Special Tools

For eguivalent regional tools, refer to Special Tools.

Note: Only use brake fluid DOT 4. The hydraulic clutch actuation must now only be bled from "below", i.e. from the bleeder valve. A brake bleeder must be used for this purpose - see "Opel/Vauxhall Workshop Equipment" catalogue. Manual bleeding is no longer permissible. Observe manufacturer's instructions before using brake bleeder. The brake bleeder must be set to an operating pressure of approx. 2 bar. Brake fluid must not come in contact with mineral oils and greases. The smallest amount of such could lead to malfunction or breakdown of the clutch.

1. Remove battery tray if needed. Refer to Battery Tray Replacement.
2. Attach brake bleeder.

•	Screw adapter (1) for corresponding brake bleeder onto brake fluid reservoir.

Note: Insert hose end in suitable brake fluid collecting basin.

•	Connect TBD TBD (2) to adapter.

•	Disconnect valve cap from bleeder valve.

•	Connect TBD TBD (3) to bleeder valve (4).

•	Connect brake bleeder to TBD TBD .

3. Bleed clutch actuation.

•	Switch on brake bleeder.

•	Open bleeder valve 2-3 turns.

•	Bleed until brake fluid escapes without bubbles at TBD TBD .

•	Close bleeder valve hand tight.

4. Detach brake bleeder.

Detach adapter of corresponding brake bleeder.

Note: The following operational stages must be undertaken to fill the pressure line between the transmission housing and the central release. When bleeding, ensure that the brake fluid reservoir is always filled up sufficiently and does not run dry.

1. Bleed pressure line between transmission housing and central release.

•	Connect TBD TBD to TBD TBD on bleeder valve, place free end in a suitable connecting container.

•	Press and hold clutch pedal.

•	Open bleeder valve until air or air/brake fluid mixture emerges.

•	Close bleeder valve hand tight.

Note: Not too fast!

•	Draw back clutch pedal as far as the stop at normal speed.

•	Wait approximately 5 seconds.

•	Repeat this bleeding process 4 times.

•	Tighten bleeder valve TBD.

•	Detach TBD TBD and TBD TBD .

•	Push valve cap on to bleeder valve to protect the bleeder valve.

2. Install battery box, if removed. Refer to Battery Tray Replacement.
3. Top up brake fluid reservoir.

•	Fill brake fluid reservoir up to "MAX" marking.

•	Seal off brake fluid reservoir.

4. Check actuation pressure of clutch pedal.
5. Check shifting for ease of movement.

•	With vehicle stationary

•	With engine running

•	With clutch disengaged

6. A test run must be undertaken to guarantee that the brake and clutch system functions perfectly.

Undertake test run using varying rpm ranges and frequent gear changes, bring vehicle to operating temperature during this process. Ensure the brake and clutch system is operating correctly.