Vauxhall Workshop Service and Repair Manuals

Transmission, Remove and Install (Z20LEL, Z20LEH, Z20LER/M32)

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

  Remove

2.   Detach pressure line (1) from transmission Note:   Collect any escaping brake fluid. •   Open retaining clamp (arrow) •   Draw pressure line out of connector •   Push retaining clamp into connector 3.   Detach bracket for wiring harness from transmission •   Unscrew bolt (2)

4.   Detach 2x gearshift cables (2) from transmission •   Detach 2x gearshift cable from shift linkage lever •   Remove 2x shift cable from counterhold – Press 2x retaining ring (1) towards the rear

5.   Release transmission at top •   Unscrew 3x bolt (1)

7.   Attach KM-6001-B to front axle body Note:   The guide pins must sit in the support bearing with no play. •   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) – until the guide pin is in contact with the front of the engine damping block •   Twist up rear support bearing (3) – until the guide pin is in contact with the rear of the engine damping block

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

12.   Disconnect wiring harness plug (1) for reversing lamp switch (2)

13.   Detach transmission from left engine damping block •   Unscrew 3x bolt (1)

16.   Remove vacuum reservoir (2) Note:   Do not detach vacuum lines. •   Unscrew 2x bolt (1) •   Put vacuum reservoir aside

17.   Detach front engine damping block bracket •   Unscrew 2x bolt (1) 18.   Detach rear engine damping block bracket •   Unscrew 3x bolt (2)

19.   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 . 20.   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.

21.   Remove transmission •   Unscrew 8x bolt (1...4) •   Press transmission off engine and slowly lower the hydraulic jack Note:   Do not damage wiring harnesses and attaching parts

  Install

25.   Install transmission •   Raise transmission and align it •   Place transmission so that it is in even contact with the engine •   Tighten 2x bolt M12 (1) and (6) – Stage 1 10 Nm – Stage 2 60 Nm •   Tighten 6x bolt (2...5) – M10 40 Nm – M12 60 Nm

27.   Install vacuum reservoir (2) •   Tighten 2x bolt (1)

29.   Attach transmission to left hand engine damping block •   Screw in 3x bolt (1) Note:   Do not tighten bolts yet

30.   Attach front engine damping block bracket •   Tighten 2x bolt (1) 80 Nm 31.   Attach rear engine damping block bracket •   Tighten 3x bolt (2) 80 Nm

32.	Install catalytic converter

35.	Attach right axle shaft to intermediate shaft

36.   Connect wiring harness plug for reversing lamp switch

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

40.   Fasten transmission at top •   Tighten 3x bolt (1) 60 Nm

41.   Attach pressure line (1) to transmission •   Press pressure line into connector Note:   Retaining clamp must engage noticeably 42.   Attach bracket for wiring harness to transmission •   Tighten bolt (2) 10 Nm

43.   Attach 2x shift cable to transmission •   Attach 2x ball socket (2) to shift linkage lever •   Engage 2x shift cables in counterhold – Press 2x retaining ring (1) towards the rear

44.	Correct transmission fluid level

46.	Bleed hydraulic clutch actuation

47.	Transmission Shift Linkage, Adjust