Vauxhall Workshop Service and Repair Manuals

  Remove

Detach rear cover plate for vehicle jack on both sides.

Attach KM-6194 (2) to vehicle jack points. Raise vehicle – attach rear lifting platform arms to KM-6194 – ensure that the rear axle retaining plates (1) remain freely accessible.

Remove rear wheels.

For vehicles with xenon low beam headlamps: Disconnect wiring harness plug (3) from vehicle level control sensor.

For vehicles with level control system: Disconnect wiring harness plug for level control sensor.

Remove exhaust system starting at catalytic converter

Remove fastening nuts (2) and fastening bolt (1) for heat shields from vehicle underbody and remove heat shields.

  Measure

Measure projection (I) of threaded rod in parking brake cable compensation yoke (3) and remove adjustment nut.

  Remove

Detach return spring (2) from brake backing plate and brake cable lever, and detach brake cable (1) from both sides of brake cable lever. Remove parking brake cables from brackets on semi-trailing arm.

Detach brake lines (3) from brake hoses at vehicle underbody, remove retaining plates (4), detach brake hoses and remove brake hoses from brackets on vehicle underbody.

Support semi-trailing arm with hydraulic jack and remove shock absorbers (1) on both sides. Carefully lower hydraulic jack.

Except V6: Remove rear springs (2).

Note:   For V6, the rear springs should be removed only when rear axle is lowered slightly.

  Remove

Remove propshaft (1) with disc joint (2) from rear differential.

Disconnect wiring harness plug (3) from wheel sensors.

Position hydraulic jack with KM-485 or KM-6195 (2) and KM-904 under rear differential – ensure that the level control sensor (1) is not damaged.

Detach front damping bushing for rear axle with supporting strut (3) from vehicle underbody.

Detach rear (4) damping blocks from vehicle underbody.

Lower rear axle – for V6, remove rear springs after lowering slightly.

Attach rear axle to vehicle underbody using hydraulic jack and KM-485 or KM-6195 and KM-904 – for V6 insert rear springs when lifting.

Attach rear damping blocks (1) to vehicle underbody – tightening torque 65 Nm / 48 lbf. ft.

Install front fastening bolts for damping blocks (2) for rear axle with supporting strut to vehicle underbody – tightening torque 125 Nm / 92 lbf. ft.

Attach supporting strut (3) to vehicle underbody – tightening torque 65 Nm / 48 lbf. ft.

Lower hydraulic jack.

  Install

Except V6: Insert rear springs (2) with rubber dampers (1).

Turn rear springs until the upper end of spring faces towards rear of vehicle.

Connect wiring harness plugs for both wheel sensors and clip onto vehicle underbody.

Apply hydraulic jack under each side of the semi-trailing arm consecutively and lift until the bore holes align with the shock absorbers (3). Attach shock absorber to semi-trailing arm – tightening torque 110 Nm /81 lbf. ft. Lower hydraulic jack.

Insert brake hoses in bracket on both sides of the vehicle underbody and attach retaining plate (2) – ensure brake hoses are not twisted. Attach brake lines (1) to brake hoses – tightening torque 16 Nm / 12 lbf. ft.

Attach parking brake cables (3) in brackets on both sides of semi-trailing arm and to brake cable lever. Attach return springs (4) to brake cable levers and to brake backing plates.

Attach parking brake compensation yoke (1) to parking brake cable threaded rod with fastening nut.

  Adjust

Adjust projection of threaded rod on parking brake cable compensation yoke to dimension (I) determined during removal.

  Install

Attach propshaft (2) with disc joint (3) to rear differential – tightening torque 95 Nm / 70 lbf. ft. (for Torx bolts: use new fastening bolts and nuts and tighten to 50 Nm / 37 lbf. ft. + 75° + 15°).

For vehicles with level control system: Disconnect wiring harness for level control sensor.

Attach heat shields (2) to vehicle underbody.

For vehicles with xenon low beam headlamps: Connect wiring harness plug (1) to vehicle level control sensor.

Caution

Following removal and installation or replacement of vehicle level control sensors, a comparison is required via TECH2 – see corresponding Checking Procedure.

  Install

Suspend exhaust system with damping rings from vehicle underbody and attach retaining plates for damping rings. Attach exhaust system (3) to catalytic converters – tightening torque 25 Nm / 18.5 lbf. ft.

Attach rear wheels – tightening torque 110 Nm / 81 lbf. ft.

Bleed brake system – see operation "Brake System, Bleed" and "Brake System, Check for Leaks" in group "H".