Vauxhall Workshop Service and Repair Manuals

Remove clamping bolt (1) on steering column intermediate spindle (interior).

Drain air conditioning – see operation "Air Conditioning, Drain" in group "D".

Open coolant drain bolt – collect escaping coolant.

Remove engine cover.

Disconnect ground cable (3) from ground connection and disconnect ground connection (4) from battery.

Disconnect positive lead (2) from positive terminal and disconnect positive terminal (1) from battery.

Remove battery.

Detach battery support (5) from body.

Remove air cleaner housing – see illustration "Air Ducts X 14 XE, Z 14 XE, X 16 XEL,Z 16 XE, Z 16 YNG" or "Air Ducts X 18 XE1, Z 18 XE, Z 18 XEL".

Disconnect wiring harness plug (1) from tank vent valve.

For X 18 XE1: press throttle valve lever (6) in direction of arrow and hold in position.

Lift retainer (2) with screwdriver and remove ball socket (3) from ball head.

If present: remove shackle for cruise control Bowden cable (7).

Compress guide for cruise control Bowden cable at the two retaining pins (4) and remove from bracket – lay cruise control Bowden cable aside.

Detach retaining clamp (5) upwards and pull guide for accelerator Bowden cable from bracket in direction of arrow and lay aside.

Note:   It must be ensured that the valve support is not damaged when disconnecting the tank vent valve hose from the valve body. Damaged valves must be replaced.

Caution

Damaged valve supports can cause a vehicle fire as a result of leaks.

  Remove

Remove tank vent valve hose (2) from tank vent valve.

Reduce fuel pressure with Pressure Tester KM-J-34730-91 via testing port – collect escaping fuel in suitable container – observe safety regulations and national legislation.

Remove fuel lines (3) from fuel distributor pipe.

For Z 16 YNG: Remove CNG low pressure line from CNG distributor pipe - see operation "CNG Low Pressure Line, Remove and Install"

Disconnect brake servo vacuum line (1) and vacuum hose for intake manifold pressure sensor (4) from inlet manifold.

Wiring harness plug

• Intake manifold pressure sensor (1)
• Multiplug (twist connection) (2)
• Multiplug (green) (3)
• Engine control unit wiring harness plug (5)
• For version with automatic transmission: Transmission wiring harness plug (4)

disconnect or detach and put cable bunch out of way.

Disconnect steering cable bunch and put out of way:

• Withdraw fuse carrier (2) from bracket
• Disconnect wiring harness plug (4)
• Detach ground cable (3) from body

Release coolant hose (1) in direction of arrow and detach from heater core.

Detach coolant hose (7) from throttle body.

Detach coolant hose (6) from coolant pipe.

Detach coolant hose (5) from radiator.

For version with manual transmission: Release pressure line with connector (1) from pressure line for central release mechanism on clutch housing – detach clutch pressure line for this. Release clamp (2) with screwdriver and remove – then bend clamp slightly together and re-insert in connector.

For version with automatic transmission: Push selector actuation cable (3) off actuation lever. Lever out retainer (4) with screwdriver and unclip selector actuation cable from counterpart.

Remove front wheels.

Remove front panelling – see operation "Front Panelling, Remove and Install " in group "A".

Detach swing arm (1) on both sides from spring strut support tube – counterhold with op-ended spanner at the two flattened surfaces.

Withdraw axle shafts on both sides from wheel hub (do not remove from transmission) – see operation "Axle Shaft, Remove and Install" in group "E".

Remove lower engine splash guard.

Unlock wiring harness plug (2) in direction of arrow and detach from cooling module control unit.

Disconnect ground cable (3) from body.

Remove front exhaust pipe with catalytic converter and centre muffler.

For version with manual transmission: Release clamp (1) from shift rod and remove shift guide from shift rod.

Note:   The drive unit must be aligned to the front axle body using KM-6173 and KM-6001-A in order to ensure correct alignment of the drive unit after releasing the fastening bolts for the right and left engine damping blocks. The attachment of KM-6173 and KM-6001-A is described in the following.

  Install

Attach KM-6173 (3) to front axle body – screw up support bearing (2) until pin is seated flush in mount (1) on cylinder block.

Release fastening bolts (arrows) for adjustment rails on KM-6001-A (1).

Insert KM-6001-A as illustrated – pins (2) and (5) must sit in guide holes of front axle body.

Tighten fastening bolts for adjustment rails.

Screw up front support bearing (4) and rear support bearing (3) until contact is made with guide pins of front engine damping block and rear engine damping block bracket – the guide pins must seat free from play in the support bearings.

For version with air conditioning:

Remove fastening bolt (1) and disconnect refrigerant line.

Remove fastening bolt (2) and detach refrigerant line from receiver-dryer.

Detach right engine damping block bracket (1) and left engine damping block bracket (2) from engine damping block support.

Install Base Frame KM-904 with Centring Mount KM-6000 on hydraulic jack and position free of play under front axle body (use hydraulic jack which can be lowered at least 100 cm).

Note:   For greater clarity, the illustration shows the front axle body without hydraulic jack and centring mount.

  Remove

Remove six rear fastening bolts (4) on left and right. Remove front fastening bolts on right (1) and left (3). Remove centre fastening bolts (2).

Carefully lower front axle body with entire drive unit, steering gear and radiator – thereby ensuring that no attaching parts are damaged.

Carefully guide front axle body with entire drive unit, steering gear and radiator into engine compartment and position free of play on chassis – thereby ensuring that no attaching parts are damaged.

Attach front axle body to vehicle underbody with new fastening bolts (1- 4) – tightening torque 90 Nm / 66.5 lbf. ft. + 45° + 15°.