Vauxhall Workshop Service and Repair Manuals

Remove and install cylinder head (Z 12 XE, Z 12 XEP, Z 14 XEP, with air conditioning, LHD)

Note:   KM-6394 must be used as of model year 04 instead of KM-6169-1 .

  Remove

3.   Release upper front panelling •   Unscrew 3 bolts (1)

5.   Release lower front panelling •   Disconnect wiring harness connector. •   Remove 3 clips (2) •   Unscrew 4x bolt (1) •   Unscrew 2x nut (3) 6.   Detach front panelling Note:   Second person required •   If present: Detach and seal headlamp washer system high-pressure hose

Important:   Angular dislocations of the flexpipe as small as 5 to 10 degrees offset from the intended installation position can cause damage and subsequent complete failure of the flexpipe. 8.   Detach front exhaust pipe (1) from catalytic converter •   Unscrew 3 nuts •   Affix the front exhaust pipe to the vehicle underbody with wire 9.   Remove ribbed V-belt cover •   Unscrew 3 bolts (1) •   Remove clip (arrow)

10.   Remove ribbed V-belt from compressor ribbed V-belt pulley •   Tension ribbed V-belt tensioner in direction of arrow with KM-6131 •   Use KM-6130 (1)

11.   Remove compressor Note:   The air conditioning system remains closed •   Disconnect wiring harness plug (arrow) •   Unscrew 3 bolts (1) •   Suspend compressor

12.   Unclip wiring harness for engine management •   Open 2 clips (arrows)

13.   Attach KM-6169-2 to transmission •   Tighten 2 bolts 95 Nm

14.   Attach KM-6169 (1) •   Attach KM-6169 to left of front axle body (arrows, illus. I) – Guide pin must be seated in bore in front axle body •   Attach both right holders on the front axle body (arrows, Illus. II). – Guide pin must be seated in bore in front axle body (arrow, Fig. III) •   Tighten 8 bolts

15.   Install support •   An KM-6169 – Adjust bracket (2) for support •   Screw on nut (1) 16.   Adjust supports •   Transmission side – Turn spindles until mounts (3) are positioned at guide journals free of play •   Engine timing side – Insert journal of the support in the bore of the cylinder block without play (arrow) – Tighten nuts (1)

17.   Loosen right engine bracket •   Loosen lower bolt (1) 18.   Lower vehicle

19.   Drain coolant •   Place collecting basin underneath. •   Open drain bolt (arrow) 20.   Lower vehicle

21.   Remove air cleaner housing (1) •   Disconnect 2 wiring harness plugs – Hot film mass air flow sensor (3), tank vent valve (2) •   Unclip tank vent valve •   Remove suction pipe (4) – Unscrew 2 nuts – Detach engine vent hose (5) •   For Z 12 XEP, Z 14 XEP: detach air intake hose – Release clamp •   Remove bolt (arrow)

22.   Detach throttle valve module preheater return hose (1) •   Release clamp 23.   Remove throttle valve module preheater feed hose (1) •   Release clamp 24.   Detach heater return hose (2) from coolant pump •   Release clamp •   Lay hose aside 25.   Detach heater return hose from exhaust gas recirculation coolant flange •   Release clamp •   Lay hose aside

26.   Detach brake servo vacuum line (4) 27.   Pull fuel evaporation hose (3) from intake manifold

Important:   Observe safety precautions and national regulations 28.   Release fuel pressure with KM-J-34730-91 •   Unscrew test connection protective cap (2) from fuel rail (1) Note:   Test connection is on top of fuel rail in Z 12 XEP and Z 14 XEP

29.   Detach fuel rail (arrow) with KM-796-A •   Unclip fuel line •   Seal using KM-807

30.   Remove intake pipe (1) •   Remove bolt (2) •   Remove oil dipstick

33.   Remove oil filter housing (1) •   Place another collecting basin underneath •   Unscrew 3 bolts (2) 34.   Remove upper radiator hose •   Release 2x clamp

35.   Detach coolant connection •   Unscrew 3 bolts

36.   Remove right engine bracket •   Remove right engine damping block – Unscrew 2 bolts (1) •   Remove engine bracket – Unscrew 2 bolts (arrows) 37.   Remove ribbed V-belt Note:   Mark running direction. 38.   Remove coolant pump ribbed V-belt pulley •   Unscrew 3 bolts

39.   Remove wiring harness for engine management •   For Z 12 XEP, Z 14 XEP: remove fuel rail cover – Unscrew 2 bolts •   Disconnect 12 wiring harness plugs – Oil pressure switch (5), coolant temperature sensor (6), camshaft sensor (1), injectors (2), throttle valve adjuster (3), engine control unit (7), combination plug (8), exhaust gas recirculation valve (9), ignition module (4) •   Detach 3 ground cables (arrows) •   Unclip wiring harness – Open 3 brackets •   Remove cable ties. •   Unclip wiring trough •   Set wiring harness to one side

40.   Remove timing case fastening bolts •   Coolant pump – Unscrew 4x bolt (1) •   Timing case – Unscrew 5 bolts (arrows)

41.   Remove ignition module •   Remove ignition module cover – Move to the right •   Unscrew 2 bolts •   Extract using KM-6009 (1) Note:   Do not tilt 42.   Remove cylinder head cover •   Detach engine vent hose – Release clamp •   Unscrew 13x bolt

43.   Set no.1 cylinder to TDC •   Remove crankshaft bearing bridge closure bolt (1) •   Insert KM-952 (2) Note:   Mark on crankshaft belt pulley (4) must line up with lug (3) on timing case – Turn crankshaft uniformly until KM-952 engages

44.   Insert KM-953 (1) Note:   KM-953 must engage in camshaft groove 45.   Remove KM-953

46.   Lock chain tensioner •   Remove closure bolt (1) •   Load intake camshaft in direction of arrow via hexagonal section using an open-ended spanner •   Insert KM-955-1 (2)

47.   Remove sliding rail (1) •   Unscrew 2 bolts 48.   Detach camshaft sprockets •   Unscrew 2 bolts (2) – Counterhold camshafts at hexagonal section (3) •   Remove phase sensor disc

49.   Remove cylinder head bolts Note:   Undo bolts in order shown •   Unscrew 10 bolts – Loosen bolts (90°) – Loosen bolts (180°) 50.   Remove cylinder head Note:   Second person required •   Guide chain tensioner past tensioning rail •   Place cylinder head on wooden blocks •   Remove cylinder head gasket

  Install

51.   Detach timing case gasket •   Cut through elastomer sealing lips (dimension I and II) from inside outwards flush to cylinder block •   Carefully bend gasket at designated break points (arrows) 52.   Clean sealing surfaces •   Cylinder block, cylinder head, timing case, exhaust manifold, oil filter housing, thermostat housing, cylinder head cover

53.   Inspect components Note:   If cylinder head is to be checked and overhauled : Remove all outer attaching parts from cylinder head. •   Cylinder block, cylinder head, timing case, exhaust manifold, oil filter housing, thermostat housing, cylinder head cover 54.   Check for plane surface •   Cylinder head, cylinder block •   With straightedge, feeler gauge

55.   Replace cylinder head gasket •   Cut off protruding elastomer (dimension I) on timing case side

56.   Apply sealant (dimension I = 2 mm) Note:   Complete assembly operations within 10 minutes •   Attach cylinder head gasket – OBEN/TOP mark must point upwards.

57.   Fit timing case upper gasket (1) •   Apply sealant (dimension I = 2 mm) •   Insert 2 upper fastening bolts into timing case (arrows) Note:   The fastening bolts are used to fix the upper timing case gasket in position •   Attach gasket Note:   Push on in vicinity of sealant

58.   Attach cylinder head Note:   Second person required •   Guide KM-955-1 through aperture in timing case •   Guide chain tensioner past tensioning rail •   Insert pin in guide rail 59.   Fasten cylinder head •   Replace cylinder head bolts – Screw in bolts by several threads •   Attach timing case. – Tighten 3 bolts (1) 8 Nm •   Position cylinder head by tapping with rubber mallet in direction of timing case •   Tighten 12 cylinder head bolts 25 Nm + 60° + 60° + 60° – Note tightening sequence.

60.   Install timing case fastening bolts Undo lower 3 bolts of cylinder head again (previously installed bolts) Coolant pump Tighten 4 bolts (1) 8 Nm Timing case Tighten 5 bolts (arrows) 8 Nm

61.   Adjust camshafts •   Insert KM-953 (1) – "Turn" the camshafts at hexagonal section (arrows)

62.   Attach camshaft sprockets •   Renew bolts •   Attach intake camshaft sprocket with phase sensor disc (2) – Bolt in bolt Note:   It must be possible to rotate phase sensor disk by hand •   Attach exhaust camshaft sprocket – Bolt in bolt 63.   Attach sliding rail •   Tighten 2 bolts 8 Nm 64.   Remove KM-955-1 •   Replace seal ring •   Tighten chain tensioner closure bolt 50 Nm 65.   Attach KM-954 •   Rotate phase sensor disk until KM-954 (1) can be attached to timing case

66.   Fasten camshaft sprockets Note:   Tightening torque of 10 Nm is used to secure the camshaft sprockets and the phase sensor disk •   Tighten 2 bolts (2) 10 Nm Note:   First tighten intake camshaft sprocket bolt – Counterhold camshafts at hexagonal section (1) 67.   Remove retaining tools Note:   Retaining tools must not be used for counterholding •   KM-952 , KM-953 , KM-954 68.   Fasten camshaft sprockets Note:   Second person required •   Tighten 2 bolts (2) 50 Nm + 60° Note:   First tighten intake camshaft sprocket bolt – Counterhold camshafts at hexagonal section

69.   Timing, Check •   Turn crankshaft (720°) •   Insert KM-952 •   Insert KM-953 •   Attach KM-954 70.   Remove retaining tools •   KM-952 , KM-953 , KM-954 71.   Attach cylinder head cover (1) •   Renew gasket (2) and seal rings •   Apply sealant (dimension I = 2 mm) Note:   Complete assembly operations within 10 minutes •   Tighten 13 bolts 8 Nm •   Attach engine vent hose – Fasten clamp