Vauxhall Workshop Service and Repair Manuals

Remove and refit engine (Z 10 XE, Z 10 XEP, with air conditioning)

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

  Remove

4.   Detach steering intermediate shaft (1) •   Remove lower clamp pin (2) – Unscrew nut (3) •   Steering in straight-ahead position •   Engage steering lock Important:   Do not alter steering wheel position •   Remove steering intermediate shaft 5.   Loosen front wheels •   Loosen 8 bolts

6.   Undo upper front panelling •   Unscrew 3 bolts (1) 7.   Raise vehicle

8.   Undo lower front panelling •   Remove 3x clips (2) •   Unscrew 4x bolt (1) •   Unscrew 2x nut (3) 9.   Detach front panelling Note:   Second person required •   Disconnect temperature sensor wiring harness plug 10.   Lower vehicle

11.   Remove ribbed V-belt cover Note:   In "ECO" model variant remove lower engine compartment cover, see operation "J481500 Removing and installing lower engine compartment cover (ECO)" in group "A" •   Unscrew 3 bolts (1) •   Remove clip (arrow)

12.   Drain coolant •   Place collecting basin underneath. •   Open drain bolt (arrow)

13.   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) •   On Z 10 XEP: Remove air intake hose – Release clamp •   Remove bolt (arrow)

14.   Detach 2x heater hoses (1) from heater core

15.   Release fuel pressure with KM-J-34730-91 at fuel rail (1) Important:   Observe safety precautions and national regulations •   Unscrew test connection protective cap (2) Note:   Test connection for Z 10 XEP at upper fuel rail

16.   Remove fuel line •   Remove using KM-796-A •   Unclip fuel line (arrow) •   Seal using KM-807

17.   Unclip brake servo vacuum line (2) •   Side release 18.   Detach fuel evaporation hose (1) •   From intake manifold

19.   Remove upper radiator hose (1) •   Release 2x clamp 20.   Remove lower coolant hose (2) •   Release 2x clamp

21.   Remove wiring harness for engine management •   Disconnect 2 wiring harness plugs – Reverse switch, combination plug (1) •   Disconnect wiring harness plug of engine control unit (2) – Release in direction of arrow •   Unclip wiring harness – Close clip •   Set wiring harness to one side

22.   Disconnect engine wiring harness •   Detach ground cable from battery. •   Detach battery positive cable •   Remove positive terminal (1) •   Disconnect combination plug (2) •   Remove rubber seal (3) •   Unclip wiring harness – Close clip (arrow) •   Remove cable harness and lay aside

23.   Detach clutch actuation pressure hose •   Remove cover of brake fluid reservoir •   Top up brake fluid reservoir to "MAX" mark •   Screw in MKM-558-10 •   Disengage retaining clip (1) with a screwdriver •   Suspend pressure line for central release Note:   Collect escaping brake fluid •   Clamp retaining clip 24.   Suspend radiator 25.   Raise vehicle 26.   Close coolant drain bolt

27.   Loosen axle shafts •   Detach 2x protective cap (1) •   Remove 2 cotter pins (2) •   Attach KM-468-B (4) – At front wheel hub – Use wheel bolts •   Unscrew 2x nut (3) – Counterhold using KM-468-B – Remove 2x washers

28.   Detach tie rods from steering knuckle •   Unscrew 2 nuts •   Push off tie rods with KM-507-C (1)

29.   Detach swing arm from spring strut support tube •   Remove 2 nuts – Counterhold with open-ended wrench

30.   Detach guide joints •   From steering knuckle •   Remove 2 nuts (1) – Remove bolts 31.   Press out axle shafts •   From wheel hub 32.   Raise vehicle

33.   Remove ribbed V-belt •   Tension ribbed V-belt tensioner in direction of arrow – With KM-6131 •   Use KM-6130 (1) •   From compressor ribbed V-belt pulley

34.   Remove compressor Note:   The air conditioning system remains closed •   Disconnect wiring harness plug (arrow) •   Unscrew 3x bolts (1, 2) – Remove compressor heat shield •   Suspend compressor

35.   Remove exhaust system •   Disconnect oxygen sensor (catalytic converter control) wiring harness plug •   Remove silencer •   Remove front exhaust pipe – Unscrew 3x nuts 36.   Remove exhaust system Note:   Second person required •   Detach exhaust system – 2 damping rings 37.   Detach shift linkage •   Loosen bolt (1)

38.   Attach KM-6169-2 •   Tighten 2x bolts 95 Nm

39.   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 bolts

40.   Attach connection to KM-6169 •   Adjust bracket (2) for support •   Screw on nut (1) 41.   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)

42.   Remove adapter for right engine bracket •   Unscrew 2 bolts (1) 43.   Detach left engine damping block adapter •   Unscrew 2 bolts (2) 44.   Raise vehicle

45.   Move in hydraulic jack with KM-904 (1) 46.   Attach KM-6168 (2) •   Position KM-6168 on KM-904 Note:   Lower body positioning pins (3) •   Position KM-6168 beneath front axle body without clearance Note:   Note centring points in front axle body (arrows).

47.   Release front axle body Note:   The removal of the front axle body with an impulse or impact screwdriver is not permitted •   Unscrew 4 bolts (arrows) 48.   Lower drive unit Note:   Second person required •   Carefully lower front axle body with engine and transmission out of engine compartment from below Note:   Do not damage attaching parts 49.   Remove drive unit 50.   Check threads of 4x lock nuts Note:   Check ease of movement of lock nut threads before installing front axle body, otherwise replace lock nuts

  Install

74.	Install ribbed V-belt cover Note:   With "ECO" model variant - install lower engine compartment cover •   Screw in 3 bolts •   Install clip

92.   Install steering intermediate shaft Note:   Wheels in straight-ahead position •   Release steering lock •   Push on steering intermediate shaft Note:   The bore for the clamp bolt must be on the flat-milled side of the stub axle •   Insert clamp pin •   Replace nut (2) •   Adjust length compensator – Fasten with KM-6181 (1) •   Tighten nuts •   Remove KM-6181

93.   Locking transmission shift linkage •   Unclip manual shift lever cover •   Lock shift lever and shift lever housing with KM-527-A (1)

94.   Lock transmission •   Engage arresting pint (1) in adjusting bore of shift cover by twisting the shift rod to the left 95.   Raise vehicle

96.   Fasten clamp •   Tighten bolt (1) 12 Nm + 90° + 90° to 90° + 90° + 45°