Vauxhall Workshop Service and Repair Manuals

Transmission, Remove and Install (Z13DTH/M20 MTA)

Note:   If the transmission is replaced, the following parts must be transferred:

  Remove

4.   Detach battery wiring harness bracket (1) from MTA supply unit •   Unscrew bolt (2)

5.   Release MTA system supply unit •   Unscrew 3x bolt (1) Note:   Note differing bolt lengths

6.   Release MTA wiring harness bracket (1) •   Unscrew bolt (2)

7.   Disconnect MTA system wiring harness •   Release wiring harness plug (1) and disconnect

9.   Attach KM-6001-B to front axle body •   Release 2x bolt (arrows) for adjustment rails on KM-6001-B (1) •   Insert KM-6001-B as shown Note:   2x journals (2) and (5) must sit flush in the guide holes of the front axle body. •   Tighten 2x bolt for adjustment rails •   Twist up front support bearing (4) – as far as the stop on the guide pin of the front engine damping block Note:   The guide pins must sit in the support bearings with no play. •   Twist up rear support bearing (3) – as far as the stop on the guide pin of the rear engine damping block bracket Note:   The guide pins must sit in the support bearings with no play.

11.	Detach right axle shaft from intermediate shaft •   Attach axle shaft to vehicle underbody

14.   Remove front engine damping block •   Unscrew 2x bolt

15.   Remove rear engine damping block •   Release wiring harness plug (1) and disconnect •   Unscrew bolt (2) from wiring harness bracket •   Unscrew 3x bolt (3)

16.   Detach left engine damping block from engine damping block bracket •   Unscrew 3x bolt (1)

19.   Release transmission at top Note:   With the vehicle raised, release the upper transmission bolts from below. •   Unscrew the front (1) and rear (2) upper transmission bolts

20.   Place transmission holder DT-47648 on KM-904 and preinstall as shown in the illustration: Component Position on base plate Designation DT-47648-2 (4) 2 Clutch housing support DT-47648-3 (2) 14 Transmission housing support DT-47648-5 left (1) A Support with rear transmission swivel arm DT-47648-5 right (3) F Support with front transmission swivel arm

Important:   It is essential to follow the manufacturer's instructions for transmission holder DT-47648 . 21.   Attach DT-47648 to transmission Note:   Before placing in position, slacken all bolt connections of the swivel arms and supports as far as the base plate. Adjust the supports using the spindles until they are as low as possible. •   Place DT-47648 with supports in position under the transmission •   Tighten bolt connections of the supports •   Attach swivel arm (1) and (2) to transmission •   Tighten bolt connections of the swivel arms starting from the transmission and going as far as the base plate Note:   Align the swivel arms so that as little leverage as possible is created.

22.   Remove transmission •   Unscrew 4x bolt (1) •   Press transmission off engine and slowly lower the hydraulic jack Note:   Do not damage wiring harnesses and attaching parts

24.   Detach left engine damping block bracket (1) from transmission Note:   Only required if the transmission is being exchanged. •   Unscrew 3x bolt (2)

  Install

25.   Attach left engine damping block bracket (1) to transmission Note:   Only required if the transmission is being exchanged. •   Tighten 3x bolt (2) 60 Nm

28.   Fasten transmission at the bottom •   Tighten 2x bolt M12 (1) – Stage 1 10 Nm – Stage 2 60 Nm

30.   Fasten transmission at the bottom •   Tighten 2x bolt M10 (1) 40 Nm Note:   Note differing bolt lengths

31.   Fasten transmission at top Note:   With the vehicle raised, fasten the upper transmission bolts from below. •   Tighten the front (1) and rear (2) M12 upper transmission bolts 60 Nm

33.   Attach the left engine damping block to the left engine damping block bracket •   Screw in 3 bolts (1) loosely

36.	Attach right axle shaft to intermediate shaft

37.   Install front engine damping block •   Tighten 2x bolt (1) 80 Nm

38.   Install rear engine damping block •   Tighten 3 bolts (3) •   Fasten wiring harness bracket – Tighten bolt (2) •   Connect and lock wiring harness plug (1)

40.   Fasten left engine damping block •   Tighten 3x bolt (1) 55 Nm

44.   Connect wiring harness, MTA-system •   Connect and lock wiring harness plug (1)

45.   Fasten MTA wiring harness bracket (2) •   Tighten bolt (1)

46.   Fasten MTA system supply unit •   Tighten 3x bolt (1) 10 Nm Note:   Note differing bolt lengths

47.   Attach battery wiring harness bracket (1) to MTA system supply unit •   Tighten bolt (2)

48.	Top up with transmission fluid

53.	Necessary Start-Up Routines for Easytronic

54.	Work to be carried out with Tech 2