Vauxhall Workshop Service and Repair Manuals

Remove lower engine compartment cover.

Open coolant drain plugs (1 and 2) on radiator and cylinder block and drain coolant. Collect escaping coolant.

Drain engine oil. Collect escaping engine oil.

Remove visco-fan – see operation "Visco-fan, Remove and Install".

Remove ribbed V-belt tensioner – see operation "Ribbed V-belt Tensioner, Remove and Install".

Remove exhaust manifold – see operation "Exhaust Manifold, Remove and Install".

Remove intake manifold – see operation "Intake Manifold, Remove and Install".

Remove vacuum pump – see operation "Vacuum Pump, Remove and Install".

Disconnect vacuum hose (1) from brake servo.

Disconnect vacuum hoses (3) from non-return valve (2).

Remove vacuum hoses.

Detach fuel injection pump oil leak line from "1st cylinder" injection nozzle bracket.

Remove injection lines – see operation "Injection Lines, Remove and Install".

Disconnect metal exhaust gas recirculation pipe – see operation "Metal Exhaust Gas Recirculation Pipe, Remove and Install X 25 DT/25 DT" in group "L".

Remove coolant hoses (1) and (6) from cylinder head.

Remove coolant hose (2) from thermostat housing.

Remove coolant hoses (3) and (5) from coolant pipe.

Disconnect coolant pipe (4) (1 attachment screw).

Turn crankshaft in direction of engine rotation to "1st Cylinder TDC" – see operation "Timing, Check".

Remove closure bolt (1) from timing case.

Place Lever KM-822 (3) between upper tensioner blade and closure bolt and tighten chain tensioner in direction of arrow, thus slackening the timing chain.

Whilst the timing chain is slackened using Lever KM-822, insert Retaining Pin KM-823 (2) into chain tensioner hole. This locks the chain tensioner.

Counterhold camshaft against camshaft hex. Remove oil injection nozzle (5) from camshaft sprocket.

Lift timing chain from camshaft sprocket and remove camshaft sprocket from cylinder head.

Remove fastening nuts of wiring harness plug for sheathed glow plug (1) (6 nuts).

Disconnect wiring harness plug from sheathed glow plugs.

Disconnect wiring harness plug (2) from coolant temperature sensor.

Disconnect wiring harness plug (4) from coolant temperature sensor.

Disconnect wiring harness plug (3) from injection nozzle needle movement sensor.

Remove stud bolt (3) for upper tensioning rail (1).

Remove upper tensioning rail.

Remove stud bolt (2) for upper guide rail.

Note:   When lifting the cylinder head, ensure that the upper guide rail is not damaged.

  Remove

Remove fastening nuts/attachment screws (I) from timing case.

Loosen cylinder head bolts in illustrated sequence from outside inwards by turning first 1/4 and then 1/2 revolutions and then remove.

Lift off cylinder head and place onto wooden blocks.

Do not damage cable and attaching parts.

Note:   If the cylinder head is to be checked and/or overhauled, the outer attaching parts must be removed from the cylinder head and then reattached – see operation "Attaching Parts from Cylinder Head, Detach and Reattach".

  Clean

Remove seal residue, clean sealing surfaces.

Threaded holes in cylinder block must be free of dirt and liquid. Ensure that no seal residue falls into the cylinder block oil and coolant channels.

Note:   When checking the swirl chambers and web plates, the following points must be observed:

• Radial cracks of up to 5 mm in length (dimension II) are permissible around the swirl chambers (2).
• Radial cracks of up to 3 mm in length (dimension I) are permissible around the swirl chambers openings (3).
• Splitting of the web plates (1) results from engine operation and is therefore permissible.

Note:   Height variations are possible in the vicinity of the valves and swirl chambers of each individual cylinder (shaded areas). Errors can occur when performing a straight edge measurement over these areas (e.g. diagonal measurement) – this method is therefore no longer permissible.

  Inspect

The measurement of longitudinal deformation of the cylinder head should be made along the dash-dot line shown in the illustration (dimension I) – use straight edge and feeler gauge:

The measurement of lateral deformation of the cylinder head should be made along the dash-dot lines shown in the illustration (dimension I) – use straight edge and feeler gauge:

Check length and width of cylinder block sealing surfaces for deformation and diagonals for warpage – use straight edge and feeler gauge. Permissible deviation in flatness and warpage:

Place Measuring Bridge KM-301 (1) with Gauge MKM-571-B on cleaned sealing surface of cylinder block and set dial pointer to "0" under pretension.

Place Measuring Bridge KM-301 (1) and Gauge MKM-571-B onto cleaned pistons and measure highest point by turning crankshaft. Piston projection is measured at positions (2) and (3) on each piston. Perform this measurement on all 6 pistons. The largest value is the piston projection value.

  Inspect

Permissible piston projection: 0.54 to 0.99 mm.

Note:   The 3 hole cylinder head gasket (arrows) can only be used if the permissible piston projection has been reached.

Check centring sleeves for damage and correct installation positions.

Apply adhesive sealing compound (white) to separating points I + II (engine block / timing case) (observe specification).

Note:   Cylinder head and seal should be installed within half an hour.

Caution

The sealant should be applied as in the diagram:

Fit new cylinder head gasket.

Turn camshaft at hex of the camshaft until the cams of the 1st cylinder point upwards.

Ensure that the upper guide rail is not damaged when putting on the cylinder head.

Lead timing chain through cylinder head.

Put on cylinder head and attach in shown order using new, oiled cylinder head screws, working from inside to outside.

Note:   Observe "General Repair Instructions".

  Install

Connect fastening nuts and attachment screws to timing case – tightening torque 9 Nm / 6.5 lbf. ft.

Insert timing chain upper tensioner blade. Ensure that timing chain upper tensioner blade is correctly seated.

Note:   Always replace oil injection nozzle.

  Install

Install stud bolt (1) for upper timing chain tensioning rail and stud bolt (2) for upper timing chain guide rail with surface sealant (green) – tightening torque 9 Nm / 6.5 lbf. ft.

Insert camshaft sprocket (5) into cylinder head, lie timing chain (4) on the camshaft sprocket and attach the camshaft sprocket to the camshaft with a new oil spray nozzle (3) – ensure that timing chain is seated correctly on the camshaft sprocket.

Connect wiring harness connector (3) and new fastening nuts to sheathed glow plugs (6 nuts) – tightening torque 5 Nm / 4 lbf. ft.

Connect wiring harness connector (2) to coolant temperature sensor.

Connect wiring harness connector (2) to coolant temperature sensor.

Connect wiring harness connector (1) to injection nozzle needle movement sensor.

Place Lever KM-822 (1) between upper timing chain tensioner blade and closure bolt and push back the chain tensioner in the direction of the arrow. The chain tensioner is slackened and the Retaining Pin KM-823 (2) can be taken out of the hole.

Install screw plug (3) and new seal into timing case – tightening torque 9 Nm / 6.5 lbf. ft.

Adjust timing – see operation "Timing, Check".

Install exhaust gas recirculation metal pipe – see operation "Exhaust Gas Recirculation Metal Pipe, Remove and Install X 25 DT / 25 DT" in group "L".

Connect oil leakage line between injection pump and "1st cylinder" injection nozzle holder.

Connect injection lines to injection nozzle holders and injection pump with KM-812 – tightening torque 25 Nm / 18 lbf. ft.

Install coolant hoses free of oil and grease.

Connect coolant hoses/coolant pipe (1 to 6).

Install vacuum pump – see operation "Vacuum Pump, Remove and Install".

Install intake manifold – see operation "Intake Manifold, Remove and Install".

Install exhaust manifold – see operation "Exhaust Manifold, Remove and Install".

Install ribbed V-belt tensioner – see operation "Ribbed V-belt Tensioner, Remove and Install".

Install visco-fan – see operation "Visco-fan, Remove and Install".

Remove cylinder head cover – see operation "Cylinder Head Cover, Remove and Install".

  Install

Tighten cylinder head in shown sequence, working from inside to outside – angle method 90° to 100°.

Install cylinder head cover – see operation "Cylinder Head Cover, Remove and Install".

  Inspect

Check engine oil level and correct if necessary.