Vauxhall Workshop Service and Repair Manuals

  Remove

Put selector lever in "N". Disconnect ground cable of battery. If present, remove engine compartment cover (10 screws).

In vehicles with OHC engine: Remove DIS ignition module – see operation "DIS Ignition Module, Remove and Install" in group "J".

Disconnect oxygen sensor wiring harness plug (1) (For Y 22 XE / Z 22 XE engines: x 2) and unclip from bracket (2) – cut cable ties (3).

Disconnect selector rod (3) from selector intermediate lever (1). For this, remove retaining plate (2).

Disconnect plug connection (1) from transmission output speed sensor. Cut off cable tie (2).

Unscrew exhaust support from front exhaust pipe.

Unscrew front exhaust pipe from catalytic converter. Remove gasket (1).

Propshaft from output flange (3 screws with nuts).

Press propshaft backwards and suspend on right side of transmission tunnel.

Only loosen engine supports on both sides of engine (1) and unscrew from converter housing (4).

Unscrew lower bolt for transmission to engine (2) on both sides..

Remove cover cap (3) from converter housing.

Remove cover plate (1) for converter housing.

Converter from drive plate (6 screws). Counterhold through bore hole in converter housing using lever.

Disconnect fluid cooler lines to connection hoses (1) with hose clamp pliers (e.g. Hazet 798, jaw width 40 mm).

Caution

Fluid escapes – stop egress of fluid by inserting connection hoses into adjacent pipes (F 3203, lower half).

Use hydraulic jack (3) with commercially available transmission lifter adapter No. 09 00 094 (1) and mounting plate F 09 18 021 (2) for fixing the transmission.

Fix transmission to adapter and secure.

Caution

Check for correct seating of adapter. Avoid damage of transmission attaching parts.

Unscrew transmission crossmember from vehicle underbody (2 bolts, arrows). Lower transmission a small amount.

Vent hose from upper side of transmission.

Bend bracket (1) open for wiring harness from left transmission side, make wiring harness accessible.

Carefully unclip wiring harness plug X 8 (1) for selector lever position switch from bracket with screwdriver and disconnect.

Caution

When wiring harness plug X 8 is pressed off, the fastening clip (2) becomes damaged and must be replaced.

Disconnect wiring harness plug X 10 (4 pin, 1) from connection plug (2) on intermediate housing.

Disconnect wiring harness plug X 9 (7 pin, 1) from connecting plug (2) on main housing.

Unscrew upper fastening screws from transmission to engine (1 to 4)..

Disconnect transmission from engine and lower.

For installation of new transmission – see operation "Transmission, Replace".

Before installation of a new transmission, blow out fluid cooling hoses with low pressure compressed air to remove deposits and remaining fluid from fluid cooler and fluid lines.

Clean threaded bore holes for microencapsulated bolts prior to installation by cutting and insert the bolts themselves with locking compound.

Coat centring seat (1) for the converter in the crankshaft with lubricating grease.

If converter is correctly installed, the distance (2) between front surface of the threaded fittings on the converter and the front edge of the converter housing is 15 mm. Secure transmission with chain on adapter.

Check easy movement of the threaded bore holes (1) in the torque converter. Check centring pin (3) of the torque converter for frictional rust, clean if necessary.

Raise transmission with hydraulic jack, align with engine and install – ensure that centring pins on engine block engage in converter housing.

Torque

Upper screws (1 to 4) for converter housing to engine – 60 Nm / 44 lbf. ft. Long screw on starter.

2 lower bolts for converter housing to engine – 60 Nm / 44 lbf. ft.

  Install

Connect wiring harness plug X 9 (7 pin) to connecting plug on main housing.

Connect wiring harness plug X 10 (4 pin) to connecting plug on intermediate housing.

Install cover plate for converter housing.

Torque

Engine supports to converter housing (3) – 22 Nm / 16 lbf. ft.

Tighten support on both sides of engine (1) – 45 Nm / 33 lbf. ft.

Attach cover cap (2) to converter housing.

Propshaft to output flange, use 3 new screws with nuts:

Tighten Torx screws M10 in 2 stages – 50 Nm / 37 lbf. ft. + 75° to 90°.

Hex screws M12 – 95 Nm / 70 lbf. ft.