Vauxhall Workshop Service and Repair Manuals

Rear Cover with Piston C1, Overhaul (AF 20/22)  

  Disassemble   

Remove rear cover. Remove thrust bearing (1). Remove hook seal rings (3) from bearing journal - ring gaps are L-shaped, press one ring gap in the groove, hook out the other.   Remove fastening bolts (2) and remove cover for piston C1. Remove spring (4) and piston C1 (5) - replace O-ring (6) at piston C1.     Measure    Measure outside diameter (I) and length (II) of the spring C1.   Measurement values:     Outside diameter (II):   20.7 mm   Inner diameter (I):   78.1 mm (with AF 20)     66.6 mm (with AF 22)     40.7 mm (with AF 20/22 with neutral shift)     Notice:  The illus. shows version AF 20 without neutral shift.

  Remove, Disconnect   

Pull needle bearing out of journal in rear cover with KM-691 (2) and KM-556-1 (1) If necessary (arms of KM-556-1 too short), lay KM-502-A underneath arms of KM-556-1.     Install, Connect    Install needle bearing in rear cover. Press in with KM-711-2 (3) until tool comes to stop at journal (4).

  Assemble   

Rear cover. Piston C1, spring and cover.     Tighten (Torque)    Cover C1 to rear cover (3) - 10 Nm / 7 lbf. ft.     Install, Connect    Install 3 cut seal rings (2) at bearing journal - do not expand more than necessary.