Removing
1. Disconnect the negative cable from the battery.
Note: On models with the Opel anti-theft system (ATWS) You must remove the negative cable from the battery within 15 seconds of turning off the ignition to prevent the alarm from triggering.
2. Block the rear wheels, then apply the handbrake. Jack up the front of the vehicle and place it securely on axle stands. Loosen the mounting bolts and remove the lower engine/transmission cover.
3. Route the hydraulic/clutch hose from the transaxle to the fitting in the bulkhead of the engine compartment. To minimize fluid loss, pinch the supply hose connecting the supply reservoir to the clutch master cylinder, then release the hose from the baffle. Pull the clip and separate the halves of the tube. Seal the ends of the tubing to minimize fluid loss and prevent dirt from entering. Install the mounting bracket into the groove of the tube, then make sure that the lower end of the tube is free and can be removed along with the transmission unit.
Attention! Do not depress the clutch pedal while the hose is disconnected.
4. Disconnect the wiring connector from the reversing light switch located at the rear of the transaxle.
5. See Section 8 and unfasten the front end of the propeller shaft from the transmission flange, then remove the vibration damper (where available). Move the cardan shaft from the transmission unit to the right and tie it to the bottom of the car.
6. Remove the shift rod as described in Chapter 4.
4 cylinder engines
7. On engines with a single overhead camshaft (SOHC), disconnect the wiring connector from the ignition control module. Loosen and remove the module bracket mounting bolts, marking the location of the engine mounting lug, then unfasten the wiring and remove the module and bracket from the rear of the cylinder head. Release the high voltage wires from the mounting brackets and move the assembly away from the transmission block.
8. On all models, disconnect the oxygen sensor wiring connector from the transmission unit and disconnect it.
9. Loosen and remove the bolts securing the front exhaust section bracket and remove the bracket. Also remove the bolts securing the front section to the intermediate section and separate the sections from each other.
10. On solid sump models, loosen and remove the bolts securing the brackets to the transmission case and cylinder block walls. Remove both brackets from the engine, then remove the bottom flywheel cover from the transmission case base.
11. On all models, loosen and remove the two bolts securing the top bracket to the rear of the transaxle.
12. Support the transmission with a jack by placing a piece of board between them and raise the jack to transfer the weight of the transmission onto it.
13. Loosen and remove the bolts securing the transmission rear suspension cross member to the vehicle body.
14. Slightly lower the transmission block, then loosen and remove all bolts securing the transmission case to the engine. Note the location of each bolt and bracket to facilitate subsequent installation. Check again that all components are disengaged and away from the transmission and that they do not interfere with removal.
15. Move the jack and transmission back to remove the block from the mounting pins, then lower the jack and move the block out from under the vehicle. Remove the dowel pins from the transmission or engine if they are loose and store them away from the work area.
16. Remove the release bearing from the release cylinder and check it for signs of wear. Make sure it turns smoothly and easily, without noise, and that its contact surface is smooth and free of cracks, pitting, and nicks. If there is any doubt about the condition of the bearing, replace it.
6 cylinder engines
17. Remove both front sections of the exhaust system (see related section).
18. Remove the transmission block as described in paragraphs 11-16.
Installation
19. Install in reverse order paying attention to the following:
- A) Clean the grooves of the input shaft and the contact surfaces of the release bearing and the release cylinder of all dirt and grease. Lubricate the inner bore of the release bearing with a small amount of high temperature grease (Opel recommends using paste 19 42 530) and apply some of the same grease to the grooves of the input shaft. Do not overdose the paste, otherwise its excess will contaminate the lining of the clutch friction disc. Install the release bearing on the cylinder, orienting it correctly.
- b) Place the locating pins each in its original place. Install the transmission block. Be very careful not to let the transmission hang under its own weight on the input shaft.
- V) Remove all traces of blocking compound from the threads of the bolts securing the transmission rear suspension cross member to the body. Apply a few drops of fresh compound (Opel recommend using 15 10 181) on the threads of each bolt, install them and tighten them with the tightening torque specified in the Specifications.
- G) Tighten all nuts and bolts with a tightening torque specified specifications (where given).
- d) Check the condition of the o-ring on the clutch hydraulic tube fitting and attach the tube/hose tip with clips in the working position. Remove clamp from master cylinder hose and bleed clutch hydraulic system as described in Section 6.
- e) Finally, check and, if necessary, top up the gear oil level (see chapter 2). If necessary, adjust the shift rod as described in Chapter 3.
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