Vauxhall Workshop Service and Repair Manuals

Oil Pump, Remove and Install (Z 18 XE, with Air Conditioning, LHD)

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

  Remove

4.   Remove air cleaner housing (1) •   Disconnect 2 wiring harness plugs – Hot film mass air flow meter (4), tank vent valve (2) •   Unclip tank vent valve •   Detach intake hose •   Detach engine vent hose (3) •   Remove bolt (arrow)

5.   Raise vehicle 6.   Remove right-hand air duct •   Unscrew 3 bolts (arrows) 7.   Remove ribbed V-belt cover •   Unscrew 3 bolts (1) •   Remove clip (2) 8.   Lower vehicle

9.   Detach front right wheel •   Loosen 4 bolts 10.   Raise vehicle 11.   Remove right front wheel. •   Remove 4 bolts 12.   Raise vehicle 13.   Remove ribbed V-belt •   Tension ribbed V-belt tensioner in direction of arrow with KM-913-A (2) •   Use KM-6130 (1)

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

15.   Detach crankshaft ribbed V-belt pulley •   Prise front closure plug out of oil pan •   Use KM-911 •   Remove bolt •   Remove KM-911

16.   Release lower part of toothed belt cover •   Remove bolt (arrow) •   Unclip from rear toothed belt cover 17.   Lower vehicle

18.   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

19.   Install support •   An KM-6169 – Adjust bracket (2) for support •   Screw on nut (1) 20.   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) 21.   Lower vehicle

22.   Remove right engine damping block •   Loosen engine bracket adapter – Unscrew 2 bolts (1) •   Loosen engine damping block – Unscrew 2 bolts (2) 23.   Remove upper part of toothed belt cover •   Unscrew 3 bolts (arrows) •   Unclip from rear toothed belt cover

24.   Remove camshaft sensor (2) •   Unscrew 2 bolts •   Disconnect wiring harness plug (1) 25.   Remove lower part of toothed belt cover •   Unclip from rear toothed belt cover •   Remove downwards

26.   Set 1st cylinder to TDC of combustion stroke •   Install crankshaft V-belt pulley bolt •   Set crankshaft to mark. – Turn crankshaft evenly – Marks on drive gear toothed belt and rear toothed belt cover must align (III). •   Fix camshaft sprockets in position. – Marks must be opposite one another and aligned with the top edge of the cylinder head (I) – Use KM-852 (II) 27.   Remove toothed belt •   Release toothed belt tension roller (IV) – 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.

28.   Remove camshaft sprocket on exhaust side •   Use KM-6347 (1), KM-956-1 (2) •   Attach KM-6347 , KM-956-1 – Release fixing bolts (3) from KM-6347 – Insert KM-6347 together with KM-956-1 into camshaft sprocket Note:   Grooves of KM-6347 must engage in camshaft sprocket (arrows). Ensure correct seating. •   Turn KM-6347 together with KM-956-1 in the direction of the arrow – Tighten 2 clamping screws •   Loosen camshaft sprocket bolt (4) •   Remove KM-6347 , KM-956-1 •   Unscrew camshaft sprocket bolt

30.   Remove intake side toothed belt guide roller •   Remove bolt (1) 31.   Remove exhaust side toothed belt guide roller •   Remove bolt (2) 32.   Remove right engine bracket (3) •   Remove 3 bolts 33.   Remove toothed belt tension roller •   Remove bolt (4)

34.   Use MKM-883-1 (1) Note:   Second person required 35.   Fasten MKM-883-1 Note:   Observe manufacturer's instructions 36.   Attach engine •   To right engine transport shackle (3) •   To front left engine transport shackle (2) Note:   Fastening to front left engine transport shackle serves only to stabilise the engine 37.   Raise vehicle

38.   Remove toothed belt drive pulley •   Use KM-911 •   Unscrew crankshaft ribbed V-belt pulley bolt •   Remove KM-911 39.   Release rear toothed belt cover •   Unscrew 2 bolts (arrows) 40.   Detach supports •   Engine timing side •   Transmission side 41.   detach KM-6169

42.   Loosen exhaust system Note:   Bends in the flex pipe with an angle as little as 5 – 10 degrees from the intended installation position may result in damage with subsequent total failure of the flex pipe. •   When removing the centre muffler, a catalytic converter, an exhaust manifold or an exhaust manifold with catalytic converter, the exhaust system piece remaining in the vehicle must be prevented from swinging uncontrollably. Note:   The exhaust system piece with the flex pipe inside can be secured for this purpose using suitable means, such as a wire on the vehicle underbody. •   Remove wiring harness plug for catalytic converter control oxygen sensor •   Detach 5 damper rings •   Unscrew 3 nuts •   Suspend front exhaust pipe from left front axle body 43.   Remove front reaction member •   Unscrew 2 bolts •   Undo bolted connection

44.   Release shift guide (3) •   Remove retaining clip (2) 45.   Release rear reaction member (4) •   Remove bolt (1)

50.   Remove oil pan •   Prise out 2x closure plugs (1) •   Transmission – Unscrew 3 bolts (2) •   Oil pump – Unscrew 3 bolts (arrows) •   Cylinder Block – Unscrew 12 bolts

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

52.   Remove oil pump •   Disconnect oil pressure switch wiring harness plug (arrow) •   Unscrew 7 bolts 53.   Remove crankshaft front seal ring •   Lever out seal ring Note:   Do not damage sealing surface

  Install

57.   Install oil pump •   Replace gasket •   Insert bolts with locking compound •   Tighten 7x bolts 8 Nm •   Connect oil pressure switch wiring harness plug 58.   Install crankshaft front 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 crankshaft front seal ring with KM-6010 (4), bolt (2) and crankshaft ribbed V-belt pulley washer (3) 59.   Install oil intake pipe •   Replace seal ring •   Insert bolts with locking compound •   Tighten 3x bolts 8 Nm

60.   Install oil pan •   Apply sealant – Complete assembly operations within 10 minutes •   Screw in bolts Note:   Note tightening sequence. •   At cylinder block – Tighten 12x bolts 10 Nm •   At oil pump – Tighten 3x bolts 10 Nm •   On transmission – Tighten 3 bolts 40 Nm •   Insert 2x closure plugs 61.   Lower vehicle 62.   Lower engine Note:   When lowering pay attention to the shift guide and rear reaction member 63.   Raise vehicle 64.   Fasten rear reaction member •   Tighten bolt 80 Nm 65.   Install front reaction member •   Tighten 2 bolts 95 Nm •   Tighten bolted connection 60 Nm

72.   Install toothed belt tension roller •   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.

73.   Install right engine bracket •   Renew bolts •   Insert bolts with locking compound (red) •   Tighten 3x bolts 65 Nm + 45° - 60°

78.   Fix camshaft sprockets in position. •   Marks must be opposite one another and aligned with the top edge of the cylinder head (I) •   Use KM-852 (II) – Turn the camshafts at hexagonal section 79.   Lock crankshaft •   Set crankshaft to mark. – Turn crankshaft evenly – Marks on drive gear toothed belt and rear toothed belt cover must align (III).

80.   Inspect components •   Ribbed V-belt, ribbed V-belt tensioner, ribbed V-belt pulleys, toothed belt drive 81.   Install toothed belt Note:   Pay attention to direction of travel and timing marks. •   Position toothed belt – Tensioned side must be taut. 82.   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) 83.   Remove KM-852

84.   Timing, Check •   Turn crankshaft in direction of engine rotation at the crankshaft ribbed V-belt pulley bolt (720°) •   Set crankshaft to mark. – Marks on drive gear toothed belt and rear toothed belt cover must align (III). •   Use KM-852 (II) – Marks must be opposite one another and aligned with the top edge of the cylinder head (I) 85.   Remove KM-852

86.   Adjust toothed belt tension •   Release toothed belt tension roller – Loosen bolt •   Turn adjustment eccentric in the direction of the arrow (clockwise) until pointer (1) of toothed belt tension roller is aligned with the notch mark NEW (2). •   Tighten toothed belt tension roller bolt 20 Nm 87.   Check toothed belt tension •   Turn crankshaft (720°) •   Pointer on the toothed belt tension roller and notch mark NEW must align