Vauxhall Workshop Service and Repair Manuals

Repair engine using a short block (Z 12 XE, Z 12 XEP, Z 14 XEP, with air conditioning)

  Remove

3.   Install engine •   Lift engine •   Attach KM-412-18 (1) to engine – Tighten 4 bolts •   Install engine in KM-412 (2) •   Tighten 8 bolted connections •   Detach KM-2358

5.   Remove clutch - see operation "Remove and install thrust plate and clutch disk" in group "K" 6.   Detach flywheel •   Attach KM-652 •   Unscrew 6 bolts •   Remove KM-652

7.   Detach right engine bracket (1) •   Unscrew 3 bolts 8.   Install oil drain bolt •   Replace seal ring •   Tighten bolt 10 Nm •   Remove collecting basin

9.   Remove ribbed V-belt Note:   Mark running direction. •   Tension ribbed V-belt tensioner in direction of arrow •   Use KM-6130 (1) 10.   Detach coolant pump ribbed V-belt pulley •   Unscrew 3 bolts 11.   Detach crankshaft ribbed V-belt pulley •   Unscrew 6 bolts •   Counterhold at crankshaft hub bolt

12.   Detach ribbed V-belt tensioner Note:   Ensure that the ribbed V-belt tensioner is stored in a proper manner (arrow pointing upwards). If this is not guaranteed, the ribbed V-belt tensioner must be bled. At least five strokes must be performed (tensile/pressure load), whereby the load speed should be constant and the application of load even. Damage to the tension element must be avoided! •   Tension ribbed V-belt tensioner in direction of arrow •   Remove KM-6130 (1) •   Release ribbed V-belt tensioner •   Unscrew 2 bolts (arrows)

13.   Disconnect engine wiring harness •   Detach alternator wiring harness – Unscrew 2 nuts •   Detach starter wiring harness – Unscrew 2 nuts (1) •   Remove cable ties.

14.   Detach alternator •   Undo 2 screw connections 15.   Remove starter •   Unscrew 2 bolts (arrows)

16.   Remove wiring harness for engine management •   For Z 12 XEP, Z 14 XEP: remove fuel rail cover – Unscrew 2 bolts •   Disconnect 12 engine management wiring harnesses – Oil pressure switch (6), coolant temperature sensor (8), camshaft sensor (9), throttle valve module (2), engine control unit (12), exhaust gas recirculation valve (4), ignition module (3), knock sensor (10), crankshaft sensor (11), injectors (1) •   Unbolt ground cable for engine control unit (13). •   Unclip wiring trough (7) •   Unclip wiring harness – 4 brackets (14) 17.   Detach 2 coolant hoses from coolant pump

19.   Remove oil dipstick guide tube •   Remove bolt 20.   Detach coolant pump (1) Note:   Note guide bushings during removal •   Place collecting basin underneath. •   Unscrew 9 bolts Note:   Pay attention to different bolt lengths (arrows = short bolts)

21.   Remove exhaust manifold heat shield •   Unscrew 2 bolts 22.   Remove exhaust manifold •   Unscrew 9 nuts •   Remove gasket. 23.   Remove ignition module •   Remove ignition module cover – Move to the right •   Unscrew 2 bolts •   Extract using KM-6009 (1) Note:   Do not tilt 24.   Detach cylinder head cover •   Detach engine vent hose – Release clamp •   Unscrew 13x bolt

25.   Loosen crankshaft hub bolt (1) Note:   Second person required •   Attach KM-956-1 KM-956-2 (2) •   Counterhold KM-956-1 KM-956-2

26.   Adjust camshafts •   Uniformly rotate crankshaft in direction of engine rotation with KM-956-1 KM-956-2 until KM-953 (1) engages in camshaft groove as far as it will go 27.   Remove crankshaft hub Note:   Pay attention to installation position •   Remove bolt •   Remove with KM-956-1 KM-956-2 28.   Detach oil pan •   Turn engine (180°) •   Unscrew 16 bolts •   Remove oil pan gasket

29.   Remove timing case •   Turn engine (90°) •   Unscrew 15x bolt (arrows) – Pay attention to bolt lengths – Do not damage camshaft sensor (1). •   Lever out timing case seal ring Note:   Do not damage sealing surface

30.   Remove chain drive •   Loosen camshaft sprocket bolts – Counterhold camshafts at hexagonal section •   Lock chain tensioner (1) – Insert KM-955-1 (2) •   Detach sliding rail (3), guide rail (5), tension rail (7) and camshaft sprockets •   Remove timing chain (4) with drive sprocket (6) •   Remove timing case gasket.

31.   Remove cylinder head •   Turn engine (90°) •   Detach KM-953 •   Unscrew 12 bolts Note:   Undo cylinder head bolts in depicted order – Loosen cylinder head bolts (90°) – Loosen cylinder head bolts (180°) – Remove cylinder head bolts •   Place cylinder head on wooden blocks •   Remove cylinder head gasket

  Install

40.   Remove oil intake pipe (1) •   Unscrew 4 bolts •   Detach seal ring (2) 41.   Clean sealing surfaces •   Cylinder block, cylinder head, cylinder head cover, oil filter housing, crankshaft bearing bridge, timing case, oil pan, coolant pump, exhaust manifold

42.   Inspect components Note:   If cylinder head is to be checked and overhauled : Remove all outer attaching parts from cylinder head. •   Cylinder block, cylinder head, cylinder head cover, oil filter housing, crankshaft bearing bridge, chain drive, timing case, oil pan, coolant pump, exhaust manifold 43.   Check that cylinder head has plane surface •   With straightedge, feeler gauge

44.   Lock crankshaft •   Remove closure bolt (1) •   Insert KM-952 (2) – Turn crankshaft uniformly until KM-952 engages

47.   Adjust camshafts •   Insert KM-953 – Turn the camshafts at hexagonal section •   Remove KM-953

48.   Install cylinder head •   Replace gasket Note:   TOP/OBEN mark must be on top •   Replace cylinder head bolts •   Align cylinder head to cylinder block using straightedge •   Tighten 12 bolts 25 Nm + 60° + 60° + 60° Note:   Note tightening sequence.

49.   Attach timing chain •   Attach KM-953 •   Replace timing case gasket Note:   Pay attention to correct seating (arrows) •   Renew bolts •   Fit drive sprocket (5) •   Attach exhaust camshaft sprocket – Bolt in bolt •   Install timing chain (3) •   Insert intake camshaft sprocket with phase sensor disc in timing chain – Bolt in bolt Note:   It must be possible to rotate phase sensor disk by hand

50.   Attach timing chain tension rail (6) •   Tighten bolt 20 Nm Note:   Ensure that timing chain is correctly seated 51.   Attach timing chain guide rail (4) •   Tighten 2 bolts 8 Nm Note:   Ensure that timing chain is correctly seated 52.   Attach timing chain sliding rail (2) •   Tighten 2 bolts 8 Nm 53.   Release chain tensioner •   Remove KM-955 (1)

54.   Note the different versions when replacing components! Be sure to use the correct part and catalogue number! 55.   Attach coolant pump Note:   Ensure that guide sleeves are correctly seated (arrows) •   Replace gasket (1) •   Attach using short bolts (2) •   Tighten 3 bolts 8 Nm •   Detach coolant connection – Unscrew 3 bolts

56.   Note the different versions when replacing components! Be sure to use the correct part and catalogue number! 57.   Attach timing case. •   Screw in bolts Note:   Note tightening sequence. •   Tighten 5 bolts (M6) (1) 8 Nm •   Tighten 14 bolts (M6) (2) 8 Nm •   Tighten 2 bolts (M10) (3) 35 Nm •   Attach coolant connection – Inspect visually, clean sealing surfaces – Replace seal ring – Tighten 3 bolts 8 Nm

58.   Replace crankshaft front seal ring (1) •   Coat sealing lips with silicon grease •   Slide onto KM-960 (2) •   Drive in until flush using KM-960 59.   Remove KM-952 KM-953 Note:   Retaining tools must not be used for counterholding

60.   Attach crankshaft hub Note:   Second person required •   Note crankshaft hub installation position (2) – Marking must point upwards •   Replace bolt •   Counterhold with KM-956-1 KM-956-2 (3) •   Tighten bolt 150 Nm + 45° •   Detach KM-956-1 KM-956-2 61.   Attach crankshaft ribbed V-belt pulley (1) •   Tighten 6 bolts 8 Nm – Counterhold at crankshaft hub bolt •   Insert KM-952 62.   Insert KM-953 into camshaft grooves

63.   Attach KM-954 (1) •   Rotate phase sensor disk (2) until KM-954 can be attached to timing case

64.   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) 65.   Remove retaining tools •   KM-952 , KM-953 , KM-954 66.   Fasten camshaft sprockets Note:   Second person required •   Tighten 2 bolts 50 Nm + 60° Note:   First tighten intake camshaft sprocket bolt – Counterhold camshafts at hexagonal section

67.   Timing, Check •   Turn crankshaft 720° •   Insert KM-952 •   Insert KM-953 •   Attach KM-954 68.   Remove retaining tools •   KM-952 , KM-953 , KM-954 69.   Install oil intake pipe (1) •   Replace gasket (2) •   Tighten 4 bolts 8 Nm

70.   Attach oil pan •   Turn engine (180°) •   Replace gasket •   Screw in bolts •   Align oil pan to cylinder block using straight edge •   Tighten 16 bolts 10 Nm 71.   Attach closure bolt of crankshaft bearing bridge •   Replace seal ring •   Tighten bolt 50 Nm 72.   Install knock sensor •   Tighten bolt 20 Nm 73.   Install crankshaft sensor •   Replace seal ring •   Tighten bolt 8 Nm

74.   Attach cylinder head cover (1) •   Turn engine (180°) •   Replace gasket (2), seal rings •   Apply sealant (dimension I = 2 mm) Note:   Complete assembly operations within 10 minutes •   Tighten 17 bolts 8 Nm •   Attach engine vent hose – Fasten clamp 75.   Attach ignition module •   Tighten 2 bolts 8 Nm 76.   Attach exhaust manifold •   Replace gasket •   Replace nuts •   Tighten 7 nuts 20 Nm 77.   Attach exhaust manifold heat shield •   Tighten 2 bolts 8 Nm 78.   Install oil dipstick guide tube •   Replace 2x seal ring •   Tighten bolt 8 Nm