Vauxhall Workshop Service and Repair Manuals

Repair engine using a short block

Important:   When working on the fuel system it is essential to pay attention to cleanliness as even the smallest dirt particles can lead to faults in engine operation or in the fuel system. Open fuel connections must be sealed with appropriate plugs from the Opel Parts Catalogue (catalogue number: 45 06 154 / part number: 9201697). Sealing plugs are only intended to be used once.

  Remove

1.	Detach transmission from engine

4.   Attach EN-46792 (1) •   Tighten bolt 5.   Remove flywheel •   Unscrew 6x bolt (2) •   Remove EN-46792 – Unscrew bolt

7.   Detach engine vent hose (2) •   Undo 2 clamps •   Unclip from bracket (1)

8.   Remove vacuum line (1) •   Detach 4x vacuum hoses Note:   Mark vacuum hoses •   Unscrew 3 bolts

9.   Remove oil separator/vacuum reservoir bracket (1) •   Detach 2x hoses – Undo 2 clamps •   Detach engine vent hose – Disconnect quick-release fitting •   Unclip wiring harness bracket •   Unscrew 3 bolts •   Unscrew 2x nuts

10.   Disconnect wiring harness plug (2) from coolant temperature sensor (1)

11.   Remove thermostat housing (1) •   Detach 4x coolant hoses – Undo 4x clamps •   Unscrew 2x bolts (2)

12.   Detach 3x coolant hoses •   Detach coolant hose (1) from top coolant pipe – Release clamp •   Detach coolant hose (3) from bottom coolant pipe – Release clamp •   Detach coolant hose (2) from EGR cooler – Release clamp

13.   Release EGR metal tube (3) from EGR valve •   Detach from EGR valve – Unscrew 2x bolts •   Release at EGR cooler – Release clamp

15.   Detach intake connection piece (1) from throttle valve module •   Unscrew 2x bolts (2)

16.   Remove engine oil filling nozzle (3) •   Unscrew 3 bolts

17.   Remove vacuum pump (2) •   Remove vacuum hose (1) •   Unscrew 4x bolts

18.   Remove compressor •   Disconnect wiring harness plug (2) •   Unscrew 3x bolts (1)

19.   Detach compressor support from engine block Note:   Note guide sleeves •   Unscrew 4x bolts (1) Note:   Remove with ribbed V-belt guide roller (2)

20.   Remove torsional vibration damper (1) •   Unscrew 4x bolts Note:   Counterhold toothed belt drive gear at bolt (2)

21.   Remove upper ribbed V-belt guide roller (1) •   Unscrew bolt

22.   Remove upper toothed belt cover •   Unscrew 5x bolts (1) with EN-47631 •   Unscrew 2x bolts (2)

23.   Remove engine damping block support (1) •   Unscrew 5x bolts Note:   Note different bolt lengths

24.   Detach engine venting pipe (2) •   Detach engine venting hose (3) from engine venting pipe – Release clamp •   Unscrew 2x bolts (1)

25.   Install EN-46789 (1) in camshaft housing •   Unscrew exhaust camshaft closure bolt •   Screw in EN-46789 26.   Set cylinder no. 1 to TDC of combustion stroke •   Rotate crankshaft in direction of engine rotation until reference drift EN-46789 audibly engages in exhaust camshaft

27.   Remove toothed belt (1) •   Slacken the toothed belt tension roller – Loosen bolt (2)

29.   Remove toothed belt guide roller (2) •   Unscrew bolt (1)

30.   Detach vacuum line from cable conduit •   Detach 2x vacuum hose •   Unclip 3x clip

32.   Detach engine management wiring harness (1) •   Disconnect wiring harness connector. – Swirl valve actuator – Load jolt sensor – EGR valve – Coolant temperature sensor – Rail pressure sensor – Pressure regulator – 4x sheathed glow plugs •   Unclip 5x brackets •   Detach cable conduit – Unscrew 2x bolts 33.   Detach coolant pipe (2) from intake manifold •   Detach coolant hose from coolant pipe – Release clamp •   Unscrew 3 bolts

34.   Detach leak oil line (1) Note:   The oil leak line must not be detached from the fuel return damping case. It if is detached, it must be replaced. •   Release 4x retaining clamp (arrows) •   Pull off oil leak line

Important:   After detaching the high pressure lines, seal off injector and pressure chamber openings with protective caps 1) 35.   Detach 4x high pressure line (1), pressure chamber on injector Note:   When releasing the retaining nut, counterhold with open-ended wrench against the injector. •   Release 8x retaining nut

Important:   After detaching the high pressure lines, seal the apertures of the injectors and the pressure chamber with protective caps 1)   36.   Detach high-pressure pump high-pressure line (1) from accumulator Note:   When releasing the retaining nut, counterhold with open-ended wrench against the injector. •   Unscrew 2x union nuts

37.   Remove accumulator (1) •   Detach return line (2) – Release clamp •   Unscrew 2x bolt (3)

38.   Remove fuel return damping case (1) with oil leak line Note:   Open fuel connections must be sealed with appropriate plugs •   Unscrew 2x bolts •   Detach 2x hoses – Undo 2 clamps

39.   Detach bracket (1) for toothed belt cover •   Unscrew bolt

40.   Remove 4x injector (2) Note:   If injectors cannot be removed by hand, use EN-46786 in conjunction with KM-328-B •   Unscrew 4x nuts (1) •   Remove 4x injector with bracket Note:   After removal, close the injector openings with protective caps 1)   •   Remove 4x seal rings

41.   Remove coolant pipe (1) •   Unscrew 4x bolts •   Remove gasket

42.   Remove 4x glow plugs with EN-48390 •   Disconnect 4x wiring harness plug, sheathed glow plug (arrows)

43.   Release high-pressure pump gear Note:   Use a second person •   Counterhold with KM-6347 (1) in combination with KM-956-1 (2) •   Unscrew nut

44.   Detach high-pressure pump gear •   Attach EN-46790 (1) – Screw in 2x bolts •   Pull off high-pressure pump drive gear – Counterhold with open-ended wrench (2)

45.   Remove high pressure pump •   Unscrew 3x nuts (1)

46.   Detach 3x alternator wiring harnesses •   Unscrew 3x nuts (1)

48.   Detach high-pressure pump bracket (1) •   Detach coolant pipe bracket from high-pressure pump bracket – Unscrew bolt •   Unscrew 6x bolts Note:   Note different bolt lengths

49.   Remove intake manifold (1) •   Unscrew 9x nuts •   Detach gasket

  Install

75.   Cleaning work •   Use EN-47632 (1) to clean the injector seats. Insert EN-47632 with coarse fleece in the injector shaft and clean the injector seat by turning. Finish by cleaning with the fine fleece.

91.   Install EN-46789 (1) in camshaft housing •   Unscrew exhaust camshaft closure bolt •   Screw in EN-46789 92.   Check camshaft setting on cylinder 1 at TDC of combustion stroke •   Reference tool EN-46789 must be engaged in exhaust camshaft

93.   Check crankshaft setting with EN-46788 •   Unscrew oil pump bolt (arrow) •   Tighten stud bolt (1) EN-46788 •   Attach positioning disk (4) EN-46788 – Screw in bolt (3) – Screw in nut (2) •   Detach positioning disk EN-46788

94.   Install toothed belt •   Observe prescribed direction of rotation Important:   Tightened end (1) must be taut •   Position toothed belt 95.   Block crankshaft. •   Attach positioning disk EN-46788 – Screw in bolt – Screw in nut 96.   Tension the toothed belt •   Screw in bolt (6) •   Tension toothed belt tension roller Note:   Push adjusting lever in direction of arrow with a screwdriver (5) until pointer (4) of toothed belt tension roller aligns with mark (2). •   Tighten bolt, toothed belt tension roller (3) 25 Nm •   Detach positioning disk EN-46788 – Unscrew bolt – Unscrew nut

98.   Turn crankshaft 720° in the direction of rotation of the engine •   Rotate crankshaft 720° in direction of engine rotation until reference drift EN-46789 audibly engages in exhaust camshaft

126.	Attach transmission to engine