When removing the clutch disc, follow the direction in which the long element of the hub points. Install the clutch disc in the same direction. Follow the installation recommendation, if available, on the Opel clutch discs.
Removing
On engines 1.5 and 1.6 l remove manual transmission (see chapter Manual 5-speed gearbox).
Engines 1.2 and 1.4 l
1. Use a screwdriver to remove the retaining clip from the threaded rod of the clutch cable.
locking bracket
2. Push the clutch release lever back with a pry bar and disconnect the cable.
3. Mark the position of the left front wheel in relation to its hub so that the balanced wheel can then be installed in its original position. Turn out bolts of fastening of a wheel. Jack up the front of the car, place it on jack stands and remove the left front wheel.
4. Turn out bolts of fastening and uncover manual transmission.
Gearbox cover bolts
Have a suitable container ready to catch the oil that escapes.
5. Remove retaining ring (arrow) cylindrical bolt and remove the bolt.
Retaining ring
6. Mark the position of the manual transmission input shaft in relation to the gear.
7. Pull out the manual transmission input shaft using the KM-556-1-A special tool and the 556-4 threaded insert to the stop from the splined engagement.
Removing the manual transmission input shaft
8. Turn out bolts of fastening and remove a cover of a basket of coupling.
9. Compress the clutch and fix in this position with three brackets KM-526, setting them evenly around the circumference. To do this, disengage the clutch with a pry bar, i.e. press it back or have an assistant depress the clutch pedal.
Clutch lock
All engines
1. Turn out bolts of fastening and disconnect assembly of a basket of coupling from a flywheel and take out it together with a conducted disk.
Do not drop the clutch disc and pressure plate when removing them.
2. Wipe the flywheel with a rag soaked in gasoline.
Installation
1. Check the clutch release guide O-ring for contamination and clean if necessary. Install the clutch release bearing.
2. Apply a thin layer of lubricant to the splines of the manual transmission input shaft. Remove any remaining grease.
Do not lubricate the slots of the driven disk.
3. Put the driven disk on the manual transmission input shaft. Wipe excess grease from the hub interface and remove the driven disc again.
Install the driven disk so that the long part of the hub is facing the manual transmission. Follow the installation instructions provided on the clutch disc.
Engines 1.5 and 1.6 l
1. Install the driven disc and center it with the HAZET-2174 mandrel or centering tool.
Centering of the driven disk
2. Evenly tighten the driven disc mounting bolts to 15 Nm.
3. Install manual transmission (see chapter Manual 5-speed gearbox).
Engines 1.2 and 1.4 l
1. Install the clutch basket assembly with the driven plate on the flywheel without fastening it.
Make sure that the marks on the clutch basket and on the flywheel match.
Clutch alignment marks
2. Slightly raise the driven disk and center it with the input shaft. Carefully insert the input shaft into the splined hole of the driven disk and the gear, making sure they mesh correctly.
Centering of the driven disk
Follow the marks made during removal on the input shaft and gear.
3. Secure the clutch with force 15 Nm.
4. Insert the input shaft using the KM-564 tool until it stops. To do this, be sure to screw a cylindrical bolt into the shaft. Do not drive in the shaft with an impact tool, otherwise the teeth of the spline may be damaged. Tighten the barrel bolt 15 Nm.
Installing the input shaft
5. Fix a primary shaft a new lock ring.
6. Glue a new manual transmission cover seal with grease.
7. Install the manual transmission cover and evenly fasten the bolts of its fastening with the required force.
8. Squeeze the clutch with a pry bar, remove the three brackets and release the clutch.
9. Install the clutch basket assembly cover and tighten the bolts of its fastening with force 7 Nm.
All engines
1. Install the left wheel so that the marks made during removal match. Fasten the wheel with bolts. Lower the vehicle to the ground and tighten the bolts crosswise with force 110 Nm.
2. Connect the clutch cable to the clutch release lever and install the locking clip on the threaded element.
3. Check the oil level in the manual transmission and add oil if necessary.
4. Check clutch adjustment.
Visitor comments