Vauxhall Workshop Service and Repair Manuals

Remove and install 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 cylinder head cover

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

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

13.   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.

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 •   Lever out front closure plug – From 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

19.   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

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

21.   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

22.   Install support •   An KM-6169 – Adjust bracket (2) for support •   Screw on nut (1) 23.   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)

25.   Remove right engine damping block •   Loosen engine bracket adapter – Remove 2 bolts (1) •   Loosen engine damping block – Remove 2 bolts (2) 26.   Remove upper part of toothed belt cover •   Remove 3 bolts (arrows) •   Unclip from rear toothed belt cover

27.   Remove camshaft sensor (1) •   Unclip from bracket •   Disconnect wiring harness plug •   Remove 2 bolts (2) 28.   Remove lower part of toothed belt cover •   Unclip from rear toothed belt cover

29.   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) 30.   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.

31.   Remove camshaft sprocket on exhaust side •   Use KM-6347 (1), KM-956-1 (2) •   Attach KM-6347 , KM-956-1 Note:   Loosen the clamping screws (3) of KM-6347 and insert KM-6347 connected to KM-956-1 in the camshaft sprocket. The notches on KM-6347 must engage in the camshaft sprocket (arrows). Ensure that it engages properly. Rotate KM-6347 in the direction of the arrow using KM-956-1 . – Tighten 2 clamping screws •   Loosen camshaft sprocket bolt (4) •   Remove KM-6347 , KM-956-1 – Loosen 2 clamping screws •   Unscrew camshaft sprocket bolt

33.   Remove intake side toothed belt guide roller (1) •   Remove bolt 34.   Remove exhaust side toothed belt guide roller (2) •   Remove bolt 35.   Remove right engine bracket (3) •   Remove 3 bolts 36.   Remove toothed belt tension roller (4) •   Remove bolt

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

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

48.   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 front crankshaft seal ring – With KM-6010 (4), bolt (2) and crankshaft ribbed V-belt pulley washer (3)

53.   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.

54.   Install right engine bracket •   Renew bolts •   Tighten bolts ( 65 Nm + 45° - 60° ) Note:   The rotating angle to be applied must be set by eye. •   Note tightening sequence (1 - 3).

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

62.   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)

64.   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) 65.   Remove KM-852

66.   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 67.   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

79.   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