Vauxhall Workshop Service and Repair Manuals

Engine, Repair Using Short-block  

  Remove, Disconnect   

Detach engine from front axle body and from transmission.   For version with AC: Remove auxiliary aggregates support.   For version without air conditioning: Remove front right engine damping block bracket.   X 16 SZR: Install engine with Adapters KM-410-10 at Mounting Trestle KM-412.   16 LZ2 and 20 NEJ: Install engine with Adapters KM-412-8 at Mounting Trestle KM-412.   Remove oil drain bolt - collect escaping engine oil.   Remove cylinder head - see operation "Cylinder Head, Remove and Install (X 16 SZR)" or "Cylinder Head, Remove and Install (16 LZ2 and 20 NEJ)".   Pull centring sleeves from cylinder head.   Remove coolant pipe and all hose connections from cylinder block.

  Remove, Disconnect   

Remove cable connections from alternator. Detach alternator with alternator bracket (for X 16 SZR with alternator support) from cylinder block.  

Remove starter - see operation "Starter, Remove and Install (X 16 SZR)" or "Starter, Remove and Install (16 LZ2 and 20 NEJ)".  

16 LZ2 and 20 NEJ: Remove ground cable from cylinder block.  

X 16 SZR and 20 NEJ: Remove knock sensor from cylinder block.  

Remove oil pump - see operation "Oil Pump, Remove and Install (X 16 SZR)", "Oil Pump, Remove and Install (16 LZ2)" or "Oil Pump, Remove and Install (20 NEJ)".  

Detach coolant pump from cylinder block.  

With 16 LZ2 and 20 NEJ: Remove crankshaft pulse pickup from cylinder block.  

Remove crankcase vent flange from cylinder block.  

  Inspect   

Check all parts for damage and wear, replace if necessary.  

  Install, Connect   

Emboss engine number in new cylinder block (arrow).   For 16 LZ2 and 20 NEJ: Install crankshaft pulse pick-up in cylinder block with new gasket - tightening torque 8 Nm / 6 lbf. ft. Attach crankcase ventilation flange with new gasket to cylinder block - tightening torque 25 Nm / 18 lbf. ft.   Before installing the coolant pump, coat sealing surface with silicone grease (white). Attach coolant pump with new seal ring to cylinder block - tightening torque for X 16 SZR: 8 Nm / 6 lbf. ft., tightening torque for 16 LZ2 and 20 NEJ: 25 Nm / 18 lbf. ft.   Install oil pump, oil pan and oil drain plug - see operation "Oil Pump, Remove and Install (X 16 SZR)", "Oil Pump, Remove and Install (16 LZ2)" or "Oil Pump, Remove and Install (20 NEJ)".   For X 16 SZR: attach knock sensor to cylinder block - see operation "Knock Sensor, Remove and Install (X 16 SZR)" in "Engine Management System Multec Central Fuel Injection".   For 20 NEJ: attach knock sensor to cylinder block - see operation "Knock Sensor, Remove and Install" in "Engine Management System Motronic M 1.5.4".

  Install, Connect   

X 16 SZR: Install alternator with alternator bracket at cylinder block - 35 Nm / 26 lbf. ft. Install cable connections at alternator.  

16 LZ2 and 20 NEJ: Install ground cable at cylinder block - 20 Nm / 15 lbf. ft. Install alternator with bracket at cylinder block - 35 Nm / 26 lbf. ft. Install cable connections at alternator.  

Install starter - see operation "Starter, Remove and Install (X 16 SZR)" or "Starter, Remove and Install (16 LZ2 and 20 NEJ)".  

Attach coolant pipe and all hose connections to cylinder block. Drive centring sleeves into cylinder block to the stop.  

Install cylinder head - see operation "Cylinder Head, Remove and Install (X 16 SZR)" or "Cylinder Head, Remove and Install (16 LZ2 and 20 NEJ)".  

Remove engine from Assembly Stand KM-412 and detach Adapter KM-410-10 from engine.  

Version without air conditioning: attach front right engine damping block bracket - 60 Nm / 44 lbf. ft.  

Version with air conditioning: Install auxiliary component bracket - 40 Nm / 29.5 lbf. ft.  

Attach engine to transmission and front axle body. Required tightening torques - see "Recommended Torque Values".  

Fill engine oil up to "MAX" mark of oil dipstick.  

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