Clutch (transmission removed) — removal and installation (Opel Vectra A)

Removal

1. Remove the transmission or the entire power unit and separate the engine from the transmission. Then proceed as follows.

2. Note the position of the mark on the flywheel that aligns with the notch in the clutch housing. Gradually unscrew the six bolts with spring washers that secure the clutch housing to the flywheel.

3. Remove the clutch assembly. Be prepared to catch the friction disc, as it may fall out when removing the housing assembly. Remember the correct orientation of the disc - the side of the hub with the smaller protrusion should face the flywheel.

4. Inspect the clutch components for signs of wear and damage as described in Chapter 5.

Installation

5. If there is no need to install the engine and transmission assembly, it is recommended to install the engine into the vehicle first, then the clutch. This will eliminate the need for friction disc alignment.

6. If the entire powertrain has been removed, the clutch can be installed before connecting the engine and transmission as follows.

7. Make sure that there is no oil or grease on the friction disc linings and the surfaces of the pressure plate and flywheel. It is recommended that you install the clutch assembly with clean hands and wipe the surface of the pressure plate and flywheel with a clean cloth.

8. Install the friction disc onto the flywheel, ensuring that the disc is oriented correctly (the side of the hub with the smaller projection should face the flywheel).



9. Install the clutch housing assembly, aligning the mark on the flywheel with the notch in the housing (see illustration). Insert six bolts (with spring washers) and tighten them manually so that the friction disc is captured but still able to move.



10. Center the friction disc so that when the transmission is installed on the engine, the slots in the transmission input shaft can fit into the slots in the friction disc hub.

11. To perform centering, insert a round rod or long screwdriver into the hole in the center of the friction disc so that the end of the rod enters the bearing in the center of the crankshaft.

If using a screwdriver, wrap the end of the screwdriver with tape to avoid damaging the bearing surface.

The displacement of the rod will move the friction disc in the same direction. Remove the rod and check by eye the centering of the friction disc hub relative to the hole in the end of the crankshaft and the circle formed by the ends of the sectors of the diaphragms of the other spring.

When the hub is perfectly centered, it is in the correct position. Alternatively, purchase a special centering tool, which eliminates the need for visual alignment.



12. Gradually tighten the cover mounting bolts (in diagonal sequence) tightening torque specified in the Specifications. Remove the alignment tool.

13. Connect the engine and transmission as described in Sections 2A, 2B or 7A (depending on the model),

14. Finally, check the clutch cable adjustment as described in Chapter 3.