Removal
Move the safety flap 2 of the main brake cylinder upward.
Remove seal 1 from the water tank as much as necessary.
Remove cap 3 from the brake fluid reservoir.
Seal the brake fluid reservoir using the MKM-558-10 tool.
Remove the rear wheels.
Note: Mark the position relative to the drum hub.
Remove the 2 ABS 4 wire harness connectors from the rear axle.
Disconnect from the brake pipe (arrows).
Disconnect from the holder on the rear axle 5.
Remove the headlight range control sensor linkage from the bracket on the rear axle.
Note: On vehicles with xenon headlights.
Disconnect the 2 parking brake cables at the rear, on both sides, from the connecting part 1.
Disconnect the parking brake cable in the middle and the parking brake cable at the rear from the guide 2 on the rear axle and set aside.
Note: On both ECO model variants, remove the air guide shield on the underbody.
Remove the rear brake pipe 4 from the rear brake hose 3 on both sides.
Remove the brake hose from the holder, leaving the safety washer 5 on the brake pipe.
Note: Rear springs are removed and installed only one after the other on each side of the vehicle.
Remove the rear springs.
Note: The procedure for removing and installing one side is described below. The work on the other side is carried out accordingly.
Support the rear axle with a hydraulic jack on the assembly side under the trailing arm.
Remove the mounting screw 1 of the shock absorber on the rear axle.
Slowly lower and remove the hydraulic jack.
From the assembly side, pull the rear axle down so far (arrow) that rear spring 2 can be removed.
Note: Pay attention to the installation position of the spring.
Reinstall the hydraulic jack under the rear axle trailing arm.
Raise the rear axle with a hydraulic jack until the shock absorber can be installed.
Install the shock absorber with mounting screw 3 on the rear axle.
Remove the rear spring from the other side.
Removal from the opposite side is done in a similar manner.
Install the hydraulic jack with the KM-904 4, KM-6180-2 3 and KM-6180-1 1 attachments under the rear axle.
Note: Make sure that the guide bolt 5 of the KM-6180-2 is correctly positioned in the guide hole of the rear axle on both sides
Remove the shock absorber mounting screw 2 on both sides.
Raise the rear axle with a hydraulic jack until it rests on the KM-6180-1 (arrow).
Remove the mounting screw 6 of the rear axle suspension trailing arm from both sides of the vehicle underbody.
Slowly lower the rear axle using a hydraulic jack and remove.
Note: When replacing the rear axle, all attachments must be re-installed.
Clean the outer sides of the damper bushing. Apply red grease to the marked area (arrows).
Installation
Raise the rear axle with the hydraulic jack KM-904, KM-6180-1 and KM-6180-2.
Install the rear axle suspension trailing arm on both sides of the vehicle underbody.
Use new mounting screw and nuts 1.
Note: Tighten the mounting screws loosely.
Note: To prevent stress from being created in the damping bushings in the rear axle trailing arm in the vehicle underbody during vehicle operation, dimension I must be adjusted for the rear axle before tightening the mounting screws to the correct tightening torque.
Raise the rear axle with a hydraulic jack, KM-904 and KM-6180-2 so that the dimension I 100 mm ±5 mm is established between the spring seat on the rear axle and the longitudinal beam at the rear (see picture).
Note: To measure, insert a ruler through the hole in the rear axle at the spring seat.
Tighten the rear axle mounting screws 1 to the underbody of the vehicle on both sides.
Tightening torque 50 Nm + 45°+15°.
Position the rear axle using a hydraulic jack, KM-904 and KM-6180-2 so that both shock absorbers can be installed on it.
Install the shock absorbers using the mounting screws 1 on both sides of the rear axle.
[Source is on this resource: opelbook]
Remove the hydraulic jack with the KM-904, KM-6180-2 and KM-6180-1 tool.
Install the rear springs by following the steps below.
Note: Rear springs are installed only separately, on each side of the car.
Support the rear axle with a hydraulic jack 3 on the assembly side under the suspension trailing arm.
Remove the mounting screw 2 of the shock absorber on the rear axle.
Slowly lower and remove the hydraulic jack.
From the assembly side, pull the rear axle down so far (arrow) that rear spring 1 can be inserted.
Reinstall the hydraulic jack under the rear axle trailing arm.
Use a hydraulic jack to raise the rear axle enough to accommodate the shock absorber.
Install the shock absorber with mounting screw 2 on the rear axle.
Tightening torque 65 Nm.
Install the rear spring on the other side.
Installation is carried out in a similar manner.
Insert brake hose 1 on both sides into the holder on the rear axle.
Connect the brake pipe 2 with the retaining clip 3 to the brake hoses.
Tightening torque 16 Nm.
Insert the parking brake cable in the middle and the parking brake cable at the rear into the guide 4 on the rear axle.
Attach to connecting piece 5.
Attach the ABS wiring harness to the holder 7 on the rear axle and at the brake pipe (arrows).
Make an electrical connection to the ABS wire harness connector 6.
Install the headlight range control chain sensor linkage system to the bracket at the rear axle.
Note: On vehicles with xenon headlights.
Tightening torque 5 Nm.
Install the rear wheels.
Tightening torque 110 Nm.
Remove tool MKM-558-10 1 from the brake fluid reservoir.
Bleed and check the brake system for leaks.
Close the brake fluid reservoir cap.
Move the safety flap 2 of the brake fluid reservoir downwards.
Place gasket 3 on the water tank.
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