Vauxhall Workshop Service and Repair Manuals

J 457300 Cylinder Head, Remove and Install (Y 17 DTL, with AC, LHD)

Note:   KM-6394 must be used from model year 04 instead of KM-6169-1 .

1. Open bonnet

2. Drain air conditioning

• Note! Drain air conditioning – see operation "Drain air conditioning" in group "D"

Caution!

On vehicles from model year 04 with ESP - the steering angle sensor loses its basic adjustment each time the battery is disconnected. It must be recalibrated.

3. Disconnect battery

• Detach ground cable

4. Remove air cleaner housing (1) Disconnect wiring harness plug for hot film mass air flow meter (3) Release in direction of arrow Remove air intake hose (4) Loosen clamp (5) Remove bolt (2)

5. Remove charge air hose

• From turbocharger, centre charge air pipe
• Release 2 clamps

6. Detach refrigerant line

• From compressor
• Remove bolt

7. Remove oil dipstick guide tube

• Unscrew upper bolt
• Unclip vacuum lines

8. Loosen right front wheel.

9. Raise vehicle 10. Drain coolant Place collecting basin underneath. Unscrew cover of coolant compensation tank Open drain bolt

11. Remove right front wheel. Remove 4 bolts 12. Raise vehicle 13. Close coolant drain bolt 14. Detach ribbed V-belt cover Remove 3 bolts (1) Remove clip (arrow).

15. Loosen coolant pump ribbed V-belt pulley (1) Loosen bolts

16. Remove front exhaust pipe Note:   When removing the centre muffler, a catalytic converter, an exhaust manifold, or an exhaust manifold with catalytic converter, secure that portion of the exhaust system remaining on the vehicle against uncontrolled suspension. For this purpose, the exhaust system portion including the flexpipe may be fastened to the vehicle underbody using suitable means, e.g. wire. Caution! Angular dislocations of the flexpipe as small as 5 to 10 degrees offset from the intended installation position can already cause damage and subsequent complete failure of the flexpipe. Remove 2 nuts 17. Detach oil dipstick guide tube Remove 2 lower bolts 18. Detach turbocharger oil return hose (1) Remove 2 clamps

19. Remove turbocharger oil feed line Unscrew nut (1) Note! Counterhold at threaded port (2)

20. Release turbocharger bracket

• Remove bolt

21. Detach waste gate unit vacuum hose

22. Detach air intake pipe From turbocharger Release clamp 23. Remove ribbed V-belt Tension ribbed V-belt tensioner in direction of arrow With KM-913-A (15) Note! Mark running direction

24. Attach KM-6169 (1) Place left of KM-6169 onto front axle body (arrows, illus. I) Note! Guide pin must be seated in bore in front axle body Set both right brackets in place on front axle body (arrows, Illus. II) Note! Guide pin must be seated in bore in front axle body Tighten bolts (arrow, Illus. III)

25. Install support To KM-6169 Adjust bracket (2) for support Screw on nut (1) 26. Adjust supports Transmission side Note! Turn spindles until the mounts (3) are positioned at the guide journals free of play Engine timing side Insert journal of the support in the bore of the cylinder block without play (arrow) Tighten nuts (1)

27. Lower vehicle

28. Detach oil dipstick guide tube bracket

• From camshaft housing cover
• Remove 2 nuts
• Unclip vacuum hoses

29. Remove oil dipstick guide tube

30. Remove compressor

• Remove wiring harness plug
• Remove 3 bolts
• Note! Note dissimilar bolt lengths

31. Remove compressor bracket

• Remove 3 bolts

32. Remove wiring harness plug for engine management Detach 2 engine control unit wiring harness plugs Release in direction of arrow Disconnect combination plug (grey) Disconnect combination plug (black)

33. Remove engine control unit Remove wiring harness plug bracket Remove 2 bolts (1) Unscrew 2 bolts (2), 2 nuts (3)

34. Detach air intake pipe Remove 2 bolts Detach engine vent hose (1) From cylinder head cover Detach air intake pipe from turbocharger Unclip wiring harness

35. Remove upper charge air pipe (1) Unscrew stud (2), 2 bolts (arrows)

36. Unclip brake servo vacuum line

• From wiring trough

37. Detach exhaust manifold heat shield Remove 4 bolts

38. Remove exhaust gas recirculation pipe Remove 2 bolts (1) Remove gasket.

39. Remove turbocharger oil feed line Unscrew banjo bolt (1) Remove seal rings

40. Remove exhaust manifold Remove 7 bolts Remove 2 nuts (1) Remove gasket.

41. Detach brake servo vacuum line From vacuum pump Unscrew nut 42. Disconnect vacuum hose for vacuum pump 43. Detach alternator wiring harness Disconnect wiring harness plug (1) Unscrew nut (2) Unclip wiring harness

44. Remove right engine damping block Remove 4 bolts

45. Detach wiring trough (1) Unclip vacuum lines (2) Unclip wiring trough 2 clips (arrows) Unscrew bolt (3)

46. Detach right engine bracket (1) Remove 3 bolts

47. Unscrew coolant pump ribbed V-belt pulley Remove bolts 48. Remove upper toothed belt cover Remove 8 bolts Note! Note dissimilar bolt lengths Remove adapter for right engine bracket

49. Raise vehicle 50. Remove torsional vibration damper (1) Remove 4 bolts

51. Remove lower toothed belt cover Remove 3 bolts

52. Lower vehicle 53. Set 1st cylinder to TDC of combustion stroke Turn crankshaft evenly until TDC-fixing bolts can be inserted Camshaft gear M6 (1) Injection pump drive gear M8 (2) Note! The mark on toothed belt drive gear must align with lug on oil pump cover

54. For toothed belt tension roller with leaf spring: loosen toothed belt tensioner Screw in bolt (M10) in lower bore (3) of toothed belt tensioner Loosen bolt (2) Remove tension spring (1)

For toothed belt tension roller with spiral spring: Loosen toothed belt tension roller (1) Rotate toothed belt tension roller anticlockwise approx. 90° Tighten bolt (2)

55. Remove toothed belt Note! Mark running direction 56. Detach camshaft pulley Unscrew TDC-fixing bolt (2) Counterhold camshaft gear using KM-6156 and KM-956-1 Remove bolt (1)

57. For toothed belt tension roller with leaf spring: undo toothed belt tension roller spring retainer

• Unscrew upper bolt

58. Release rear toothed belt cover

• Remove 2 upper bolts

59. Remove engine control unit bracket Unscrew 2 bolts (2), nut (1) Unclip wiring harness (arrows)

60. Remove wiring harness for engine management Disconnect wiring harness plug Coolant temperature sensor (arrow), oil pressure switch, diesel injection pump (3), sheathed glow plugs Unclip wiring harness Set wiring harness to one side

61. Disconnect wiring harness plug From exhaust gas recirculation solenoid valve (2), charge pressure sensor (1)

62. Remove starter/alternator wiring harness bracket

• From exhaust recirculation valve
• Unscrew nut

63. Remove exhaust gas recirculation valve (1) Unscrew studs (3), 2 bolts (arrows) Detach vacuum hose (2) Remove gasket. 64. Remove oil filter insert Place collecting basin underneath. Unscrew oil filter housing cover 65. Detach oil filter housing return hose From oil filter housing

66. Detach injection line spacers (1) Remove 3 bolts 67. Remove injection lines With KM-6098 4 off

68. Detach vacuum hose from exhaust gas recirculation solenoid valve

69. Detach oil leak line

• Release clamp

70. Detach coolant hoses From thermostat Upper radiator hose (6), coolant pipe 2 off (1), coolant compensation tank (2), add-on heater (5), heater core (4) From cylinder head (3)

71. Detach waste gate unit vacuum hose bracket

• Remove bolt

72. Remove engine transport shackles

• 3 off
• Remove bolts

73. Detach injection nozzle outer seals Remove 8 bolts

74. Detach camshaft housing cover Unscrew 7 bolts (1), 3 studs (2)

75. Detach inner oil leak line Unscrew 5 banjo bolts (1) Note! Note sealing rings

76. Remove injector nozzles Caution! Ensure that upon removal of injector nozzles heat protection sleeves remain in their position on the cylinder head. Otherwise, heat protection sleeves must be removed completely and installed again using new sealing rings. This is the only way to ensure that no coolant can reach the combustion chamber, which would inevitably cause engine damage. Replace heat protection sleeves – see operation "Replace heat protection sleeves" in document "Check and measure cylinder head". Remove injection nozzle bracket Remove 2 nuts (1) Remove injector nozzles

77. Remove camshaft housing cover Loosen bolts, stud bolts (180°) Caution! Observe sequence Unscrew 15 bolts, 2 stud bolts Remove gasket.

78. Remove cup tappets With KM-845 Caution! Observe installation position and allocation 79. Remove cylinder head bolts Remove 10 bolts Note! Loosen bolts in order shown (180° – 360°)

80. Remove cylinder head

• Note! 2. mechanic
• Caution! Place cylinder head on wooden blocks, note sheathed glow plugs
• Remove gasket.

81. Clean sealing surfaces

• Cylinder head, cylinder block, camshaft housing, camshaft housing cover, exhaust manifold, turbocharger, exhaust gas recirculation valve

82. Check for plane surface Cylinder head, cylinder block With straightedge, feeler gauge

83. Measure piston projection Insert MKM-571-B (1) in KM-301 (2) Note pretension Set dial to zero Place probe on cylinder block Measure piston projection on all four pistons Carry out measurement on two different locations (3 and 4) or (5 and 6) Determine high point by turning crankshaft

84. Turn crankshaft

• approx. 60° before TDC of cylinder-1

85. Replace cylinder head gasket Piston projection Thickness of cylinder head gasket Code 0.630 – 0.696 mm 1.45 mm no hole 0.697 – 0.763 mm 1.50 mm one hole 0.764 – 0.830 mm 1.55 mm two holes Caution! The largest determined piston projection is used for the selection of the cylinder head gasket with corresponding identification (arrows). Lay cylinder head gasket in place Note guide bushings

86. Attach cylinder head

• Note! 2. mechanic

87. Fasten cylinder head Replace cylinder head bolts Screw in bolts by several threads Tighten cylinder head bolts (39.2 Nm + 60° + 13° + 60° + 13°) Note! Observe tightening sequence

88. Insert cup tappets

• Coat with engine oil
• Caution! Observe sequence and allocation

89. Install camshaft housing Replace gasket Tighten bolts M8 (21.6 Nm / 16 lbf. ft.) Tighten bolts M10 (43.1 Nm / 32 lbf. ft.) Caution! Observe sequence

90. Fasten rear toothed belt cover

• Tighten bolts (9.8 Nm / 7.2 lbf. ft.)

91. Attach camshaft gear

• Counterhold using KM-6156 and KM-956-1
• Tighten bolt (63.7 Nm / 47.0 lbf. ft.)

92. Turn camshafts

• Turn camshaft evenly until TDC-fixing bolt can be inserted

93. For toothed belt tension roller with leaf spring: remove toothed belt tension roller spring retainer

• Tighten bolt 9.8 Nm

94. Set 1st cylinder to TDC of combustion stroke Mark on toothed belt drive gear (2) must align with casting lug at oil pump cover (1)

95. Install toothed belt

Note:   Toothed belt must be taut from toothed belt drive gear via oil pump drive gear and injection pump drive gear

• Position toothed belt

• For toothed belt tension roller with leaf spring:
• Attach leaf spring

• Unscrew TDC-fixing bolt
• Rotate crankshaft 60° against direction of engine rotation
• Tighten bolt of toothed belt tension roller
• For toothed belt tension roller with spiral spring 49 Nm
• For toothed belt tension roller with leaf spring 38.2 Nm

• For toothed belt tension roller with leaf spring: unscrew bolt (M10) from lower bore of toothed belt tensioner

96. Check timing Turn crankshaft approx. 780° in direction of engine rotation At toothed belt drive gear bolt Note! The mark on toothed belt drive gear must align with lug on oil pump cover (arrows) Install TDC-fixing bolt Camshaft gear M6 (1) Injection pump drive gear M8 (2) Note! If the TDC fixing bolts cannot be inserted, the basic adjustment must be repeated

97. Unscrew TDC-fixing bolts

98. Turn crankshaft Turn crankshaft until cam pairs (1) and (2) point upwards

99. Check valve play

• Using feeler gauge
• Test values: Intake valves/Exhaust valves (0.35 – 0.45 mm)
• Note! The valve clearances are checked on a cold engine – room temperature

100. Adjust valve play

• Turn cup tappet until tappet groove points outwards
• Press down cup tappets using KM-6090
• Note! Note different tool versions for intake and exhaust valves
• Mark – IN = Intake side
• Mark – EX = Exhaust side
• Caution! Ensure that valves do not interfere with piston head
• Remove adjustment shim

Example for determination of shim thickness

101. Insert shim

• Coat new shim with engine oil and insert in cup tappet with identification mark facing downwards

102. Turn crankshaft

• In direction of engine rotation by 180°
• Check and adjust valve pair (6) and (2)
• In direction of engine rotation by 180°
• Check and adjust valve pair (5) and (3)
• In direction of engine rotation by 180°
• Check and adjust valve pair (4) and (1)
• Note! Valve clearances must be checked again for all adjusted valves

103. Raise vehicle

104. Install lower toothed belt cover

• Tighten bolts (9.8 Nm / 7.2 lbf. ft.)

105. Install torsional vibration damper

• Tighten bolts (19.6 Nm / 14.5 lbf. ft.)

106. Lower vehicle

107. Attach right engine bracket

• Insert lower bolt
• Into right engine bracket and right engine bracket adapter
• Insert right engine bracket, right engine bracket adapter, upper part of toothed belt cover
• Install 2 upper bolts
• Tighten 3 bolts (40 Nm / 29.5 lbf. ft.)

108. Fasten upper toothed belt cover

• Tighten bolts (9.8 Nm / 7.2 lbf. ft.)
• Note! Note dissimilar bolt lengths

109. Install injector nozzles

• Renew seal rings
• Renew copper sealing washers
• Insert injection nozzles in cylinder head.
• Install injector nozzle bracket (22.1 Nm/16.3 lbf. ft.)

110. Attach new inner oil leak line

• Renew seal rings
• Tighten banjo bolt (14.7 Nm/10.8 lbf. ft.)

111. Attach camshaft housing cover Replace gasket Apply adhesive sealant compound (white) Areas (1, 3) Caution! Oil return bore (2) must not be covered with adhesive sealing compound or by the camshaft housing cover gasket Tighten bolts, studs (9.8 Nm/7.2 lbf. ft.)

112. Attach injection nozzle outer seals

• Replace seals
• Tighten bolts

113. Install injection lines

• Caution! Injection lines must be installed without tension. Hand-tighten at injector nozzles and injection pump.
• With KM-6098
• Tighten union nuts (22.5 Nm/16.6 lbf. ft.)

114. Install injection line spacers

• Note! Note spacer positions

115. Attach oil filter housing return hose

• Fasten clamp

116. Install oil filter element (1) Replace seal rings (2, 3) Tighten oil filter housing cover (25 Nm/18.5 lbf. ft.)

117. Attach waste gate unit vacuum hose bracket

• Tighten bolt (24.5 Nm / 18.1 lbf. ft.)

118. Attach coolant hoses

• 7 off

119. Attach engine transport shackles

• 3 off
• Tighten bolts (20 Nm / 15 lbf. ft.)

120. Attach oil leak hose

• Fasten clamp

121. Attach vacuum hose to exhaust gas recirculation solenoid valve

122. Install exhaust gas recirculation valve

• Replace gasket
• Tighten stud bolt, bolt (24.5 Nm / 18.1 lbf. ft.)
• Connect vacuum hose.

123. Attach exhaust gas recirculation pipe bracket

• On camshaft housing
• Tighten bolt (8.8 Nm / 6.5 lbf. ft.)

124. Attach upper charge air pipe

• Clean sealing surface
• Replace gasket
• Tighten stud bolt, bolt
• Upper charge air pipe bracket to camshaft housing
• Tighten bolt (24.5 Nm / 18.1 lbf. ft.)

125. Attach starter/alternator wiring harness bracket

• Tighten nuts

126. Connect wiring harness plug

• Exhaust gas recirculation solenoid valve, charge pressure sensork

127. Attach wiring harness for engine management

• Route wiring harness
• Connect wiring harness plug.
• 7 off

128. Install engine control unit bracket

• Tighten bolts (9.8 Nm / 7.2 lbf. ft.)
• Tighten nut (9.8 Nm/7.2 lbf. ft.)
• Clip-in wiring trough

129. Attach wiring trough

• Clip-in wiring trough
• Tighten bolt

130. Install right engine damping block

• To side member
• Tighten bolts (40 Nm / 29.5 lbf. ft.)
• To right engine bracket
• Tighten bolts (60 Nm/44 lbf. ft + 30° + 15°.)

131. Install alternator wiring harness

• Tighten nuts
• Connect wiring harness plug.
• Attach wiring harness

132. Attach vacuum hose for vacuum pump

• Connect and route hose

133. Attach brake servo vacuum line

• Route and clip in hose
• Tighten nut (18 Nm / 13.3 lbf. ft)

134. Install exhaust manifold

• Replace gasket
• Replace nuts
• Tighten bolts, nuts (23.5 Nm/17.3 lbf. ft.)

135. Attach exhaust gas recirculation pipe

• Replace gasket
• Tighten bolts (28.4 Nm / 20.9 lbf. ft.)

136. Attach turbocharger oil feed line

• Renew seal rings
• Tighten banjo bolt (9.8 Nm / 7.2 lbf. ft.)

137. Attach exhaust manifold heat shield

• Tighten bolts (11.7 Nm / 8.6 lbf. ft.)

138. Clip in brake servo vacuum line

• To wiring trough

139. Attach charge air hose

• Fasten clamps (3.5 Nm / 2.5 lbf. ft.)

140. Install air intake pipe

• Tighten bolts
• Attach engine vent hose
• Attach wiring harness

141. Install engine control unit

• Tighten bolts, nuts (5.9 Nm/4.4 lbf. ft.)
• Install wiring harness plug bracket
• Tighten bolts

142. Attach wiring harness for engine management

• Connect wiring harness plug for engine control unit
• Attach combination plug
• Attach wiring harness

143. Install compressor bracket

• Tighten bolts

144. Install compressor

• Tighten bolts (22 Nm / 16.2 lbf. ft)
• Connect wiring harness plug.

145. Install oil dipstick guide tube bracket

• Tighten nuts
• Clip in vacuum hoses

146. Install oil dipstick guide tube

• Replace seal ring

147. Raise vehicle

148. Detach support

149. Detach KM-6169

150. Attach coolant pump ribbed V-belt pulley

• Screw in bolts

151. Install ribbed V-belt

• Note! Observe running direction and installation position
• Release ribbed V-belt tensioner

152. Fasten coolant pump ribbed V-belt pulley

• Tighten bolts (9.8 Nm / 7.2 lbf. ft.)

153. Fasten air intake pipe

• To turbocharger
• Tighten clamp (3.5 Nm / 2.6 lbf. ft.)

154. Connect waste gate unit vacuum hose

155. Attach turbocharger oil feed line

• Renew seal rings
• Note! Counterhold at threaded port
• Tighten nut (9.8 Nm/7.2 lbf. ft.)

156. Install turbocharger oil return hose

157. Attach turbocharger bracket

• Tighten bolt (26.5 Nm / 19.6 lbf. ft.)

158. Attach oil dipstick guide tube

• Tighten bolts (9.8 Nm / 7.2 lbf. ft.)

159. Attach front exhaust pipe

• Replace gasket, nuts
• Tighten nuts (65 Nm / 48 lbf. ft.)

160. Attach ribbed V-belt cover

• Tighten bolts
• Install clip

161. Lower vehicle

162. Fasten right front wheel

• Screw in bolts

163. Lower vehicle

164. Fasten right front wheel

• Tighten bolts (110 Nm / 81 lbf. ft.)

165. Fasten oil dipstick guide tube

• Tighten bolt
• Clip in vacuum lines

166. Attach refrigerant line

• Renew seal rings
• Tighten bolt (20 Nm / 15 lbf. ft.)

167. Install air cleaner housing

• Tighten bolt
• Fasten air intake hose.
• Fasten clamp (3.5 Nm / 2.6 lbf. ft.)
• Connect wiring harness plug to hot film mass air flow meter

168. Check and correct engine oil level

• Observe specified engine oil quantity

169. Top up coolant

• Note! Top up and bleed cooling system – see operation "Top up and bleed cooling system"
• Observe specified coolant quantity

170. Connect battery

171. Calibrate steering angle sensor

• Switch on ignition

Note:   Rotate the steering wheel one time from its right-hand to its left-hand stop.

172. Program volatile memories

173. Charge air conditioning

• Note! Charge air conditioning – see operation "Evacuate and charge air conditioning" in group "D".

174. Close bonnet