Opel Insignia: Repair Instructions

Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection

Removal Procedure

1.

Pull the plastic cap(1) back from the quick connect fitting (2)and down along the cooler pipe enough to expose the transmission fluid cooler pipe fitting retainer.

2.

Using a small flat bladed tool, small pick or other suitable tool, lift one of the open ends of the retaining ring(1) in order to rotate the retaining ring around the quick connect fitting until the retaining ring is out of position and can be completely removed.

3. Remove the transmission fluid cooler pipe fitting retainer from the quick connect fitting.

4. Discard the retainer.

5.

Pull the cooler pipe(1) straight out from the quick connect fitting(2).

Installation Procedure

NOTE:

• Do not reuse any of the existing transmission fluid cooler pipes or transmission fluid cooler pipe fittings if there is excessive corrosion.
• Do not reuse any transmission fluid cooler pipe fitting retainer that was removed from the quick connect fittings. Always install NEW transmission fluid cooler pipe fitting retainers.
• Ensure the following procedures are performed when installing the new retainer onto the fittings.

1. Install a new retainer into the quick connect fitting using the following procedure:

Do not install the new retainer (1) onto the quick connect fitting (2)by forcing the retainer over the fitting causing the retainer to expand.

Hook one of the open ends of the retainer (1) in one of the slots in the quick connect fitting.

Rotate the retainer(1) around the fitting until the retainer is positioned with all three ears through the three slots on the fitting.

4. Ensure that the three retainer ears (1)are seen from inside the fitting and that the retainer moves freely in the fitting slots.

2.

Install the cooler pipe (1) into the quick connect fitting(2)until a click is either heard or felt.

3.

4. Pull back sharply on the cooler pipe in order to ensure that the cooler pipe is fastened into the quick connect fitting.

NOTE: Do not manually depress the retaining clip when installing the plastic cap.

5. Position (snap) the plastic cap (1)onto the fitting. Do not manually depress the retainer when installing the plastic cap onto the quick connect fitting.

6. Ensure that the plastic cap (1)is fully seated against the fitting.

7. Ensure that no gap is present between the plastic cap(1) and the fitting(2).

8.

A visible yellow identification band(1) indicates an improper joint seating. make sure that the yellow indicator band IS NOT present when completely installed.

9. Fill the transmission to the proper level.

Transmission Fluid Cooler Inlet Pipe Replacement (9T50 / 9T60)

Removal Procedure

1. Place a suitable container under the vehicle to catch any spilled transmission fluid.

2. Front Wheelhouse Liner-Left Side - Remove.

3. Front Compartment Splash Shield-Right Side - Remove.

4.

NOTE: Cover or plug all open transmission fluid cooler pipe connection points to help avoid any accidental contamination or spills.

Transmission Fluid Cooler Inlet Pipe(1)@Radiator - Remove.

5.

Transmission Fluid Cooler Inlet Pipe(1)@Radiator - Unclip.

6.

Transmission Fluid Cooler Inlet Pipe(1)@Transmission - Unclip.

7.

Transmission Fluid Cooler Inlet Pipe Bolt(1)@Transmission - Remove.

8.

Transmission Fluid Cooler Inlet Pipe(1)@Transmission - Remove.

9. Remove the transmission fluid cooler inlet pipe (1) from the vehicle.

Installation Procedure

1. Remove the caps from the fittings and plugs from the holes before installing the transmission fluid cooler pipes.

2. Install the transmission fluid cooler inlet pipe to the vehicle.

3.

Transmission Fluid Cooler Inlet Pipe(1)@Transmission - Install.

4.

CAUTION: Refer to Fastener Caution.

Transmission Fluid Cooler Inlet Pipe Bolt(1)@Transmission - Install and tighten9 N.m (80 lb in).

5.

Transmission Fluid Cooler Inlet Pipe(1)@Transmission - Install.

6.

Transmission Fluid Cooler Inlet Pipe(1)@Radiator - Install.

7.

Transmission Fluid Cooler Outlet Pipe(1)@Radiator - Install.

8. Front Wheelhouse Liner-Left Side - Install.

9. Front Compartment Splash Shield-Right Side - Install.

10. Fill the transmission to the proper level with NEW transmission fluid. 11. Inspect for transmission fluid leaks.

Transmission Fluid Cooler Outlet Pipe Replacement (9T50 / 9T60)

Removal Procedure

1. Place a suitable container under the vehicle to catch any spilled transmission fluid.

2.

NOTE: Cover or plug all open transmission fluid cooler pipe connection points to help avoid any accidental contamination or spills.

Transmission Fluid Cooler Outlet Pipe(1)@Radiator - Remove.

3. Front Wheelhouse Liner-Left Side - Remove.

4.

Transmission Fluid Cooler Outlet Pipe(1)@Radiator - Unclip.

5.

Transmission Fluid Cooler Outlet Pipe(1)@Transmission - Unclip.

6.

Transmission Fluid Cooler Outlet Pipe Nut(1)@Transmission - Remove.

7. Transmission Fluid Cooler Outlet Pipe(2)@Transmission - Remove.

8. Remove and DISCARD the sealing washer.(3).

9. Remove the transmission fluid cooler outlet pipe (2) from the vehicle.

Installation Procedure

1. Remove the caps from the fittings and plugs from the holes before installing the transmission fluid cooler pipes.

2. Install the transmission fluid cooler outlet pipe to the vehicle.

3.

Install a NEW sealing washer.(3) 4. Transmission Fluid Cooler Outlet Pipe(2)@Transmission - Install.

CAUTION: Refer to Fastener Caution.

5. Transmission Fluid Cooler Outlet Pipe Nut(1)@Transmission - Install and tighten22 N.m (16 lb ft).

6.

Transmission Fluid Cooler Outlet Pipe(1)@Transmission - Engage.

7.

Transmission Fluid Cooler Outlet Pipe(1)@Radiator - Install.

8. Front Wheelhouse Liner-Left Side - Install.

9.

Transmission Fluid Cooler Outlet Pipe(1)@Radiator - Install.

10. Fill the transmission to the proper level with NEW transmission fluid.

11. Inspect for transmission fluid leaks.

Transmission Fluid Cooler Inlet and Outlet Pipe Replacement (AF50-8)

Removal Procedure

1.

Place a drain pan under the vehicle.

2. Transmission Fluid Cooler Pipe Connector Cap(1)@Radiator - Unclip.

3. Transmission Fluid Cooler Outlet Pipe(2)@Quick Connect Fitting - Disconnect.

4. Raise and support the vehicle.

5. Charge Air Cooler Inlet Air Tube - Remove.

6.

Transmission Fluid Cooler Pipe Nut(2) - Remove.

7. Transmission Fluid Cooler Inlet and Outlet Pipe(1)@Transmission - Disconnect.

8.

Unclip the retainer with a screwdriver. (3) [2x].

9. Transmission Fluid Cooler Inlet and Outlet Pipe(1) - Pull out.

10.

Transmission Fluid Cooler Pipe Connector Cap(1)@Radiator - Unclip.

11. Transmission Fluid Cooler Outlet Pipe(2)@Quick Connect Fitting - Disconnect.

12. Route the transmission fluid cooler inlet and outlet pipe out of the vehicle.

Installation Procedure

1. Route the transmission fluid cooler inlet and outlet pipe into proper position.

2.

Transmission Fluid Cooler Outlet Pipe(2)@Quick Connect Fitting - Connect.

3. Transmission Fluid Cooler Pipe Connector Cap(1)@Radiator - Clip.

4.

Transmission Fluid Cooler Inlet and Outlet Pipe(1) - Install.

5. Transmission Fluid Cooler Inlet and Outlet Pipe Retainer(2) - Close[2x].

6.

Transmission Fluid Cooler Inlet and Outlet Pipe(1)@Transmission - Connect.

CAUTION: Fastener Caution.

7. Transmission Fluid Cooler Pipe Nut(2) - Install and tighten10N.m (89 lb in).

8. Charge Air Cooler Inlet Air Tube - Install.

9. Lower the vehicle.

10.

Transmission Fluid Cooler Outlet Pipe(2)@Quick Connect Fitting - Connect.

11. Transmission Fluid Cooler Pipe Connector Cap(1)@Radiator - Clip.

12. Remove the drain pan.

13. Check the transmission fluid level.

TRANSMISSION FLUID COOLER PIPE FITTING SEAL REPLACEMENT

Special Tools

• DT - 41239-1A Cooler Line Seal Installer
• DT - 45201 Cooler Line Seal Remover

For equivalent regional tools, refer to Special Tools.

Removal Procedure

1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle.

2. Place a drain pan or suitable container under the vehicle.

3.

Remove the transmission oil cooler line assembly nut from the transmission.

4. Disconnect the transmission oil cooler lines from the vehicle.

5.

NOTE: Ensure that the J 45201 is fully seated into the transmission seal bore.

Insert the collet piece (2) of the DT - 45201 Cooler Line Seal Remover into the cooler line seal.

6. Insert the forcing screw piece (1) of the DT - 45201 Cooler Line Seal Remover into the collet (2).

7. Tighten the forcing screw (1) until snug.

8.

Thread the collar piece (1) of the DT - 45201 Cooler Line Seal Remover onto the collet (3) until snug.

9.

Turn the collar clockwise in order to remove the cooler line seal (87).

10. Discard the seal (87).

11. Clean the case bores for the cooler line seals.

Installation Procedure

1. Insert a new transmission cooler line seal into the case bore.

2.

Remove the nub from the DT - 41239-1A Cooler Line Seal Installer.

3.

Install the nub of the DT - 41239-1A Cooler Line Seal Installer on the transmission cooler line seal.

4. Tap the new transmission cooler line seal into the case bore.

5.

Install the transmission oil cooler line assembly to the transmission.

CAUTION: Refer to Fastener Caution.

6. Install the transmission oil cooler line assembly nut and tighten to 9 N.m (80 lb in).

7. Lower the vehicle.

8. Check and adjust transmission fluid level as necessary.

9. Start the engine and check for leaks.

SPECIAL TOOLS AND EQUIPMENT

SPECIAL TOOLS

DT-41239 - 1A

J-41239 - 1A

Cooler Line Seal Installer

DT - 45096

J - 45096

Transmission Cooler Flusher

DT - 45096- 30

J - 45096-30

Transmission Cooler Flush Adapter

DT - 45096- 50

J - 45096-50

Transmission Cooler Flush Adapter

DT-45201

J-45201

Cooler Line Seal Remover

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