frame. Refer to «Steering Gear Replacement (ZF)»(ref-302308-S28651334002008102100000) or «Steering Gear Replacement (TRW without NR1, NS1, NS2)»(ref-302308-S18337508882008102100000) .
  5. Install the electrohydraulic supply unit to the front frame. Refer to «Electronic Brake Control Module Replacement (MK70)»(ref-302307-S21832616372008102100000) or «Electronic Brake Control Module Replacement (MK60)»(ref-302307-S03128347172008102100000) .
  6. For the vehicles with manual transmission, attach the shift guide bracket to the front frame. Tighten: Tighten to 20 N.m (15 lb ft).
  7. Attach the bracket for rear engine damping block to engine damping block. Use the new nut (1). Tighten: Tighten to 55 N.m (40 lb ft).
  8. Attach the stabilizer to the front frame. Refer to «Stabilizer Shaft Replacement»(ref-302306-S03005974082008102100000) .
  9. Attach the 2 radiator brackets to front frame. Tighten: Tighten to 15 N.m (11 lb ft).
  10. Install the front frame. Refer to «Front Frame Replacement (Replacement)»(ref-302303-S17522976952008102100000) or «Front Frame Replacement (Removal)»(ref-302303-S01377642962008102100000) .
  11. Install the 2 bolted connections, control arm to the front frame. Tighten: Tighten the 2 new screw connections for control arm on front frame to 90 N.m (67 lb ft) plus 75 degree, plus 15 degrees.
  12. Tighten control arm to frame bolt at trim height. Refer to «Trim Height Specifications»(ref-302309-S01474546742008102100000) .
  13. Perform the chassis alignment. Refer to «Alignment Checking»(ref-302303-S26889884832008102100000) . If necessary, adjust toe-in-refer to «Front Toe Adjustment»(ref-302310-S05041170402008102100000) . If necessary, adjust camber-refer to «Front Camber Adjustment»(ref-302310-S16984997142008102100000) .
  14. Fill and bleed the hydraulic system. Refer to «Hydraulic Brake System Bleeding»(ref-302299-S01246720642008102100000) .
  1. Install the front frame to the front frame.
  2. Raise the front frame with hydraulic jack, KM-904 and KM-6390 . See «Special Tools»(ref-302303-S29374387322008102100000) .
  3. Align the front frame. Tighten: Tighten the 4 new bolts to 90 N.m (67 lb ft), plus 45 degrees, plus 15 degrees.
  4. Install the triangular plates. Tighten: Tighten the 6 new bolts to 90 N.m (67 lb ft), plus 45 degrees, plus 15 degrees.
  5. Detach the hydraulic jack, KM-904 and KM-6390 . See «Special Tools»(ref-302303-S29374387322008102100000) .
  6. Install the bracket for rear engine damping block to the transmission. Tighten: Tighten to 80 N.m (59 lb ft).
  7. Install front engine damping block to the front frame. Tighten: Tighten to 55 N.m (40 lb ft). Insert the bolt. Install the new nut.
  8. In vehicles with manual transmission, install the shift guide to shift rod. Slide onto the shift rod. Install the clamping screw loosely. Place rocker onto the shift guide bracket. Secure using new retaining clip.
  9. Install the front exhaust pipe, catalytic converter and center muffler. Refer to «Mid Muffler Replacement»(ref-302311-S23419456572008102100000) .
  10. If present, install the lower engine compartment cover.
  11. Connect the guide joint to the steering knuckle on the right and left side. Tighten: Tighten the 2 new nuts to 50 N.m (37 lb ft).
  12. Connect the tie rod end to the steering knuckle. Refer to «Rack and Pinion Outer Tie Rod End Replacement»(ref-302308-S14293351942008102100000) .
  13. Install the swing arm to the spring strut support tube on the right and left side. Tighten: Tighten to 55 N.m (40 lb ft). Use 2 new nuts. Counterhold at the two flattened areas with open-ended wrench.
  14. Install the right lower wheelhouse panelling. Tighten: Tighten to 5 N.m (44 lb in).
  15. Install the front paneling. Refer to «Front Bumper Fascia Replacement»(ref-302288-S30625941892008102100000) .
  16. Install the right and left engine splash guards.
  17. Install the front wheels. Tighten: Tighten to 110 N.m (81 lb ft).
  18. Disconnect MKM-883-1 and MKM-883-2 from the engine. See «Special Tools»(ref-302303-S29374387322008102100000) .
  19. Connect the steering wiring harness.
  20. Connect the ground connection to insulated ground terminal.
  21. Connect the steering wiring harness plug.
  22. Install the coolant expansion tank to bracket.
  23. Install the upper engine cover. Remove the oil filler cap. Install the upper engine cover. Install the 2 bolts. Tighten: Tighten to 8 N.m (71 lb in). Install the oil filler cap.
  24. Install 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) .
  25. Remove the wire brackets for securing radiator.
  26. Position the wheels in straight-ahead position.
  27. Slide the intermediate spindle (2) onto steering gear spindle. Tighten: Tighten clamping bolt (1) on intermediate shaft to 24 N.m (18 lb ft).
  28. For vehicles with shift guide, adjust the shift. Refer to «Selector Lever Link Adjustment»(ref-302312-S12716027652008102100000) .
  29. Install the battery carrier. Tighten: Tighten the 3 bolts to 15 N.m (11 lb ft).
  30. Connect the 2 cable ties.
  31. Install the battery.
  32. Install the battery shield.
  33. Install the bolt. Connect the 2 shield, battery carrier.
  34. Install the battery holder. Tighten: Tighten the bolt to 7 N.m (62 lb in).
  35. Connect the battery. Connect the positive cable. Connect the ground cable.
  36. For programming procedures, refer to «Control Module References»(ref-302291-S24032387652008102100000) .
  1. Remove the front frame. Refer to «Front Frame Replacement (Replacement)»(ref-302303-S17522976952008102100000) or «Front Frame Replacement (Removal)»(ref-302303-S01377642962008102100000) .
  2. Press the corresponding damping bushing (4) out of the front frame with the KM-907-11 (3), KM-907-12 (1) and KM-907-30 (2).
  1. Install the new damping bushings in the front frame. Coat the damping bushings and guide in the front axle body with soapy solution. Draw the corresponding damping bushing (3) into the front frame with the KM-907-13 (2), KM-907-14 (1) and KM-907-30.
  2. Install the front frame. Refer to «Front Frame Replacement (Replacement)»(ref-302303-S17522976952008102100000) or «Front Frame Replacement (Removal)»(ref-302303-S01377642962008102100000) .
  1. Remove the front fender liner. Remove the 2 bolts (1).
  2. Remove the front fender liner. Remove the 8 body-bound rivets (arrows).
  1. Install the front fender liner. Install the 8 body-bound rivets.
  2. Fasten the front fender liner. Tighten: Tighten the 2 bolts to 2.5 N.m (22 lb in).

Scheme 1

Scheme 1: Removal Procedure
Scheme 1: Removal Procedure

Remove the rear wheelhouse panel liner.

  1. Remove the 2 bolts (2).
  2. Remove the 2 nuts (1).

Note. Refer to Fastener Notice .

Install the rear wheelhouse panel liner.

Tighten

  1. Tighten the 2 nuts to 2.0 N.m (18 lb in).
  2. Tighten the 2 bolts to 2.5 N.m (22 lb in).

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