Vauxhall Workshop Service and Repair Manuals

Trailer Hitch, Service Install

Mechanical Equipment on Models 33, 34, 43, 44

Remove luggage compartment floor covering

Remove spare wheel and vehicle tool kit.

Remove rear bumper.

2 screws to rear end panel

2 screws to each rear quarter panel

Heat up any existing insulating material in contact area of left and right retaining plates using hot air drier and remove.

Drill 4 holes Æ 12 mm/0.47 in. in floor panel, 2 each above left and right sidemembers.

Locate existing centre punch marks by holding retaining plates in position.

Drill 3 holes Æ 14 mm/0.55 in. and 1 hole Æ 18 mm/0.71 in. in floor panel. Centre punch marks are present.

Drill 4 holes Æ 14 mm/0.55 in. in rear end panel.

Centre punch marks are present.

Insert reinforcement.

Insert retaining plates with threaded bolts through left and right sidemembers and loosely tighten with washers and nuts.

To do this, remove any PVC or bitumen on contact surfaces of sidemembers.

Left sidemember

Right sidemember

Apply plastic compound around fastening holes in rear end panel and floor panel.

Bolt coupling with washer and hex nut as well as washer and hex bolt to reinforcement.

Tighten all hex bolts and hex nuts - observe prescribed torque.

Cut out section of bumper marked on inside for ball head of trailer hitch.

Reinstall bumper.

Illus. B 9788 shows saloon except GSi/GTE.

On GSi/GTE end piece is cut off.

On vehicles with rear apron on rear bumper, the rear apron is cut to match the cut-out in the bumper.

Apply paint to cut edge.

Due to the cut-out: on vehicles with factory-installed apron the centre retaining spring is not present; on vehicles with service-installed apron the centre securing screw is not present.

Instead, the rear spoiler is secured to the rear bumper with two self-tapping screws with washer 4.8 x 12, located 100 mm/3.9 in to the right and left respectively of the cut-out.

To do this, drill 2 holes Æ 5 mm/0.19 in in rear apron and 2 holes Æ 3 mm/0.12 in in rear bumper.

Mount towbar load plate on underside of tail gate.

Use luggage compartment floor covering for vehicles with trailer hitch.

Mechanical Equipment on Models 39, 49

Remove luggage compartment floor covering.

Remove spare wheel and vehicle tool kit.

Heat up any existing insulating material in contact area of left and right retaining plates using hot air dryer and remove.

Drill two holes Æ 25 mm/0.98 in. in floor panel, 2 each above left and right sidemembers.

Locate existing centre punch marks by holding retaining plates in position.

Insert retaining plates with threaded bolts in floor panel and tighten with self-tapping screws.

To do this, drill hole Æ 3.5 mm/0.14 in. in floor panel.

Insert hitch socket from below with threaded bolts through left and right sidemembers and tighten with washers and nuts.

Remove any PVC or bitumen on contact surfaces sidemembers if necessary.

Left sidemember

Right sidemember

Tighten all hex nuts - observe prescribed torque.

Mount tongue load plate on underside of luggage compartment lid.

Mechanical Equipment on Models 35, 36, 45, 46

Raise load compartment floor.

Remove spare wheel and vehicle tool kit.

Remove rear bumper.

1 screw to upper side of rear end panel

1 screw to lower side of rear end panel

2 screws to each rear quarter panel.

Drill 4 holes Æ 23 mm/0.91 in. and 1 hole Æ 18 mm/0.71 in. in rear end panel. Centre punch marks are present.

Drill 3 holes Æ 14 mm/0.55 in. in floor panel.

Centre punch marks are present.

Insert reinforcement and loosely bolt to flange of load compartment floor with retaining plates and hex nuts. Apply plastic compound around fastening holes in rear end panel and floor panel.

Loosen screwed joint from trailer hitch ball to retaining plate and tip retaining plate towards trailer hitch ball.

Bolt coupling with shims and hex nuts as well as washer and hex bolt to reinforcement.

Ensure that no cables are caught in the spacer sleeves when inserting coupling.

Tighten all hex bolts and hex nuts - observe prescribed torque.

Reinstall bumper.

Mount tongue load plate to underside of tail gate (see saloon).

Electrical Equipment

Disconnect battery ground cable.

Models 33, 34, 43, 44 without Check Control

Feed wiring harness for trailer socket through floor panel and insert grommet. Lay wiring harness to rear lamps through rear end panel.

Screw brown ground lead to rear end panel. On vehicles with RHD, connect black/blue cable for rear fog lamps.

Connect wiring harness for trailer socket to both rear lamp assemblies and to vehicle wiring harness.

On vehicles with LHD, lay red single cable alongside vehicle wiring harness to fuse box and connect to terminal "30".

This lead is available with contact spring on wiring harness according to vehicle equipment. When connecting rear fog lamps, connect red lead to black/blue rear fog lamp lead using splice connector.

Models 39, 49

Drill hole Æ 18 mm/0.71 in. in rear end panel.

Centre punch marks are present.

Models 39, 49, without Check Control

Feed wiring harness for trailer hitch through rear end panel and insert grommet.

Lay wiring harness to rear lamps through rear end panel.

Screw brown ground lead to rear end panel.

On vehicles with RHD, connect black/blue cable for rear fog lamps.

Disconnect multiple plug of vehicle wiring harness from both rear lamps and connect with socket of trailer hitch wiring harness.

Connect trailer hitch wiring harness multiple plugs to both rear lamp assemblies.

On vehicles with LHD, lay single red cable alongside vehicle wiring harness to fuse box and connect to terminal "30".

This lead is available with contact spring on wiring harness according to vehicle equipment.

When connecting rear fog lamps, connect red lead to black/blue rear fog lamp lead using splice connector.

Models 39, 49 with Check Control

Feed wiring harness for trailer socket through rear end panel and insert grommet.

Lay wiring harness to rear lamps through rear end panel.

Screw brown ground lead to rear end panel.

Connect wiring harness for trailer hitch to vehicle wiring harness.

If on vehicles with LHD a trailer socket for rear fog lamps is required, an adapter can be mounted using two splice connectors.

Using a splice connector, a connection is made between rear fog lamp lead (black/blue) in vehicle wiring harness and adapter, and between adapter and red wiring harness lead for trailer hitch.

Separate red lead between connecting lead and plug wiring harness plug connection for trailer hitch.

Models 35, 36, 45, 46 without Check Control

Feed wiring harness for trailer socket through rear end panel and insert grommet. Lay wiring harness to rear lamps through rear end panel. On vehicles with RHD, connect black/blue lead for rear fog lamps.

Connect wiring harness for trailer socket to both rear lamp assemblies and vehicle wiring harness.

On vehicles with LHD, connect red single cable to existing cable with contact spring.

Screw brown ground lead to rear quarter panel. When connecting rear fog lamps, connect red lead to black/blue rear fog lamp lead using splice connector.

Models 33, 34, 43, 44 with Check Control

Feed wiring harness for trailer socket through floor panel and insert grommet.

Lay wiring harness to left hand rear quarter panel through rear end panel.

Screw on brown ground lead to rear end panel.

Connect socket wiring harness to existing multiple plug of vehicle wiring harness.

Models 35, 36, 45, 46 with Check Control

Feed wiring harness for trailer socket through rear end panel and insert grommet. Lay wiring harness to left hand rear quarter panel through rear end panel.

Connect socket wiring harness to existing multiple plug of vehicle wiring harness.

Screw on brown ground lead to rear quarter panel.

All Models

Push protective cap on to wiring harness. Connect socket electrically and install.

1/L         Left turn signal lamp                   black/white

2/54 g    Constant current/rear for light     red, or black/blue

3/31       Ground                                        brown

4/R         Right turn signal lamp                 black/green

5/58 R    Right parking lamp                      grey/red

6/54       Brake lamp                                  black/yellow

7/58 L    Left parking lamp                        grey/black

Remove instrument housing.

Remove cover cap with horn button from steering wheel.

Remove upper signal switch panelling.

To do this, remove 4 screws, turning steering wheel 90° to left each time.

Remove instrument panel panelling.

2 screws

Pull off wiring harness from instrument panel panelling switches.

Pull off speedometer cable from speedometer connection.

To do this, press down retaining springs at cable connection and simultaneously pull off cable.

Unscrew instrument housing, lift from lower retainers and pull out.

Insert telltale in instrument housing and make electrical connections.

On vehicles with special equipment, positive and negative leads are present on wiring harness.

Disconnect fuse box, pull off turn signal unit.

Insert positive lead in turn signal unit multiple socket housing (already present on vehicles with special equipment wiring harness).

Mount turn signal unit for trailer operation.

Connect ground lead with self-tapping screw and toothed lock washer to steering column support (already present on vehicles with special equipment wiring harness).

Reinstall removed parts.

Connect battery ground cable.

Check System for Correct Functioning

The trailer to be used should as a general rule be hitched up when making this test, as only then can the vehicle and trailer systems be checked for proper functioning.

When checking without a trailer, a 5 watt bulb is to be connected to each of the socket terminals "5/58 R" and "7/58 L". A 21 watt bulb is to be connected to each of the terminals "1/L" and "4/R".

When operating with a trailer, the double turn signal telltale system is a closed system, i.e. when the trailer telltale fails to light, a turn signal lamp either at the front or rear of the towing vehicle or on the trailer may have failed, even though the towing vehicle telltale is lit.

When operating without a trailer, only the vehicle telltale is of importance. Additional electrical fuses are not necessary, as the socket connections are protected by existing fuses in the vehicle.

Additional turn signal telltale

Standard turn signal telltale

Status of turn signal unit on side actuated

flashes

Operatig with trailer

flashes

turn signal system OK

not flashing

flashes at double speed

one turn signal lamp - on towing vehicle or trailer - is defective

not flashing

flashes at double speed or not at all

two turn signal lamps - on towing vehicle alone or on towing vehicle and trailer or three turn signal lamps - on towing vehicle and trailer - are defective

Operating without trailer

not flashing

Note:

flashing one to three times immediately after actuation is of no significance

flashes

turn signal system OK

not flashing

flashes at double speed or not at all

one or two turn signal lamps are defective

Vehicle

Engine

Trans.

Standard front panelling, radiator

Changes for front panelling, radiator

when installing trailer hitch

MT

AT

Upper two

grille rows

Opening behind

license plate

Open upper

two grille

rows

Open aperture

behind license

plate

Install

heavy duty

radiator

open

close

open

closed

12 SC

12 ST

x

x

x

x

13 N

13 NB

13 S

C 13 N

x

x

x

x

x

All

except

GSi

and

16

16 S

16 SV

x

x

x

x

GTE

up to

and incl.

C 16 LZ

S 18 NV

C 18 NT

x

x

x

x¹⁾

MY '1988

C 18 NE

18 SE

x

x

x

x

x

16 D

16 DA

x

x

x

x

18 E

C 18 NE

x

x

x

x

x

GSi

GTE

20 XE,

C 20 XE

20 SEH

C 20 NE

20 XEJ

x

x

x

x

Vehicle

Engine

Transmission

Standard fronto panelling, radiator

Changes for front panelling, radiator

when installing trailer hitch

MT

AT

Upper row of

of radiator grille

Lower row of

front panelling

Open upper

row of

radiator grille

Open lower

row of front

panelling

open

closed

open

closed

12 SC

13 S

x

x

x

x

x

All

except

13 NB

C 13 NZ

14 NV **)

C 14 NZ **)

x

x

x

GSi/GTE

as of

MY '1989

E 16 NZ

C 16 NZ

16 SV

x

x

x

x

x

E 18 NV

E 18 SE *)

C 18 NZ *)

C 20 NE

x

x

x

15 DTR

x

x

x

17 D

x

x

x

x

17 DT

x

x

x

Notes on Changes to Front Panelling Up to Model Year 1989

Depending on vehicle equipment - see Table - two upper rows on grille "A" and opening behind license plate "B" are to be cut out using a suitable knife and, if necessary, filed smooth.

On front panelling with a separate cover behind the grille rows "A", remove this cover, if necessary, by filing off the retaining pins.

On GSi/GTE, remove cover by filing off retaining pins behind license plate "B".

As of Model Year 1989:

The 1st air slot row "A" in radiator grille as well as lower row "B" in front panelling should be cut out according to vehicle type - see tables - using an appropriate knife and if necessary filed.

Notes on Installing Heavy Duty Cooling System

Release oil dipstick wiring harness from venturi, if present.

Disconnect plug connector and lay to one side. Pull wiring harness from fan and release from venturi.

Unscrew venturi from upper mounting (2 hex screws) and pull from lower retainer.

Unscrew fan from venturi - 3 hex nuts with washers. Screw fan with 366 mm/14.4 in. diameter blades "A" to corresponding venturi "B". When doing this, note position of electrical connection - lower left looking in direction of travel.

Use hex nuts and washers from previous fan.

Insert venturi in lower retainer on radiator and secure to upper mounting with 2 hex screws.

Connect wiring harness "A" to blower and attach to shroud support with retaining strap "B".

Connect wiring harness for oil gauge and attach to shroud with 2 retaining straps "C".