Vauxhall Workshop Service and Repair Manuals

Remove and install manual transmission (Z13DTH/M20 MTA)

Note:   Follow Easytronic safety notes .

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

  Remove

3.   Pull off top charge air hose (2) •   Release clamp (1)

4.   Remove coolant expansion tank •   Unscrew bolt (1) •   Unclip tank and lay aside

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

6.   Detach holder for high pressure line MTA system (1) •   Unscrew bolt (2)

7.   Detach MTA system wiring harness plug •   Unlock and separate wiring harness plug (3) at TCU •   Detach wiring harness bracket (2) – Unscrew bolt (1)

10.   Detach charge air hose (2) from bracket •   Unscrew bolt (1)

13.   Unlock and separate brake fluid level sensor wiring harness plug (1) •   Unclip wiring harness plug

14.   Attach engine hoist 15.   Detach transmission from left engine damping block •   Unscrew 3x bolts (1) 16.   Lower engine with transmission on EN 47650 by approx. 20 cm Note:   Ensure that the coolant hoses and wiring harnesses are not stretched. Do not damage wiring harnesses and attaching parts Be careful of vacuum line on throttle valve module

17.   Raise vehicle 18.   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

19.   Detach intake pipe (3) from turbocharger •   Release clamp (1) •   Unscrew bolt (2) on holder

20.   Remove rear engine damping block •   Unscrew 2x bolts (1)

21.   Place transmission fixture DT-47648 on KM-904 and assemble as shown in 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 Rear transmission support with pivot arm DT-47648-5 right (3) F Front transmission support with pivot arm

Important:   Pay strict attention to manufacturer's notice for transmission fixture DT-47648 . 22.   Attach DT-47648 to transmission Note:   Loosen all screw connections of the swivel arms and supports to the base plate before placing them under load. Rotate the supports as far down as possible by way of the spindles. •   Place DT-47648 with supports beneath the transmission •   Tighten screw connections on the supports •   Attach pivot arms (1) and (2) to transmission •   Tighten the screw connections of the pivot arms starting from the transmission to the base plate Note:   Align the swivel arms so that as a little lever force as possible is created.

23.   Removing transmission •   Unscrew 4x bolts (1) •   Press the engine away from the transmission and slowly lower the hydraulic jack Note:   Do not damage wiring harnesses and attaching parts

  Install

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

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

30.   Fasten transmission at the top Note:   With the vehicle raised, attach the upper gearbox bolts from below. •   Tighten front (1) and rear (2) upper gearbox bolts M12 60 Nm

31.   Attach intake pipe (3) to turbocharger •   Fasten clamp (1) •   Tighten bolt (2) on holder

32.   Install rear engine damping block •   Tighten 2x bolts (1) 80 Nm + 45°

34.   Attach transmission to left hand engine damping block •   Tighten 3x bolts (1) 55 Nm 35.   Detach engine hoist

36.   Connect wiring harness plug (1) for brake fluid level sensor and lock •   Attach wiring harness

37.   Attach charge air hose (2) to bracket •   Tighten bolt (1)

41.   Attach MTA system wiring harness •   Connect wiring harness plug (3) to TCU and lock •   Attach wiring harness bracket (2) – Tighten bolt (1)

42.   Attach holder for high pressure line MTA system (1) •   Tighten bolt (2)

43.   Attach supply unit for MTA system •   Tighten 3x bolts (1) 10 Nm Note:   Note different bolt lengths

44.   Attach coolant expansion tank •   Clip in tank •   Tighten bolt (1)

45.   Connect top charge air hose (2) •   Fasten clamp (1)

47.	Top up with transmission fluid

51.	Necessary commissioning routines for Easytronic

52.	Work to be performed with Tech 2