Vauxhall Workshop Service and Repair Manuals

Engine, Remove and Install

Disconnect ground strap from battery.

Remove air cleaner.

Detach lower coolant hose from radiator and drain coolant.

Place drip tray underneath.

Unscrew upper coolant hose from thermostat housing.

Unscrew heater hoses from intake manifold and coolant pipe.

Loosen and pull off hoses from carburettor, automatic choke cover.

Detach bowden cable from carburettor.

Pull vacuum hose from brake servo.

Loosen hose clamps and pull off fuel feed and return lines.

Disconnect cable for reversing lamps from transmission.

Detach positive cable from battery.

Part multiple plug of engine wiring harness.

Press lock and pull plug apart.

Pull multiple plug and ignition cable from ignition coil.

Raise vehicle.

Remove front exhaust pipe completely.

Unbolt exhaust pipe from manifold and intermediate flange.

Unscrew closure plug from transmission case cover and pull out drive shaft using KM-556-1.

See corresponding operation in group K.

On GSi, unscrew hoses to oil cooler from oil filter intermediate flange.

Catch escaping engine oil.

Unbolt clutch cover plate.

Unscrew lower bolts from clutch housing to engine block.

Lower vehicle.

Attach sling to engine by hooks provided.

Remove front right engine mounting completely.

Support transmission with vehicle jack.

Unscrew upper bolts from clutch housing to engine block.

Press engine from clutch housing and remove upwards from engine compartment.

To do this, open bonnet to full extent.

Install Engine

Lower engine into engine compartment and guide into centering point in clutch housing.

Screw in fastening bolts from clutch housing to engine block.

Bolt on front right engine mounting.

Remove transmission support.

Remove engine from sling and raise vehicle.

Mount clutch cover plate and screw in lower fastening bolts from clutch housing to engine block.

Mount drive shaft using KM-564.

See corresponding operation in group K.

Install front exhaust pipe.

Important:     On GSi, screw on hoses to oil cooler to oil filter intermediate flange.

Ensure that spacer dimension "A" =  mm/   in. is maintained. If necessary, correct position of hoses by turning intermediate flange.

Connect cable for reversing lamps to transmission case, ignition cable and multiple plug to ignition coil, multiple plug of wiring harness and battery positive cable.

Connect fuel feed and return lines.

Mount hose clamps.

Connect vacuum line to brake servo.

Fasten bowden cable to carburettor free of tension.

Connect coolant hoses, heater hoses and hoses to carburettor, automatic choke cover.

Install air filter.

Fill coolant system through expansion tank.

To bleed system, unscrew temperature sensor from intake manifold and fill system at expansion tank until coolant escapes.

Continue to fill coolant as far as "KALT" mark.

Connect ground strap to battery.

Refill collected engine oil.