Vauxhall Workshop Service and Repair Manuals

Remove and install timing case (Z 12 XE, Z 12 XEP, Z 14 XEP, with air conditioning, LHD)

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

  Remove

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

5.   Lower vehicle 6.   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) •   For Z 12 XEP, Z 14 XEP: detach air intake hose – Release clamp •   Remove bolt (arrow)

7.   Detach throttle body preheater hose (1) 8.   Detach heater supply hose (6) from coolant pump

9.   Remove engine management wiring harness •   Disconnect 3 wiring harness plugs – oil pressure switch (3), coolant temperature sensor (4) and camshaft sensor (5) •   Unclip wiring trough (2) •   Set wiring harness to one side 10.   Remove upper radiator hose (1) •   Release 2x clamp 11.   Detach lower radiator hose (2) from coolant pump •   Release clamp 12.   Loosen compressor •   Disconnect wiring harness connector. •   Unscrew upper bolt

13.   Remove ignition module •   Remove ignition module cover – Move to the right •   Disconnect wiring harness connector. •   Unscrew 2 bolts •   Extract using KM-6009 (1) Note:   Do not tilt

14.   Remove cylinder head cover •   Detach engine vent hose – Release clamp •   Unscrew 13x bolt 15.   Detach front right wheel •   Loosen 4 bolts 16.   Raise vehicle 17.   Remove right front wheel •   Unscrew 4 bolts 18.   Raise vehicle 19.   Remove ribbed V-belt cover •   Unscrew 3 bolts (1) •   Remove clip (arrow) 20.   Close coolant drain bolt 21.   Drain engine oil •   Place another collecting basin underneath •   Remove drain bolt

Important:   Angular dislocations of the flexpipe as small as 5 to 10 degrees offset from the intended installation position can cause damage and subsequent complete failure of the flexpipe. 22.   Loosen exhaust system Note:   When removing the centre muffler, a catalytic converter, an exhaust manifold or exhaust manifold with catalytic converter, the exhaust system piece remaining in the vehicle must be secured to prevent it sagging uncontrollably. The exhaust system piece with the flex pipe inside it can be fastened to the vehicle underbody with suitable materials such as wire. •   Detach oxygen sensor (catalytic converter control) wiring harness plug (1) •   Detach 2x damper rings (arrows) •   Unbolt front exhaust pipe (2) – Unscrew 3 nuts •   Suspend front exhaust pipe from left front axle body 23.   Install engine oil drain bolt •   Replace seal ring •   Tighten bolt 10 Nm

24.   Remove alternator wiring harness (1) •   Unscrew 2 nuts •   Remove cable ties.

25.   Remove ribbed V-belt •   Tension ribbed V-belt tensioner in direction of arrow with KM-6131 •   Fit KM-6130 (2)

26.   Remove ribbed V-belt tensioner Note:   Ensure that the ribbed V-belt tensioner is positioned correctly (arrow pointing upwards). If this is not guaranteed, the ribbed V-belt tensioner must be bled. At least 5 strokes must be performed (tensile/pressure load), whereby the load speed should be constant and the application of load even. Damage to the tensioning element must be avoided! •   Tension ribbed V-belt tensioner with KM-6131 •   Remove KM-6130 (2) •   Release ribbed V-belt tensioner •   Unscrew 2 bolts (1)

27.   Remove alternator •   Undo 2 screw connections (1) •   Remove oxygen sensor (catalytic converter control) bracket

28.   Remove oil pan •   Transmission – Unscrew 3 bolts (1) •   Crankshaft bearing bridge – Unscrew 16 bolts 29.   Remove compressor Note:   The air conditioning system remains closed •   Unscrew 2 bolts •   Lay compressor aside

30.   Attach KM-6169-2 to transmission •   Tighten 2 bolts 95 Nm

31.   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, Fig. III) •   Tighten 8 bolts

32.   Install support •   An KM-6169 – Adjust bracket (2) for support •   Screw on nut (1) 33.   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)

34.   Loosen right engine bracket •   Loosen lower bolt (1) 35.   Lower vehicle 36.   Lower vehicle 37.   Suspend compressor

38.   Remove right engine bracket •   Loosen engine damping block – Unscrew 2 bolts (1) •   Unscrew 2x bolt (arrows) 39.   Remove ribbed V-belt Note:   Mark running direction. 40.   Remove coolant pump ribbed V-belt pulley •   Unscrew 3 bolts (1)

41.   Detach ribbed V-belt tensioner •   Remove bolt 42.   Detach thermostat housing •   Unscrew 3 bolts

43.   Set no.1 cylinder to TDC •   Remove closure bolt for crankshaft bearing bridge (1) •   Insert KM-952 (2) Note:   Mark on crankshaft belt pulley (4) must line up with lug (3) on timing case – Turn crankshaft uniformly until KM-952 engages

44.   Insert KM-953 (1) Note:   KM-953 must engage in camshaft groove 45.   Remove KM-953 46.   Raise vehicle

47.   Detach crankshaft ribbed V-belt pulley (1) •   Unscrew 6 bolts •   Counterhold at crankshaft hub bolt 48.   Loosen crankshaft hub bolt Note:   Second person required •   Remove KM-952 •   Attach KM-6013 (3) – Tighten 2 bolts •   Attach KM-956-1 KM-956-2 (4) •   Counterhold KM-956-1 KM-956-2 49.   Detach crankshaft hub (2) Note:   Pay attention to installation position •   Insert KM-952 •   Remove bolt •   Remove with KM-956-1 KM-956-2

50.   Loosen timing case at bottom Note:   Note dissimilar bolt lengths •   Unscrew 2 bolts (3) (M10) •   Unscrew 14 bolts (M6) (arrows) 51.   Lower vehicle 52.   Remove coolant pump Note:   Note guide bushings during removal •   Place another collecting basin underneath •   Unscrew 4 bolts (2) Note:   Note dissimilar bolt lengths 53.   Remove timing case •   Unscrew 4x bolt (1) Note:   Note dissimilar bolt lengths

54.   Remove chain drive •   Undo 2 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. 55.   Remove front crankshaft seal ring •   Lever out seal ring Note:   Do not damage sealing surface

  Install

59.   Replace crankshaft front seal ring (1) •   Coat sealing lips with silicon grease •   Slide onto KM-960 (2) •   Drive in until flush using KM-960

60.   Replace timing case gasket •   Apply silicone sealant to joint between cylinder block and crankshaft bearing bridge Note:   Complete assembly operations within 10 minutes •   Cut off excess elastomer of cylinder head gasket (1) and replace with a 2 mm thick bead of silicone sealant (2) Note:   If no excess elastomer is present, the bead of silicone sealant can be applied directly

61.   Attach timing chain Note:   Ensure that guide sleeves are correctly seated (arrows) •   Attach KM-953 •   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

62.   Attach timing chain tension rail (6) •   Tighten bolt 20 Nm Note:   Ensure that timing chain is correctly seated 63.   Attach timing chain guide rail (4) Note:   Ensure that timing chain is correctly seated •   Tighten bolt 8 Nm 64.   Attach timing chain sliding rail (2) •   Tighten 2 bolts 8 Nm 65.   Remove KM-955-1 (1)

66.   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

67.   Attach timing case. Note:   Note tightening sequence. •   Screw in 21 bolts •   Tighten 5 bolts (1) (M6) 8 Nm •   Tighten 14 bolts (2) (M6) 8 Nm •   Tighten 2 bolts (3) (M10) 35 Nm 68.   Install thermostat housing •   Replace gasket •   Tighten 3 bolts 8 Nm 69.   Raise vehicle 70.   Remove KM-952 Note:   Retaining tools must not be used for counterholding

71.   Attach crankshaft hub (1) Note:   Note crankshaft hub installation position - mark must point upwards •   Replace bolt 72.   Tighten crankshaft hub bolt Note:   Second person required •   Counterhold with KM-956-1 KM-956-2 (2) •   Tighten bolt 150 Nm + 45° •   Detach KM-956-1 KM-956-2 73.   Attach crankshaft ribbed V-belt pulley •   Tighten 6 bolts 8 Nm •   Counterhold at crankshaft hub bolt 74.   Insert KM-952 75.   Lower vehicle

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

77.   Fasten camshaft sprockets Note:   First tighten intake camshaft sprocket bolt •   Tighten 2 bolts (2) 10 Nm Note:   Tightening torque of 10 Nm is used to secure the camshaft sprockets and the phase sensor disk – Counterhold camshafts at hexagonal section (1) 78.   Remove retaining tools Note:   Retaining tools must not be used for counterholding •   KM-952 , KM-953 , KM-954 79.   Fasten camshaft sprockets Note:   Second person required •   Tighten bolts 50 Nm + 60° Note:   First tighten intake camshaft sprocket bolt – Counterhold camshafts at hexagonal section

105.   Attach cylinder head cover (1) Note:   Complete assembly operations within 10 minutes •   Replace gasket (2) •   Apply sealant (dimension I = 2 mm) •   Tighten 13 bolts 8 Nm •   Attach engine vent hose 106.   Install ignition module •   Unscrew KM-6009 •   Tighten 2 bolts 8 Nm •   Connect wiring harness plug •   Attach ignition module cover 107.   Connect wiring harness for engine management •   Route wiring harness •   Clip-in wiring trough •   Connect 3 wiring harness plugs 108.   Fasten compressor •   Tighten upper bolt ( 20 Nm •   Connect wiring harness plug