Vauxhall Workshop Service and Repair Manuals

Engine, Remove and Install (Without Air Conditioning, MTA)

  Remove

2.   Remove steering column interim spindle •   Move steering wheel to straight-ahead position •   Remove ignition key and engage steering lock •   Unscrew bolt (1)

3.	1. Remove air cleaner housing - Z16XEP 2. Remove air cleaner housing - Z16XE1

4.   Detach earth cable •   Detach earth cables (4) and (5) from earth terminal (3) – Unscrew 2x bolts •   Detach earth connection from negative terminal – Loosen bolt 5.   Detach positive cable •   Detach positive cable (2) from positive terminal (1) – Unscrew bolt •   Detach positive connection from positive terminal – Unscrew bolt

6.   Remove battery •   Unscrew bolt (1) – Remove retaining plate (2) •   Remove battery

7.   Remove battery support (2) •   Unscrew 3x bolts (1) •   Detach wiring harness – Undo cable ties

8.   Disconnect tank vent valve hose •   Unlatch tank vent valve connection (1) in the direction of the arrow •   Unclip hose

Important:   Exiting fuel - observe safety regulations and national legislation 9.   Reduce fuel pressure •   Reduce fuel pressure with pressure gauge KM-J-34730-91 (2) via test connection (1) – Collect exiting fuel in a suitable container

10.   Detach fuel line (2) from fuel rail •   Disconnect with KM-796-A (1) •   Unclip from mounting

11.   Detach brake servo vacuum line (1) from intake manifold

12.   Remove radiator grille •   Remove 4x body-bound rivets (1) •   Unclip radiator grille (2) upwards from front panelling

13.   Raise vehicle by half its height 14.   Release front panelling (3) •   Remove 4x clip (1) •   Remove 5x body-bound rivets (2)

15.   Detach high-pressure headlamp cleaning system hose from reservoir (2) •   Undo quick-release fitting (1) Note:   Escaping fluid

16.   Remove front panelling Note:   Second mechanic •   Push front panelling upwards in direction of arrow and pull out of bracket •   Remove front panelling – Unclip 4x clips (1) •   Unclip outside temperature sensor

19.   Detach swing arm (2) from spring strut support tube •   Unscrew 2x nuts Note:   Use spanner (1) to hold against flat surface 20.   Detach tie rods from steering knuckle with KM-507-C (3) •   Unscrew 2x nuts 21.   Detach guide joints (4) from steering knuckle •   Unscrew 2x nuts •   Take out 2x bolt •   Expand steering knuckle bolts with KM-915 •   Pull guide joints out of steering knuckle

22.   Remove axle shafts from wheel hub •   Unscrew 2x nuts – Counterhold at wheel hub with KM-468-B (1)

24.   Drain coolant •   Place collecting basin underneath. •   Attach suitable hose to drain connection (2) •   Open coolant drain screw (1) – Drain coolant •   Close coolant drain screw

25.   Disconnect cooling module wiring harness plug (1)

26.   Expose wiring harness, oxygen sensor (1) •   Unfasten cable tie (2) •   Disconnect wiring harness connector (3)

27.   Remove end silencer (1) •   Slacken fastening clamp (3) – Unscrew nut •   Remove from bracket – Detach 2x rubber bearings (2) •   Detach end silencer from front silencer Note:   Second mechanic

28.   Detach front exhaust pipe (2) from catalytic converter •   Unscrew 3x nuts (1)

29.   Take out front exhaust pipe with front silencer •   Detach 2x rubber bearings (1)

30.   Disconnect wiring harness plug, selector lever MTA-transmission (1) •   Open latch in the direction of the arrow •   Detach 2x cable ties •   Unclip wiring harness from mounting

31.   Disconnect wiring harness plug, MTA-transmission (1) •   Open latch (2)

32.   Insert KM-6173 (3) •   Slacken 4x bolts (arrows) and hand-tighten •   Align KM-6173 at front axle body •   Wind up the support bearing (1) – Journal (2) must sit in mount at cylinder block •   Tighten 4x bolts

33.   Attach KM-6001-A (1) Note:   Attaching KM-6001-A guarantees perfect alignment of the drive unit with the front axle body •   Slacken 3x bolts (arrows) in adjusting rails •   Insert KM-6001-A – The journals (2) and (5) must sit in the guide holes of the front axle body •   Tighten 3x bolts in adjusting rails •   Adjust support bearings, front (4) and rear (3) – Raise support bearings up to the stop on the guide journals Note:   The guide journals must be seated free from play in the support bearings

35.   Disconnect wiring harness plugs from engine control unit (1) •   Open latch (2) •   Undo cable tie •   Unclip 3x wiring harnesses

36.   Remove coolant expansion tank (1) •   Pull out of bracket in direction of arrow

37.   Disconnect steering wiring harness •   Remove fuse carrier cover •   Detach positive cable (2) from fuse carrier – Unscrew nut (3) •   Disconnect wiring harness plug (1) •   Expose wiring harness – Undo cable ties – Unclip 3x wiring harnesses

38.   Disconnect wiring harness plug (1) •   Release retainer in direction of arrow

39.   Detach coolant hoses (1) from heater core Note:   Mark assignment using coloured markings •   Place collecting basin underneath. •   Release 2x quick-release fittings in direction of arrow •   Detach coolant hoses

40.   Detach right engine damping block from engine damping block bracket •   Unscrew 3x bolts (1) 41.   Detach left engine damping block from engine damping block bracket •   Unscrew 3x bolts (2)

43.   Attach KM-904 with KM-6390 •   Attach to hydraulic lifter Note:   Use hydraulic jack that can be lowered to a height of at least 100 cm •   Lower centring pins (1) – Remove 2x splines •   Place under front axle body, ensure there is no play – Centring pins (2) must engage in the relevant holes in the front axle body

Important:   It is not permissible to disassemble the front axle body with an impulse or impact screwdriver 44.   Remove front axle body •   Unscrew 10x bolts (1, 2, 3, 4) Note:   Note different bolt lengths

  Install

Important:   It is imperative to adhere to the following assembly order 53.   Attach cooling hoses to heater core •   Fit 2x quick release fittings (1) onto heater core connection port (2) as far as they will go Note:   Pay attention to coloured markings •   Slide the 2x quick-release fitting catches (3) in the direction of the arrow all the way to the stop by simultaneously pressing the release buttons (4) – The colour rings (5) must be visible •   Check that quick release fittings are correctly seated and that the colour rings (5) are visible

82.	1. Install air cleaner housing - Z16XEP 2. Install air cleaner housing - Z16XE1