Vauxhall Workshop Service and Repair Manuals

Remove and install timing case (Z 12 XE, Z 12 XEP, Z 14 XEP, without 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.   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

13.   Remove cylinder head cover •   Detach engine vent hose – Release clamp •   Unscrew 13x bolt 14.   Detach front right wheel •   Loosen 4 bolts 15.   Raise vehicle 16.   Remove right front wheel •   Unscrew 4 bolts 17.   Raise vehicle 18.   Remove ribbed V-belt cover •   Unscrew 3 bolts (1) •   Remove clip (arrow) 19.   Close coolant drain bolt 20.   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. 21.   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 22.   Install engine oil drain bolt •   Replace seal ring •   Tighten bolt 10 Nm

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

24.   Remove ribbed V-belt •   Tension ribbed V-belt tensioner in direction of arrow with KM-6131 •   Insert KM-955-2 (1) •   Release ribbed V-belt tensioner

25.   Remove ribbed V-belt tensioner •   Tension ribbed V-belt tensioner in direction of arrow with KM-6131 •   Remove locking pin KM-955-2 •   Relax ribbed V-belt tensioner with KM-6131 •   Unscrew 2x bolt (arrows)

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

27.   Remove oil pan •   Transmission – Unscrew 3 bolts (1) •   Crankshaft bearing bridge – Unscrew 16 bolts

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

29.   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

30.   Install support •   An KM-6169 – Adjust bracket (2) for support •   Screw on nut (1) 31.   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)

32.   Loosen right engine bracket •   Loosen lower bolt (1) 33.   Lower vehicle 34.   Lower vehicle

35.   Remove right engine bracket •   Loosen engine damping block – Unscrew 2 bolts (1) •   Unscrew 2x bolt (arrows) 36.   Remove ribbed V-belt Note:   Mark running direction. 37.   Remove coolant pump ribbed V-belt pulley •   Unscrew 3 bolts (1)

38.   Detach ribbed V-belt tensioner •   Remove bolt 39.   Detach thermostat housing •   Unscrew 3 bolts

40.   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

41.   Insert KM-953 (1) Note:   KM-953 must engage in camshaft groove 42.   Remove KM-953 43.   Raise vehicle

44.   Detach crankshaft ribbed V-belt pulley (1) •   Unscrew 6 bolts •   Counterhold at crankshaft hub bolt 45.   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 46.   Detach crankshaft hub (2) Note:   Pay attention to installation position •   Insert KM-952 •   Remove bolt •   Remove with KM-956-1 KM-956-2

47.   Loosen timing case at bottom Note:   Note dissimilar bolt lengths •   Unscrew 2 bolts (3) (M10) •   Unscrew 14 bolts (M6) (arrows) 48.   Lower vehicle 49.   Remove coolant pump Note:   Note guide bushings during removal •   Place another collecting basin underneath •   Unscrew 4 bolts (2) Note:   Note dissimilar bolt lengths 50.   Remove timing case •   Unscrew 4x bolt (1) Note:   Note dissimilar bolt lengths

51.   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. 52.   Remove front crankshaft seal ring •   Lever out seal ring Note:   Do not damage sealing surface

  Install

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

57.   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

58.   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

59.   Attach timing chain tension rail (6) •   Tighten bolt 20 Nm Note:   Ensure that timing chain is correctly seated 60.   Attach timing chain guide rail (4) Note:   Ensure that timing chain is correctly seated •   Tighten bolt 8 Nm 61.   Attach timing chain sliding rail (2) •   Tighten 2 bolts 8 Nm 62.   Remove KM-955-1 (1)

63.   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

64.   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 65.   Install thermostat housing •   Replace gasket •   Tighten 3 bolts 8 Nm 66.   Raise vehicle 67.   Remove KM-952 Note:   Retaining tools must not be used for counterholding

68.   Attach crankshaft hub (1) Note:   Note crankshaft hub installation position - mark must point upwards •   Replace bolt 69.   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 70.   Attach crankshaft ribbed V-belt pulley •   Tighten 6 bolts 8 Nm •   Counterhold at crankshaft hub bolt 71.   Insert KM-952 72.   Lower vehicle

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

74.   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) 75.   Remove retaining tools Note:   Retaining tools must not be used for counterholding •   KM-952 , KM-953 , KM-954 76.   Fasten camshaft sprockets Note:   Second person required •   Tighten bolts 50 Nm + 60° Note:   First tighten intake camshaft sprocket bolt – Counterhold camshafts at hexagonal section

101.   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 102.   Install ignition module •   Unscrew KM-6009 •   Tighten 2 bolts 8 Nm •   Connect wiring harness plug •   Attach ignition module cover 103.   Connect wiring harness for engine management •   Route wiring harness •   Clip-in wiring trough •   Connect 3 wiring harness plugs 104.   Fasten compressor •   Tighten upper bolt ( 20 Nm •   Connect wiring harness plug