You can check which shape of the flywheel is installed on your car by removing the clutch housing cover. If the vehicle has a flywheel shown in Fig. D6457 (bowl-shaped), the gearbox must be removed, and if shown in Fig. B2607 (see next page) - no need to remove.
Removing
Attention! After removing the clutch disc, check the condition of the O-ring in the thrust bearing. If contaminated, it must be replaced.
Flywheel vehicles
Remove gearbox.
Cars with a flat flywheel
Loosen the left front wheel mounting bolts.
On the threaded end of the clutch cable, use a screwdriver to remove the lock washers (see arrow in fig.).
Rotate the clutch release lever and remove the cable.
Raise the vehicle and place it on stands.
Loosen the bolts and remove the left front wheel.
Loosen the gearbox cover bolts.
Attention! Place a container to collect the escaping oil.
Remove retaining ring (see arrow in fig.) from the axle.
Loosen the threaded axle.
Extend the input shaft of the gearbox to the stop using the Opel KM-556-1-A puller and the Opel 556-4 threaded insert. If the specified puller is not available, a conventional puller with an M7 threaded insert can be used.
Loosen the clutch housing cover bolts.
Fix the clutch with three KM-526 clamps, while pulling the driven disk back with the mounting lever.
Attention! Clamps evenly distributed around the circumference (after 60°).
Loosen the bolts securing the clutch pressure plate to the flywheel and remove the pressure plate assembly with the driven plate.
Attention! When removing discs, do not subject them to shock. Otherwise, during subsequent operation, it may cause jerks and other malfunctions in the operation of the clutch. Wipe the flywheel with a rag soaked in gasoline.
Examination
Check the clutch pressure plate for burns and cracks.
Check pressure spring for damage (see arrows in fig.).
Check the reliability of the fastening of the spring between the pressure plate and the cover, check the riveted connections for strength. If there are defects in the connections, replace the clutch (see fig.).
Check the working surface of the pressure plate for damage and wear. Discs with out-of-flatness up to 0.3 mm are still considered suitable. Checking is carried out using a ruler and a probe (see fig.).
Check flywheel for defects, replace if necessary.
Clean clutch pressure plate and flywheel with fine sandpaper.
Replace oily or damaged clutch discs.
Remove and inspect the clutch release bearing.
Installation
Check thrust bearing seal, replace if dirty.
Install the clutch release bearing.
Lubricate the splines of the hub with a thin layer of universal grease, for example, Opel 1948524 (90001825).
Flywheel vehicles
Install the clutch disc and center it with a drift, e.g. Hazet 2173-1 (see fig.).
Install the pressure plate and evenly tighten its fastening bolts to 15 Nm.
Install gearbox.
Cars with a flat flywheel
Install the clutch assembly on the flywheel and screw in the bolts without tightening them.
Attention! Check the alignment of marks on the clutch housing and flywheel (see arrow in fig. P0565). The extended part of the clutch disc hub must face the gearbox.
Raise the clutch disc slightly and center it with the gearbox input shaft. Carefully manually engage the gearbox input shaft with the clutch disc and gear assembly so that the splines of the shaft engage the splines of the disc.
Tighten clutch mounting bolts to 15 Nm.
Press the input shaft to the stop with a special tool Opel KM-564. While doing this, screw the threaded shaft into the input shaft. Do not drive the shaft with a hammer and mandrel, so as not to damage the splines.
Install a new circlip on the shaft.
Apply a light coat of lubricant to the transmission mating surface and install the transmission cover gasket.
Install the gearbox cover and evenly tighten the bolts of its fastening: M7x1.0 bolts with a torque of 15 Nm, M6x1.25 bolts with a torque of 20 Nm.
Compress the clutch with a pry bar, remove the three clips.
Tighten clutch housing cover bolts to 7 Nm.
Install the left front wheel and screw in the bolts of its fastening without tightening them.
Lower the car.
Tighten wheel bolts crosswise to 90 Nm.
Attach the clutch cable to the clutch release lever. Install the lock washers on the adjusting screw.
Check the oil level in the gearbox, add gear oil if necessary.
Check clutch adjustment.
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