Vauxhall Workshop Service and Repair Manuals

Check oil pump (Z 14 XE with air conditioning LHD, Z 16 YNG)

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

4.   Remove air cleaner housing (1) •   Disconnect wiring harness plug – Intake air temperature sensor (4), tank vent valve (2) •   Unclip tank vent valve •   Detach intake hose •   Detach engine vent hose (5) •   Remove bolt (3)

5.   Remove ignition module •   Disconnect wiring harness plug •   Remove 4 bolts Important:   Do not tilt •   Extract using KM-6009 (1) 6.   Detach preheater hose for throttle valve module (2) •   Place collecting basin underneath. •   From thermostat housing 7.   Disconnect wiring harness plug for coolant temperature sensor (3) •   Unclip from rear toothed belt cover

8.   Remove cylinder head cover •   Detach engine vent hose – 2 off •   Remove 10 bolts •   Remove seal

9.   Remove catalytic converter control oxygen sensor wiring harness plug •   Disconnect wiring harness plug •   Remove from bracket

15.   Remove ribbed V-belt cover •   Remove 3 bolts (1) •   Remove clip (arrow).

16.   Remove ribbed V-belt •   Tension ribbed V-belt tensioner in direction of arrow – Using KM-913-A (2) (SW 15) •   Use KM-6130 (1) •   Mark running direction.

17.   Remove ribbed V-belt tensioner •   Tension ribbed V-belt tensioner. •   Remove KM-6130 (2) •   Release ribbed V-belt tensioner •   Remove bolt (1)

18.   Detach crankshaft ribbed V-belt pulley •   Lever out front closure plug – From oil pan •   Use KM-911 •   Remove bolt •   Remove KM-911

19.   Release lower part of toothed belt cover •   Remove bolt (arrow) •   Unclip from rear toothed belt cover

22.   Remove oil pan •   Lever out rear sealing plug (1) •   Transmission – Remove 3 bolts (2) •   Oil pump – Remove 3 bolts (arrows) •   Cylinder Block – Remove 12 bolts

23.   Attach KM-6169-3 •   Tighten bolts 95 Nm

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

25.   Install support •   An KM-6169 – Adjust bracket for support (2) •   Screw on nut (1) 26.   Adjust supports •   Transmission side Note:   Turn spindles until mounts (3) are positioned at the 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)

28.   Remove right engine damping block •   Loosen engine bracket adapter – Remove 2 bolts (1) •   Loosen engine damping block – Remove 2 bolts (2) 29.   Remove upper part of toothed belt cover •   Remove 3 bolts (arrows) •   Unclip from rear toothed belt cover

30.   Remove camshaft sensor (1) •   Unclip from bracket •   Disconnect wiring harness plug •   Remove 2 bolts (2) 31.   Remove lower part of toothed belt cover •   Unclip from rear toothed belt cover

32.   Set 1st cylinder to TDC of combustion stroke •   Install crankshaft V-belt pulley bolt •   Set crankshaft to mark. – Turn crankshaft evenly Note:   Marks on drive gear toothed belt and rear toothed belt cover must align (III). •   Fix camshaft sprockets in position. Note:   Marks must be opposite one another and aligned with the top edge of the cylinder head (I) – Use KM-852 (II) 33.   Remove toothed belt •   Release toothed belt tension roller (IV) Note:   Mark running direction. – Loosen bolt – Turn adjusting eccentric in direction of arrow (clockwise) until pointer (1) of the toothed belt tension roller is located just before left stop. •   Remove toothed belt.

34.   Remove camshaft sprockets •   Remove KM-852 •   Remove 2 bolts – Counterhold camshafts at hexagonal section

35.   Remove intake side toothed belt guide roller (1) •   Remove bolt 36.   Remove exhaust side toothed belt guide roller (2) •   Remove bolt 37.   Remove right engine bracket (3) •   Remove 3 bolts 38.   Remove toothed belt tension roller (4) •   Remove bolt

43.   Remove oil intake pipe (1) •   Remove 3 bolts (arrows) •   Remove seal ring

44.   Remove oil pump •   Disconnect oil pressure switch wiring harness plug (arrow) •   Remove 7 bolts

46.   Disassemble oil pump •   Detach oil pump cover (2) – Remove 5 bolts •   Remove inner and outer cusp (gear pair) 47.   Remove oil pump pressure regulating valve •   Remove bolt (1) •   Remove piston spring 48.   Inspect components •   Oil pump housing, inner rotor, outer rotor, oil pump cover 49.   Check oil pump Important:   The bevel running around the outside edge of the outer cusp must face the oil pump housing. •   Insert inner and outer cusp (gear pair) •   Measure gap Note:   The maximum amount of play that is permitted between the gear pair and the top edge of the oil pump housing is 0.03 to 0.10 mm. – With straightedge (3), feeler gauge (4) •   Remove gear pair

56.   Install front crankshaft seal ring •   Coat seal lip with grease •   Attach KM-6010 to crankshaft journal (1) •   Slide seal ring over KM-6010 •   Remove KM-6010 •   Pull in front crankshaft seal ring – With KM-6010 (4), bolt (2) and crankshaft ribbed V-belt pulley washer (3)

61.   Install toothed belt tension roller Important:   Detent lever (1) of toothed belt tension roller must engage in guide web (2) of oil pump. •   Bolt in bolt Note:   Adjust toothed belt tension before tightening bolt.

62.   Install right engine bracket •   Renew bolts •   Tighten bolts ( 65 Nm + 45° + 15° ) Note:   The rotating angle to be applied must be set by eye. •   Note tightening sequence.

68.   Install toothed belt Note:   Pay attention to direction of travel and timing marks. •   Position toothed belt Note:   Tensioned side must be taut (I).

69.   Tension toothed belt •   Tension toothed belt tension roller – Turn adjusting eccentric in direction of arrow (anticlockwise) until pointer of the toothed belt tension roller is located just before left stop •   Fasten toothed belt tension roller bolt (1)

71.   Timing, Check •   Turn crankshaft (720°) – At crankshaft ribbed V-belt pulley bolt Note:   In direction of engine rotation. •   Set crankshaft to mark. Note:   Marks on drive gear toothed belt and rear toothed belt cover must align (III). •   Use KM-852 (II) Note:   Marks must be opposite one another and aligned with the top edge of the cylinder head (I)

73.   Adjust toothed belt tension •   Release toothed belt tension roller – Loosen bolt •   Turn adjustment eccentric in the direction of the arrow (clockwise) until pointer (1) is aligned with the notch mark at the toothed belt tension roller (2). – Adjust used toothed belts to the marking USED – Adjust new toothed belts to the marking NEW •   Tighten toothed belt tension roller bolt 20 Nm 74.   Check toothed belt tension •   Turn crankshaft (720°) Note:   Pointers on the toothed belt tension roller and notch mark must align. – Adjust used toothed belts to the marking USED – Adjust new toothed belts to the marking NEW

86.   Install oil pan Important:   Complete installation work within 10 minutes •   Apply sealant •   Screw in bolts •   At cylinder block – Tighten bolts 10 Nm •   At oil pump – Tighten bolts 10 Nm •   On transmission – Tighten bolts 40 Nm •   Insert rear closure plug

96.   Install cylinder head cover •   Replace gasket Important:   Complete installation work within 10 minutes •   Apply sealant to sealing surfaces(1) •   Tighten bolts 8 Nm •   Attach engine vent hose •   Connect cable harness plug of oxygen sensor, mixture regulation, heated