Vauxhall Workshop Service and Repair Manuals

  Remove

Top up brake fluid reservoir to "MAX" mark and seal with KM-558-10 (1).

Remove corresponding rear wheel.

Attach KM-468-B to wheel hub with two wheel bolts. Remove drive shaft from wheel journal flange (2) – counterhold at KM-468-B. Remove fastening bolts (arrows, 6) with washers. Attach axle shaft to vehicle underbody or rear spring with wire.

Remove retaining plate (1) for brake pressure hose from bracket on semi-trailing arm. Detach brake line from brake hose – collect escaping brake fluid. Remove brake calliper from bracket and lay aside with brake line – ensure that the brake line is not damaged.

Note:   It is necessary to open the brake circuit to prevent damage (kinking) to the brake line.

Place hydraulic jack under semi-trailing arm and remove shock absorber from semi-trailing arm.

Release adjusting unit (2) of parking brake shoes through installation hole in the brake disc. To do this, turn knurled adjuster downwards. Detach brake disc from wheel hub and remove.

Remove both upper and rear lower fastening bolts (arrows) for brake backing plate (triple square head extra long).

Secure retaining plate (1) for fastening nut of wheel journal flange and prise out of wheel journal flange.

Remove fastening nut (2) for wheel journal flange – high release torque, counterhold at wheel hub with KM-468-B.

Note:   In the following operating steps, Special Service Tool KM-620-1-B is used. If necessary, modify KM-620-1-A as shown Illustration I. Dimension I = 52 mm. After modifying, the KM number is changed to KM-620-1-B.

  Install

Attach KM-620-2 (1) and KM-620-1-B (2) to wheel journal flange with three fastening bolts on axle shaft (Illustration II) – ensure correct hole pattern (A or B) is used.

If necessary: Bolt KM-620-4-A (3) onto KM-620-3 (4) (Illustration III).

Push KM-620-5-B (3) into KM-620-3 and KM-620-10 (1) onto KM-620-3 (Illustration I).

Attach KM-620-4-A to KM-620-1-B with three fastening bolts (Illustration II).

  Remove

Pull out wheel journal flange by turning at KM-620-3 (2) – counterhold at KM-468-B.

Remove KM-468-B from wheel hub.

Remove three fastening bolts (4) for axle shaft from wheel journal flange – remove KM-620-1-B and KM-620-2 from wheel journal flange – the other fitted parts of KM-620 remain fitted on KM-620-1-B.

Screw KM-620-7-A (1, 3) into semi-trailing arm and attach KM-620-1-B in assembly to KM-620-7-A with fastening nuts (2) (Illustration II).

Press wheel hub out of wheel bearing by turning at KM-620-3 – counterhold at KM-620-1-B.

If necessary: Clamp wheel hub in vice with protective jaws. Detach wheel bearing shell from wheel hub with KM-500-1-B (4) and KM-616 (3) (Illustration III).

Remove wheel-side retaining ring (5) from wheel bearing (Illustration IV).

Place KM-620-6 (1) on KM-620-5-B (2) and press out wheel bearing (5) towards the wheel side by turning at KM-620-3 (4) (Illustration II) – counterhold at KM-620-1-B (3).

Remove KM-620-5-B (2) and KM-620-6 (1) from semi-trailing arm (Illustration III). Remove fastening bolts (6, 3) for KM-620-4-A from KM-620-1-B (Illustration IV).

  Install

Turn back KM-620-3 (2) and insert KM-620-9-A (1) with shoulder (arrow) towards KM-620-1-B (Illustration I). – For Saloons, additionally KM-620-11 (3) must be inserted between KM-620-9-A and KM-620-1-B (Illustration II).

Attach new wheel bearing to KM-620-3 with KM-620-8-A (4) (Illustration III) and pull into semi-trailing arm by turning at KM-620-4-A (5) to the stop (Illustration IV) – counterhold at KM-620-3 (2).

Remove KM-620-8-A from KM-620-3.

Insert retaining ring (1) of wheel bearing into semi-trailing arm (Illustration I) – ensure correct seating in groove.

Bolt wheel hub (2) into KM-620-3 (3) (Illustration II) and then pull into wheel bearing by turning at KM-620-4-A (4) (Illustration III) – counterhold at KM-620-3.

  Remove

Remove KM-620-3 from wheel hub. Remove fastening nuts (5) from KM-620-7 and remove KM-620-1-A in assembly from KM-620-7 (Illustration IV).

Remove KM-620-7 (1) from semi-trailing arm (Illustration I).

  Install

Attach KM-620-1-A (3) to wheel journal flange (2) with KM-620-2 and three fastening bolts for axle shaft. Place KM-620-1-A with wheel journal flange on semi-trailing arm and bolt KM-620-3 to wheel hub (Illustration II).

Pull wheel journal flange onto wheel hub by turning at KM-620-4-A (5) (Illustration III) – counterhold at KM-620-3 (4).

  Remove

Remove KM-620-3 from wheel hub. Remove KM-620-1-A from wheel journal flange and remove completely with KM-620-2 (Illustration IV).

  Install

Attach KM-468-B (1) to wheel hub. Attach new fastening nut for wheel journal flange to wheel hub (Illustration I) – tightening torque 300 Nm / 221 lbf. ft. – counterhold with KM-468-B.

Fit retaining ring in wheel journal flange on fastening nut with KM-393-2 (2) (Illustration II).

Attach axle shaft to wheel journal flange with washers and fastening bolts (Illustration III) – tightening torque 50 Nm / 37 lbf. ft. + 60° + 15° – counterhold at KM-468-B.

Remove KM-468-B from wheel hub.

Attach fastening bolts for brake backing plate to semi-trailing arm (Illustration IV) – tightening torque 50 Nm / 37 lbf. ft. + 30° + 15°.

  Clean

Remove rust and dirt from contact surfaces of brake disc and wheel hub.

  Install

Brake disc to front wheel hub – tightening torque 4 Nm / 3 lbf. ft.

Place brake calliper with brake line on brake disc and attach to semi-trailing arm with fastening bolts (1) – re-cut thread and insert fastening bolts with locking compound – tightening torque 80 Nm / 59 lbf. ft.

Attach shock absorber to semi-trailing arm – tightening torque 110 Nm / 81 lbf. ft.

Attach brake line to brake pressure hose – tightening torque 16 Nm / 12 lbf. ft.

Secure brake pressure hose to bracket with retaining plate (2).

  Adjust

Turn knurled adjuster of adjusting unit for parking brake shoes upwards through installation hole until brake disc is secured, then turn back again until the brake disc can just turn freely.

  Install

Bleed brake system – see operation "Brake System, Bleed" in group "H".

Mount rear wheel – tightening torque 110 Nm / 81 lbf. ft.