Vauxhall Workshop Service and Repair Manuals

Engine with Transmission, Remove and Install (Version with Pot Flywheel, X 17 DTL)  

  Remove, Disconnect   

Disconnect ground cable from battery. Disconnect positive cable from battery. Disconnect ground cable (2) and positive cable (3) from battery terminals.   Remove fuse box (1) from retainer and lay aside on engine.   Disconnect engine wiring harness plug (4).

Remove air intake hose (1), air cleaner housing (2) and air intake shroud (3).

  Remove, Disconnect   

Remove upper charge air hose (4) from intercooler and intake manifold.   Remove lower charge air hose (3) from intercooler and charge air pipe (1).   Remove fastening bolt (2) from charge air pipe.   Push charge air pipe aside.   Detach brake servo vacuum hose from vacuum pump.   Remove Bowden cable for engine speed adjusting lever from fuel injection pump - note cable routing.

  Remove, Disconnect   

Remove lower coolant hose (7) from radiator and coolant pipe - collect escaping coolant.   Remove upper coolant hose (2) from radiator and thermostat housing.   Disconnect wiring harness plug from thermoswitch (1).   Remove coolant hoses (3) and (4) from thermostat housing.   Remove coolant hoses (5) and (6) from coolant pipe.

  Remove, Disconnect   

Close off fuel lines with spring clamps.  

Disconnect wiring harness plug (3) from single-box filter. Detach fuel lines (1) and (2) from single-box filter - collect escaping fuel.   Detach clutch cable from clutch release lever.   Detach speedometer cable from transmission.

Loosen fastening bolts (arrow) and detach shift guide from shift rod.   Attach engine to Engine Bridge KM-263-B or MKM-883-1.   Remove front wheels.   Remove front exhaust pipe with catalytic converter.

  Remove, Disconnect   

Remove banjo bolts (1) with seal rings - collect escaping engine oil. Remove fastening clamp for oil cooler lines from front axle body and lay aside oil cooler lines.   Detach oil lines from power steering hydraulic pump - collect escaping hydraulic fluid.   Remove front axle body - see operation "Front Axle Body, Remove and Install" in group "E".   Remove axle shafts from transmission - see operation "Axle Shafts, Remove and Install" in group "E".   Remove front right and left engine damping blocks from side members.   Place suitable engine hoist under engine.   Detach engine from Engine Bridge KM-263-B or MKM-883-1.   Carefully remove engine with transmission and engine damping blocks downwards - take care not to damage any attaching parts.

  Install, Connect   

Install engine with transmission and engine damping blocks in engine compartment - note attaching parts. Attach engine to Engine Bridge KM-263-B or MKM-883-1.  

Install front right and left engine damping blocks to side member - tightening torque 65 Nm/48 lbf. ft. ¹⁾ .  

Fasten axle shafts to transmission - see operation "Axle Shafts, Remove and Install" in group "E".  

Install front axle body - see operation "Front Axle Body, Remove and Install" in group "E".  

Attach oil lines to power steering pump - tightening torque 28 Nm/20.5 lbf. ft.  

Attach oil cooler lines with banjo bolts and new seal rings to oil cooler adapter - tightening torque 30 Nm/22 lbf. ft. Fasten fastening clamp for oil cooler lines to front axle body.  

Install front exhaust pipe with catalytic converter. Front exhaust pipe to exhaust manifold - tightening torque 25 Nm/18.5 lbf. ft.  

Attach speedometer cable. Attach clutch cable to clutch release lever.  

Install shift guide on shift rod - tightening torque 15 Nm/11 lbf. ft. Adjust shifting - see operation "Transmission Shift Linkage, Adjust" in group "K".  

1)  Re-cut bolts before re-use and insert with screw locking compound (red).  

  Install, Connect   

Attach fuel lines with banjo bolts and new seal rings to single-box filter - tightening torque 15 Nm/11 lbf. ft. Remove spring clamps. Connect wiring harness plug to single-box filter. Connect brake servo vacuum line to vacuum pump - tightening torque 18 Nm/13.5 lbf. ft.  

Fasten Bowden cable for engine speed adjusting lever to fuel injection pump - note cable routing. With cable clip, loosely attach Bowden cable for engine speed adjusting lever to crankcase vent pipe - avoid contact with glow plug rail.  

Attach coolant hoses (5) and (6) to coolant pipe. Attach coolant hoses (3) and (4) to thermostat housing. Install upper coolant hose (2) and lower coolant hose (7). Connect wiring harness plug to thermoswitch (1).   Install charge air pipe on cylinder block. Attach lower charge air hose to intercooler and charge air pipe. Attach upper charge air hose to intake manifold and intercooler.   Install air intake shroud, air intake hose and air cleaner housing.

  Install, Connect   

Connect engine wiring harness plug (4).   Press fuse box (1) into retainer.   Connect ground cable (2) and positive cable (3) to battery terminals.   Connect positive cable to battery.   Connect ground cable to battery.     Inspect    Check engine oil level and correct if necessary.   Check transmission fluid level and correct if necessary - see operation "Transmission Fluid Level, Check" in group "K".   Charge hydraulic system - see operation "Hydraulic System, Charge and Bleed" in group "M".   Top up cooling system - see operation "Cooling System, Top Up and Bleed" and "Cooling System, Check for Leaks".