Vauxhall Workshop Service and Repair Manuals

Manual Transmission, Remove from Engine and Install (M20-6 MTA transmission)

  Remove

1.   Detach ribbed V-belt (1) •   Mark direction of rotation •   Apply tension clockwise to tensioner roller at tension roller bolt •   Lock tensioner with KM-6130 (2)

2.   Detach supply unit for MTA system •   Unscrew 3x bolts (1) Note:   Note different bolt lengths

3.   Detach wiring harness bracket MTA (1) •   Unscrew bolt (2)

4.   Disconnect wiring harness MTA system •   Release wiring harness plug (1) and separate.

5.   Detach wiring harness alternator and starter (1) •   Detach from alternator (2) – Unscrew 3x nut •   Detach from starter (4) – Unscrew 2x nuts •   Detach earth cable – Unscrew nut (3) •   Unclip vacuum line •   Unclip 3x from bracket

6.   Detach alternator (1) •   Unscrew 3 bolts Note:   Note 2x guide sleeve!

7.   Detach wiring harness for remaining oil quantity (1) •   Disconnect wiring harness connector. •   Unclip 2 cable ties •   Undo cable tie

8.   Detach alternator support (1) •   Unscrew 4x bolts •   Undo cable ties Note:   Note 2x guide sleeve!

10.   Remove heat shield, oil filter housing (1) •   Unscrew 2x bolts (2) •   Unscrew nut (3)

12.   Detach engine management wiring harness •   Disconnect 4x wiring harness plugs, sheathed glow plug (3) •   Separate wiring harness plug, oil pressure switch (2)

13.   Detach exhaust manifold heat shield (1) •   Unscrew nut •   Unscrew bolt – Remove engine transport shackle •   Fit engine transport shackle (2) – Tighten bolt 25 Nm

14.   Detach turbocharger oil feed line (1) •   Unscrew 2x bolts

15.   Detach turbocharger oil return line (1) •   Unscrew 4x bolts

16.   Detach catalytic converter (1) from transmission bracket •   Unscrew bolt (2)

17.   Detach turbocharger •   Separate vacuum hose •   Unscrew 3x nuts (1)

18.   Detach compressor support (1) •   Unscrew 4x bolts (2)

21.   Detach right axle shaft (1) from intermediate shaft Note:   Use a second person •   Knock out axle shaft with KM-6003-1 and KM-313 Note:   Seal opening using closure plugs

22.   Remove left axle shaft (1) from transmission Note:   Use a second person •   Knock out axle shaft with KM-6003-1 and KM-313 Note:   Seal opening using closure plugs

23.   Remove intermediate shaft with bearing (1) •   Detach intermediate shaft bearing from bearing support – Unscrew 3 bolts

26.   Attach KM-412-32 to cylinder block •   Tighten 6x bolts

28.   Release transmission at top Note:   With the vehicle raised, release the upper gearbox bolts from below. •   Unscrew front (1) and rear (2) upper gearbox bolts

29.   Removing transmission •   Attach KM-2358 •   Unscrew 4x bolts (1) •   Press gearbox off engine Note:   Requires 2 people, do not damage wiring harnesses and attaching parts

  Install

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

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

33.   Fasten transmission at the top •   Tighten front (1) and rear (2) upper gearbox bolts M12 60 Nm

39.   Install left axle shaft in the transmission •   Attach new circlip (1) to axle body – Remove closure cover

60.   Install ribbed V-belt •   Observe rotational direction of ribbed V-belt •   Position ribbed V-belt – I. Ribbed V-belt routing without air conditioning – II. Ribbed V-belt routing with air conditioning •   Apply tension to ribbed V-belt tensioner clockwise at the tension roller bolt •   Remove KM-6130