Vauxhall Workshop Service and Repair Manuals

Disconnect battery. Completely fill brake fluid reservoir and seal with dummy seal. Open retaining band (2) for connection part at bulkhead. Press retaining clamp (1) out of connection part with small screwdriver. Disconnect clutch actuation pressure line. Press retaining clamp (1) in again.

Caution

Collect escaping brake fluid.

  Remove

Raise vehicle.

Vehicles with 4 cylinder OHC engine only: Remove wiring harness plug from dual spark ignition coil – accessible from vehicle underside. Unscrew fastening screw (1). Unclip wiring harness from bracket of dual spark ignition coil.

Unscrew fastening bolt (1) with engine transport shackle from camshaft housing. Unscrew fastening bolt (2) from cylinder head.

Illustration shows the dual spark ignition coil with engine removed for better presentation.

Remove dual spark ignition coil (1) upwards.

Remove ignition lead plugs from dual spark ignition coil.

All vehicles:

Unclip wiring harness plug (1) of oxygen sensor from bracket (2), lift retaining bracket and disconnect wiring harness plug.

Lift retaining bracket and disconnect wiring harness plug from reverse lamp switch.

For Engines Y 22 XE/Z 22 XE: In addition, disconnect wiring harness plug of front oxygen sensor.

Unscrew catalytic converter from front muffler. Unscrew exhaust bracket from transmission (1) and loosen at exhaust pipe (2).

Make pressure line of clutch actuation accessible from below.

Unscrew propshaft from transmission flange, MKM-604-18. Slide propshaft together and connect on the side to the right.

Pull 4 clips (arrows) of shift rod cover out of shift outrigger. Push cover forwards.

Remove retaining clamp from pin. Pull pin out of shift rod and gearshift lever.

Unscrew shift outrigger from transmission (2 screws).

Secure shift outrigger against falling down by jamming in a tyre lever.

Unscrew engine supports (2 screws each) on both sides of transmission (1). Loosen engine supports (1 screw each) on both sides of engine block (2).

Remove cover plate (3) from clutch.

Unscrew 2 lower screws (1) for transmission to engine block.

Support transmission with hydraulic jack. Unscrew crossmember (2) from vehicle floor.

Lower transmission using hydraulic jack, so that it can be moved past the shift outrigger. Unscrew 4 upper screws (1) for transmission to engine block. Press transmission off engine block and lower.

Caution

Do not damage oxygen sensor.

Install manual transmission (vehicles with 4-cylinder engine):

  Install

Engage a gear at the shift actuation. Thinly coat teeth of transmission drive shaft with lubricating paste. Raise transmission with hydraulic jack, align with engine and flange.

2 lower screws (1) for transmission to engine – 60 Nm / 44 lbf. ft.

Position cover plate (3) for clutch, engine supports to transmission (4, on left side with exhaust bracket) – 22 Nm / 16 lbf. ft.

Engine supports to engine block – 60 Nm / 44.5 lbf. ft. (M 10), 22 Nm / 16 lbf. ft. (M 8).

Exhaust bracket (2) to exhaust pipe – 20 Nm / 15 lbf. ft.

Catalytic converter to front exhaust pipe – 25 Nm / 18 lbf. ft. Remove tyre lever from shift outrigger.

Shift outrigger to transmission – 22 Nm / 16 lbf. ft.

  Install

Insert pin in shift rod and fork. Secure pin with retaining clamp. Fasten cover for shift rod with 4 clips.

Propshaft with new fastening bolts to output flange (1) – 50 Nm / 37 lbf. ft. + 75° + 15°, MKM-604-18 (at the same time align vibration damper (2)).

Connect wiring harness plug (2) for oxygen sensor, so that retaining bracket engages. Clip wiring harness plug into transmission bracket.

Connect wiring harness plug to reverse lamp switch (1), so that retaining bracket snaps in.

For Engines Y 22 XE/Z 22 XE: In addition, connect front oxygen sensor wiring harness plug.

Vehicles with 4-cylinder OHC engines only:

Install dual spark ignition coil (1). Connect ignition cable plugs.

Caution

Note ignition sequence – ignition cables and dual spark ignition coil are marked with cylinder numbers.

Screw fastening bolt (1) into cylinder head, fastening bolt (2) with engine transport shackle to camshaft housing and fastening bolt (3) and tighten. Attach wiring harness plug for dual spark ignition coil. Clip wiring harness to bracket of dual spark ignition coil.

Torque

Dual spark ignition coil bracket to cylinder head 15 Nm / 11 lbf. ft.

All vehicles:

Route pressure line of clutch actuation upwards.

Lower vehicle. Insert pressure line in connection piece, thereby ensuring that pressure line engages audibly in retaining clamp (1). Fasten connection piece to bulkhead with retaining strap (2).

Unscrew dummy cap from brake fluid reservoir.

  Install

Bleed clutch actuation – see operation "Hydraulic Clutch Actuation, Bleed".

Connect battery.