Vauxhall Workshop Service and Repair Manuals

Transmission, Remove and Install (Z13DTH/M20)

Note:   If the transmission is replaced, the following parts must be transferred:

  Remove

2.   Detach pressure line (2) from transmission Note:   Collect any escaping brake fluid. •   Open retaining clamp (1) •   Draw pressure line out of connector •   Push retaining clamp into connector

3.   Detach 2x gearshift cables (2) from transmission •   Detach 2x gearshift cable from shift linkage lever •   Remove 2x shift cable from counterhold – Press 2x retaining ring (1) towards the rear

4.   Detach bracket for upper wiring harness (3) from transmission •   Unscrew bolt (1) •   Unclip wiring harness plug (2) 5.   Detach bracket for front wiring harness plug (4) from transmission •   Unclip wiring harness plug for oxygen sensor (6) •   Unclip wiring harness for oxygen sensor •   Unscrew bolt (5)

7.   Release transmission at top •   Unscrew 2x bolt (1)

8.   Attach KM-60001-B to front axle body •   Release 2x bolt (arrows) for adjustment rails on KM-60001-B (1) •   Insert KM-60001-B as shown Note:   2x journals (2) and (5) must sit flush in the guide holes of the front axle body. •   Tighten 2x bolt for adjustment rails •   Twist up front support bearing (4) – as far as the stop on the guide pin of the front engine damping block Note:   The guide pins must sit in the support bearings with no play. •   Twist up rear support bearing (3) – as far as the stop on the guide pin of the rear engine damping block bracket Note:   The guide pins must sit in the support bearings with no play.

10.	Detach right axle shaft from intermediate shaft •   Attach axle shaft to vehicle underbody

13.   Detach transmission from left engine damping block •   Unscrew 3x bolt (1)

15.   Release starter at the bottom •   Unscrew bolt (1)

16.   Detach front engine damping block bracket •   Unscrew 2x bolt (1) 17.   Detach rear engine damping block bracket •   Unscrew 3x bolt (2)

18.   Place transmission holder DT-47648 on KM-904 and preinstall as shown in the illustration: Component Position on base plate Designation DT-47648-2 (4) 2 Clutch housing support DT-47648-3 (2) 14 Transmission housing support DT-47648-5 left (1) A Support with rear transmission swivel arm DT-47648-5 right (3) F Support with front transmission swivel arm

Important:   It is essential to follow the manufacturer's instructions for transmission holder DT-47648 . 19.   Attach DT-47648 to transmission Note:   Before placing in position, slacken all bolt connections of the swivel arms and supports as far as the base plate. Adjust the supports using the spindles until they are as low as possible. •   Place DT-47648 with supports in position under the transmission •   Tighten bolt connections of the supports •   Attach swivel arm (1) and (2) to transmission •   Tighten bolt connections of the swivel arms starting from the transmission and going as far as the base plate Note:   Align the swivel arms so that as little leverage as possible is created.

20.   Remove transmission •   Unscrew 4x bolt (1) •   Press transmission off engine and slowly lower the hydraulic jack Note:   Do not damage wiring harnesses and attaching parts

  Install

24.   Fasten transmission at the bottom •   Tighten 2x bolt M12 (1) – Stage 1 10 Nm – Stage 2 60 Nm

26.   Fasten transmission at the bottom •   Tighten 2x bolt M10 (1) 40 Nm Note:   Note differing bolt lengths

27.   Fasten starter at the bottom •   Tighten bolt (1) 25 Nm

28.   Attach front engine damping block bracket •   Tighten 2x bolt (1) 80 Nm 29.   Attach rear engine damping block bracket •   Tighten 3x bolt (2) 80 Nm

34.	Attach right axle shaft to intermediate shaft

36.   Fasten left engine damping block •   Tighten 3x bolt (1) 55 Nm

39.   Fasten transmission at top •   Tighten 2x bolt (1) 60 Nm

42.   Attach bracket for upper wiring harness (3) to transmission •   Tighten bolt (1) •   Clip in wiring harness (2) 43.   Attach bracket for front wiring harness (4) to transmission •   Tighten bolt (5) •   Clip in wiring harness for oxygen sensor •   Clip in wiring harness plug for oxygen sensor (6)

44.   Attach pressure line (2) to transmission •   Press pressure line into connector Note:   Pressure line must engage noticeably. •   Lock retaining clamp (1)

45.   Attach 2x shift cable (2) to transmission •   Suspend 2x shift cable in counterhold – Press 2x retaining ring (1) towards the rear •   Attach 2x shift cable to shift linkage lever

46.	Correct transmission fluid level

47.	Bleed hydraulic clutch actuation

48.	Transmission Shift Linkage, Adjust