Vauxhall Workshop Service and Repair Manuals

Install oil pump and oil pan – see operation "Oil Pump, Remove and Install".

Engine support to cylinder block – tightening torque 40 Nm / 29.5 lbf. ft.

Coat crankshaft needle bearing with lubricating grease (brown) and drive into crankshaft using KM-235-D (1).

Attach crankcase ventilation flange with new gasket to cylinder block – tightening torque 25 Nm / 18 lbf. ft.

Install crankshaft pulse pick-up on cylinder block – tightening torque 8 Nm / 6 lbf. ft.

Auxiliary aggregates support to cylinder block – tightening torque 35 Nm / 26 lbf. ft.

Before installing coolant pump, coat sealing surface (1) with silicon grease (white). Attach coolant pump to cylinder block with new seal ring – tightening torque 25 Nm / 18.5 lbf. ft.

Install rear toothed belt cover to oil pump – tightening torque 6 Nm / 4.5 lbf. ft.

Attach toothed belt drive gear with new bolt to crankshaft – tightening torque 130 Nm / 96 lbf. ft. + 45° ± 5°. Counterhold toothed belt drive gear with KM-662-C.

Attach toothed belt tension roller to oil pump – tightening torque 20 Nm / 15 lbf. ft.

Attach coolant hose to cylinder block.

The entire contact surface of the knock sensor must lie directly on the cylinder block – ensure utmost cleanliness. Do not use washers, spring washers or toothed washers. Recommended tightening torque must be observed. Attach knock sensor (1) to cylinder block – tightening torque 20 Nm / 15 lbf. ft.

Attach starter to cylinder block – tightening torque 45 Nm / 33 lbf. ft. Install starter bracket on cylinder block – tightening torque 25 Nm / 18.5 lbf. ft.

Cable connection (terminal 30) to starter – tightening torque 12.5 Nm / 9.2 lbf. ft. Cable connection (terminal 50) to starter – tightening torque 4.4 Nm / 3 lbf. ft.

Connect wiring harness plug to knock sensor. Attach ground cable to cylinder block – tightening torque 20 Nm / 15 lbf. ft. Connect wiring harness plug to oil pressure switch.

Drive centring sleeves (1) to stop in cylinder block with KM-427.

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

Attach oil drain bolt with new seal ring to oil pan – tightening torque 55 Nm / 41 lbf. ft. Top up engine oil.

Remove engine from Assembly Stands KM-412, remove Adapter KM-412-8-A from engine. Attach engine bracket to cylinder block – tightening torque 60 Nm / 44.5 lbf. ft.

Install engine – see operation "Engine, Remove and Install".