Vauxhall Workshop Service and Repair Manuals

Engine with Manual Transmission and Differential, 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.

Release 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.

Detach positive cable from battery.

Part multiple plug of engine wiring harness.

Press lock and pull plug apart.

Pull off multiple plug and ignition cable from ignition coil.

Separate shifting shaft.

Unscrew speedometer cable from transmission.

Detach clutch cable.

Raise vehicle.

Remove both front wheels.

Remove front exhaust pipe completely.

Unbolt exhaust pipe from manifold and intermediate flange.

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

Catch escaping engine oil.

Unscrew ground strap from transmission.

Press swivel joint out of steering knuckle using KM-507-B.

To do this, release and remove castellated nut.

Press both left and right drive shafts out of transmission using KM-460-A.

Install plug 90 93 035 to prevent transmission fluid escaping.

Suspend drive shafts.

Place engine lifter under engine and transmission and raise slightly.

Unbolt engine mountings at front right, front left and rear from frame.

See illus. B 9494 on Page J-113

Remove engine with manual transmission and differential downwards from engine compartment.

Engine, Install

Raise engine with manual transmission and differential evenly into engine compartment.

Bolt engine mountings at front right, front left and rear to frame.

Initially tighten bolts only finger tight to avoid tension.

See Technical Data for torque values.

Remove engine lifter.

Install drive shafts.

Fasten swivel joints to steering knuckles.

                Screw on castellated nut and secure with clamp.

Install front exhaust pipe.

Screw ground strap to transmission.

Mount front wheels.

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.

Lower vehicle.

Attach clutch cable.

Screw speedometer cable to transmission and mount shifting shaft.

Connect ignition cable and multiple plug to ignition coil, multiple plug of wiring harness and positive cable to battery.

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 cooling system through expansion tank.

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

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

Connect ground strap to battery.

Refill collected engine oil.