Disconnect Power Steering Positive Cable From Junction Box Terminal; Disconnect Power Steering Wiring At Block Connector; Undo Nut And Remove Bolt Securing Front Engine Mounting; Unscrew The Subframe Front Mounting Bolts - Opel Zafira B MPV 2006 Owners Workshop Manual

7.9 Disconnect the power steering
positive cable (arrowed) from the junction
box terminal
brackets (see illustration). This is necessary
as the radiator bottom mounting rubbers are
located in the subframe.
9 Lift off the cover from the wiring junction
box at the left-hand rear corner of the engine
compartment. Undo the nut and disconnect
the electro-hydraulic power steering system
positive cable from the junction box terminal
(see illustration).
10 Disconnect the wiring connector for the
electro-hydraulic power steering system at the
block connector adjacent to the ABS hydraulic
modulator (see illustration).
11 Undo the bolt and disconnect the electro-
hydraulic power steering system earth cable
from the battery negative terminal clamp.
12 Working under the car, release the cable
ties and retaining clips and release the
power steering wiring harness from its body
attachments. The wiring harness must be free
to be removed with the subframe.
13 Connect a hoist to the engine/transmission
assembly and support its weight. If available,
the type of support bar which locates in
the engine compartment side channels is
to be preferred, as this will ensure correct
repositioning during refitting. Connect the
hoist chains to the lifting brackets on the
cylinder head.
14 Unscrew the nut and disconnect the
anti-roll bar link rod from the strut. Use a
spanner on the special flats to hold the
link while the nut is being loosened {see
illustration 4.5).
15 Unscrew the nut securing the track rod
end to the steering arm on the swivel hub,
then use a balljoint separator tool to remove
the track rod end (see illustration 2.7).
16 Unscrew the nut and remove the clamp bolt
securing the front suspension lower arm ball-
joint to the swivel hub (see illustration 2.8).
Note that a new clamp bolt and nut will be
required for refitting.
17 Use a chisel or screwdriver as a wedge
to expand the lower portion of the swivel hub
(see illustration 2.9).
18 Using a lever, push down on the
suspension lower arm to free the balljoint from
the swivel hub, then move the swivel hub to
one side and release the arm, taking care
not to damage the balljoint rubber boot. It is
advisable to place a protective cover over the
7 .10 Disconnect the power steering wiring
at the block connector (arrowed)
rubber boot such as the plastic cap from an
aerosol can, suitably cut to fit.
19 Undo the three bolts and detach the rear
engine mounting/torque link bracket from the
transmission.
20 Slacken and remove the nut securing
the front engine mounting/torque link to the
subframe bracket. Withdraw the through-bolt
(see illustration).
21 Support the subframe with a length of
wood on a trolley jack. Ideally, a purpose-made
cradle should be used. Enlist the help of an
assistant.
22 Accurately mark the position of the
subframe and mounting bolts to ensure
correct refitting. Note that Vauxhall/Opel
technicians use a special jig with guide pins
located through the alignment holes in the
subframe and underbody.
23 Unscrew and remove the subframe
7 .23a Unscrew the subframe front
mounting bolts ...
7.23c •.• and rear support bracket bolts
Suspension and steering 10•9
7.20 Undo the nut (arrowed) and remove
the bolt securing the front engine mounting/
torque link to the subframe bracket
mounting bolts, noting the position of each
bolt, as they are of different lengths (see
illustrations). There are two bolts at the front,
two bolts located above the lower suspension
arms, and six bolts located on the triangular
rear support brackets.
24 With the help of an assistant, carefully
lower the subframe taking care not to damage
the wiring harness for the power steering. As
it is being lowered, guide the steering gear
pinion through the rubber grommet in the floor
(see illustrations).
25 Remove the steering gear, front suspension
lower arms and anti-roll bar with reference
to Sections 18, 5 and 8. If necessary, the
subframe mounting rubbers may be renewed,
however, they must be renewed in pairs only
(ie, left and right together). Use a metal tube, a
long threaded bar, and two nuts and washers
to force out the rubbers. If necessary, unbolt
7 .23b ..• side mounting bolts •.•
7.24 Guide the steering gear pinion
through the rubber grommet when
lowering the subframe