Vauxhall Workshop Service and Repair Manuals

Cylinder Head, Remove and Install (Z 17 DTH, with AC, LHD)

  Remove

Note:   Before the oil change, the customer should be informed of the ECOService-Flex and ECOService options.

5.   Drain coolant •   Place collecting basin underneath. •   Open drain bolt

7.   Remove engine control unit (1) •   Disconnect 2 wiring harness plugs •   Unscrew 2 bolts •   Unscrew 2 nuts

10.   Remove engine management wiring harness •   Disconnect wiring harness plug – 4 injectors (1) – 4 glow pins (arrows) – Coolant temperature sensor (4) – Throttle valve module (2) – Exhaust gas recirculation valve (3) – 2 combination plugs – Camshaft sensor – Changeover valve solenoid valves – Charge pressure sensor •   Expose wiring harness

12.   Remove air intake pipe (1) •   Unscrew 2 bolts •   Release clamp •   Detach engine vent hose

13.   Remove charge air pipe (1) •   Unscrew and remove 3 stud bolts •   Unscrew 3 bolts •   Unscrew nut •   Remove 2 gaskets

15.   Detach thermostat housing •   Detach coolant hose, return, exhaust gas recirculation valve •   Detach EGR cooler – Unscrew 2 bolts •   Unscrew upper bolt •   Disconnect upper radiator hose •   Detach 2x heating hose •   Unscrew 2 nuts •   Remove bolt

18.   Detach cooling module wiring harness •   Draw 2 series fuses (1) •   Remove relay holder •   Disconnect ground cable (arrow)

23.   Remove ribbed V-belt cover •   Unscrew 3 bolts (1) •   Remove clip (arrow)

26.   Drain engine oil •   Place collecting basin underneath. •   Unscrew drain bolt (1) 27.   Fit drain bolt •   Replace seal ring •   Tighten bolt 78.4 Nm

32.   Loosen cooling module bracket •   Unscrew 2 bolts •   Loosen 2 bolts

34.   Loosen coolant pump ribbed V-belt pulley (1) •   Undo 3 bolts

37.   Remove front exhaust pipe •   Unscrew 3x nut (1) •   Remove gasket.

41.   Detach EGR cooler (1) •   Release 2 clamps (arrows) •   Unscrew 5 bolts •   Remove 2 gaskets

42.   Detach exhaust manifold heat shield •   Remove 4 bolts (1)

43.   Remove exhaust manifold (1) with turbocharger •   Detach turbocharger oil feed line – Unscrew banjo bolt •   Detach turbocharger oil return line – Release clamp •   Detach wastegate unit vacuum line •   Unscrew 2 bolts •   Unscrew 7x nuts •   Remove 2 gaskets

44.   Remove oil dipstick guide tube •   Unscrew 2 bolts (1)

48.   Attach KM-6394 •   Position KM-6394 (1) at the front on the front axle body Note:   Both locating pins (arrows) must be seated in the holes in the front axle body •   Push front bracket (2) in the direction of the arrow •   Place rear bracket (4), right hand side, on front axle body •   Attach rear bracket (3), left hand side – Screw in 2x bolt •   Tighten 6 bolts

49.   Install support •   On KM-6394 – Adjust bracket (2) for support •   Screw on nut (1) 50.   Adjust 3x support •   Transmission side Note:   Turn spindles until mounts (3) are positioned at guide journals free of play •   Engine timing side – Insert journal of the support in the bore of the cylinder block free of play (arrow) – Tighten nuts (1)

52.   Remove oil filter element •   Unscrew oil filter housing cover (1)

53.   Remove oil filter housing •   Detach coolant hose from cylinder head •   Place collecting basin underneath. •   Remove bolt (1)

54.   Remove 2 high pressure line spacers (2) Note:   Mark installation position •   Unscrew 2 bolts 55.   Detach 4 high-pressure lines (1) •   Use KM-6098

56.   Detach outer fuel return line (1) •   Unscrew banjo bolt •   Unscrew nut •   Release clamp (arrow)

60.   Remove right engine damping block (1) •   Unscrew 4 bolts

61.   Detach right engine bracket (1) •   Unscrew 3 bolts Note:   Lower bolt cannot be removed •   With right engine bracket adapter

62.   Remove camshaft sensor (1) •   Remove bolt (2) 63.   Remove upper toothed belt cover (3) Important:   Take care not to damage the increment counter on the camshaft sprocket when removing the upper toothed belt cover •   Unscrew 8 bolts Note:   Note dissimilar bolt lengths

65.   Detach coolant pump ribbed V-belt pulley (1) •   Unscrew 3 bolts

66.   Remove torsional vibration damper (1) •   Unscrew 4 bolts

67.   Detach lower part of toothed belt cover •   Unscrew 3 bolts

69.   Set 1st cylinder to TDC •   Turn crankshaft evenly until TDC fixing bolt (1) can be screwed in Note:   Mark (3) on toothed belt drive gear must align with mark (2) on oil pump cover

70.   Remove toothed belt Note:   Mark running direction. •   Loosen toothed belt tension roller (1) – Loosen bolt (2) •   Pretension toothed belt tension roller in direction of arrow •   Secure toothed belt tension roller in pretensioned position

73.   Detach camshaft pulley •   Unscrew TDC fixing bolt (1) •   Use KM-6347 (3) KM-956-1 (2) •   Remove bolt

74.   Loosen rear toothed belt cover •   Unscrew 3 bolts (1)

76.   Remove rear right engine transport shackle (1) •   Unscrew 2 bolts

77.   Remove 4 injector connection seals (1) •   Unscrew 8 bolts

78.   Remove 4 injector seals (1) •   Unscrew 8 bolts

79.   Remove camshaft housing cover •   Unscrew 9 bolts •   Remove gasket.

80.   Remove 4x injector (1) Note:   Mark the injectors. If the heat insulation sleeve (5) is also drawn out when an injector is removed, the gaskets (3) must be replaced and the heat insulation sleeve must be driven into the cylinder head using KM-6357 (4). •   Remove 4x bracket (2) – Unscrew 4 bolts

81.   Check injector bracket Note:   If an old injector bracket was installed, it must be replaced with a new one New injector bracket Old injector bracket

83.   Remove camshaft housing cover •   Unscrew 17x bolt – Loosen 1/2 turn in the order illustrated, then unscrew •   Remove gasket.

85.   Unscrew 10 cylinder head bolts Note:   Loosen bolts 1/2 to 1 turn in a spiral in the order illustrated.

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

89.   Measure piston projection •   Insert MKM-571-B (5) into KM-301 (6) – 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 (1 and 2) or (3 and 4) – Determine high point by turning crankshaft

90.   Rotate crankshaft approx. 60° against direction of engine rotation

Important:   The largest determined piston projection determines the selection of the cylinder head gasket with appropriate identification. 91.   Replace cylinder head gasket Piston projection Thickness of cylinder head gasket Code 0.630 – 0.696 mm 1.350 mm no hole 0.697 – 0.763 mm 1.400 mm one hole 0.764 – 0.830 mm 1.450 mm two holes •   Lay cylinder head gasket in place – Note guide bushings

  Install

93.   Fasten cylinder head •   Tighten 10 new bolts 39.2 Nm + 60° + 60° Note:   Tighten in a spiral from inside to outside in the order shown with MKM-610 in combination with KM-470-B .

95.   Install camshaft housing •   Replace gasket Note:   Note tightening sequence. – Tighten 12 bolts 21.6 Nm – Tighten 5 bolts 26.5 Nm

Warning:   The different camshaft sprockets (with different part numbers) have different torques for the camshaft sprocket bolt. 97.   Attach camshaft sprocket with part number 97320335 •   Camshaft journal (2) must engage in the bore in the camshaft sprocket (1) •   Use KM-6347 in combination with KM-956-1 •   Tighten bolt 64 Nm •   Install TDC-fixing bolt 98.   Attach camshaft sprocket with part number 98021306 •   Camshaft journal (2) must engage in the bore in the camshaft sprocket (1) •   Use KM-6347 in combination with KM-956-1 •   Tighten bolt 111 Nm •   Install TDC-fixing bolt

100.   Rotate crankshaft to 1st cylinder TDC •   Mark on toothed belt drive gear (2) must align with cast lug (1) on oil pump cover

101.   Install toothed belt Note:   TDC locking bolt must be installed in the camshaft sprocket and marking (6) and (7) must align. •   Position toothed belt – Toothed belt must be tensioned in the direction of the arrow from the toothed belt drive gear (5) via the oil pump drive gear (4), via the high pressure pump drive gear (2) to the camshaft sprocket (1) – Note running direction •   Loosen toothed belt tension roller (3) •   Remove TDC locking bolt •   Rotate crankshaft 60° against direction of engine rotation •   Tighten toothed belt tension roller 38Nm

102.   Timing, Check •   Turn crankshaft approx. 780° in direction of engine rotation •   Mark on toothed belt drive gear (3) must align with cast lug (2) on oil pump cover •   Screw in TDC fixing bolt (1). If the TDC fixing bolt cannot be screwed in, basic adjustment must be repeated. •   Unscrew TDC fixing bolt

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

109.   Insert adjustment shim •   Coat new shim with engine oil and insert in cup tappet with identification mark facing downwards 110.   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:   The clearance of all adjusted valves must be re-checked

111.   Detach accumulator •   Unscrew 2x bolts 1 - 1 1/2 turns 112.   Replace 8 injector seals •   4 O-rings (1) •   4 copper seal rings (2)

113.   Install 4 injectors •   Install 4x brackets – Align injectors with EN-48560 (1)

115.   Fasten 4x injectors •   Tighten 4 bolts in three stages – 1. Tighten bolt 40 Nm – 2. Loosen bolt – 3. Tighten bolt 32 Nm

118.   Install camshaft housing cover Important:   The oil hole (2) must not be covered with adhesive sealing compound •   Replace gasket •   Apply adhesive sealing compound to sealing surfaces (1) and (3) •   Tighten 9 bolts 9.8 Nm

120.   Fit 4 injector connection seals •   Replace 4 gaskets Note:   Note installation position (arrow) •   Tighten 8 bolts

145.   Install ribbed V-belt Note:   Note running direction and installation position •   Tension ribbed V-belt tensioner (1) – I Ribbed V-belt without AC – II Ribbed V-belt with AC

154.   Insert oil filter element (1) •   Replace oil filter element •   Install 3 new gaskets (2) and (3) •   Tighten oil filter housing cover 25 Nm

191.	Reset service interval using TECH 2 Note:   If the customer decides to have ECOService - attach TECH 2 and reprogram engine control unit. Reset service interval using TECH 2