Vauxhall Workshop Service and Repair Manuals

1. Open bonnet

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.

2. Disconnect battery

3. Remove air cleaner housing (1)

• Remove 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)

4. Loosen front right wheel

5. Raise vehicle

6. Remove front right wheel

• Remove 4 bolts

7. Raise vehicle

8. Detach ribbed V-belt cover

• Remove 3 bolts (1)
• Remove clip (arrow).

9. Detach ribbed V-belt

• Tension ribbed V-belt tensioner in direction of arrow
• With KM-913-A (15)
• Note! Mark running direction

10. Release air intake pipe

• From turbocharger
• Release clamp

11. 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
• Attach both right holders on the front axle body (arrows, Illus. II).
• Note! Guide pin must be seated in bore in front axle body (arrow, Illus. III)
• Tighten bolt

12. Install support

• To KM-6169
• Adjust bracket (2) for support
• Screw on nut (1)

13. 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)

14. Lower vehicle

15. Drain coolant

• Place collecting basin underneath.
• Open drain bolt

16. Remove oil dipstick guide tube bracket

• Remove bolt, 2 nuts (arrows)
• Unclip vacuum hoses

17. Remove wiring harness plug for engine management

• Wiring harness plug, engine control unit
• Release in direction of arrow
• Disconnect combination plug (grey)
• Disconnect combination plug (black)

18. Remove engine control unit

• Remove wiring harness plug bracket
• Remove 2 bolts (1)
• Unscrew 2 bolts (2), 2 nuts (3)

19. Remove air intake pipe (2)

• Remove 2 bolts (arrows)
• Detach engine vent hose (1)
• From cylinder head cover
• Detach air intake pipe from turbocharger

20. Remove right engine damping block

• Remove 4 bolts

21. Remove wiring trough

• Unclip vacuum line (2)
• Unclip wiring trough (1)
• 2 clips (arrows)
• Remove bolt (3)

22. Remove coolant pump ribbed V-belt pulley

• Bolts

23. Remove upper toothed belt cover

• Remove 8 bolts
• Note! Note dissimilar bolt lengths

24. Detach right engine bracket (1)

• Remove 3 bolts
• Remove right engine bracket, right engine bracket adapter, upper part of toothed belt cover

25. Raise vehicle

26. Remove torsional vibration damper (1)

• Remove 4 bolts

27. Remove lower toothed belt cover

• Remove 3 bolts

28. Lower vehicle

29. Install right front wheel

• Screw in bolts

30. Lower vehicle

31. 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 (arrows)

32. 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)

33. Remove toothed belt

• Note! Mark running direction

34. Detach camshaft pulley

• Unscrew TDC-fixing bolt (2)
• Counterhold using KM-6156 and KM-956-1
• Remove bolt (1)

35. Release rear toothed belt cover

• Remove 2 upper bolts

36. Remove engine control unit bracket

• Unscrew 2 bolts (2), nut (1)
• Unclip wiring harness (arrows)

37. Detach injection line

• From camshaft housing cover (1)
• 4 off

38. Detach injection line

• From diesel injection pump (2)
• With KM-6098
• 4 off

39. Detach injection nozzle outer seal

• Remove 8 bolts

40. Detach right rear engine transport shackle

41. Loosen left rear engine transport shackle

42. Remove camshaft housing cover

• Unscrew 7 bolts, 3 studs

43. Detach inner oil leak line (1)

• Remove 5 banjo bolts
• Note! Note sealing rings

44. 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 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

45. Lock exhaust camshaft equaliser gear

• Insert KM-955-2 (1)
• Note! Insert in exhaust camshaft gear and exhaust camshaft equaliser gear up to camshaft bearing cap stop. Exhaust camshaft gear and exhaust camshaft equaliser gear must be locked in place with rotation impossible.

46. Remove camshaft bearing caps

• 5 off
• Unscrew 3 bolts, 10 nuts, and 2 stud bolts
• Note! Note identification on camshaft bearing caps. The camshafts must be uniformly released from the bearing seats. Loosen nuts, stud bolts and bolts (180° – 360°)

47. Remove camshafts

• Remove intake camshaft seal ring

48. Remove cup tappets

• With KM-845
• Caution! Observe installation position and allocation

49. Remove sheathed glow plugs (arrows)

• Disconnect sheathed glow plug wiring harness plugs
• Remove sheathed glow plugs using MKM-6104.

54. Assemble Automatic Valve Spring Compressor MKM-6086

• Adjust supports
• Complete lever arm
• Using joint, removal head
• Assemble assembly head
• Insert thrust piece 6d (1)
• Note! Observe manufacturer's instructions

55. Attach Automatic Valve Spring Compressor MKM-6086 supports

• To exhaust side camshaft housing cover stud bolts (1, 2 and 4, 5)

56. Install diesel injection nozzles

• Turn 180° offset from installation position
• 4 off
• Insert injection nozzles in cylinder head.
• Attach injection nozzle bracket
• Tighten 2 nuts (2) (22.1 Nm / 16.3 lbf. ft.)

57. Insert installation shaft and joint (1) in supports

58. Secure installation shaft

• Tighten 2 bolts (arrows)

59. Fasten supports

• Tighten 4 nuts

60. Secure the engine against rotation

• 5. Engage gear
• Apply parking brake
• Note! Wheels must be touching the ground

61. Install compressed air adapter (1)

• Screw into sheathed glow plug thread of 1st cylinder
• Apply compressed air to 1st cylinder

62. Attach Automatic Valve Spring Compressor MKM-6068 lever arm (3)

• To joint (4)
• Note! Removal head (2) must face toward intake side of 1st cylinder

63. Remove intake valve springs for 1st cylinder

• 2 off
• Carefully push valve springs downwards
• With lever arm
• Note! Removal head must be positioned vertically above the valve stem
• Remove valve keepers, valve heads, valve springs
• Caution! Observe allocation
• Note! Do not use magnetic tools

64. Replace valve stem seals

• 2 off
• Pull off using KM-840 (1)
• Attach new valve stem seal to valve stem
• Drive in using KM-6091

65. Remove intake valve springs for 1st cylinder

• Insert valve springs, valve heads
• Insert valve keepers in assembly head (1)
• Slide clamping sleeve towards lever mount (arrow)
• Caution! Insert valve keepers with taper towards valve
• Slide clamping sleeve (2) towards valve (arrow)
• Attach assembly head to lever arm
• Carefully push valve springs downwards
• With lever arm
• Caution! Installation head must be positioned vertically above the valve stem. Valve keepers must engage audibly

86. Fasten supports

• Tighten 4 nuts

87. Attach Automatic Valve Spring Compressor MKM-6068 lever arm (2)

• To joint
• Note! Removal head (1) must face toward exhaust side of 3rd cylinder

88. Install compressed air adapter (3)

• Screw into sheathed glow plug thread of 3rd cylinder
• Apply compressed air to 3rd cylinder

115. Insert camshafts

• Caution! Mark on exhaust camshaft gear (1) must be positioned between both intake camshaft gear marks (2). The marks must be in one plane with the top edge of the camshaft housing.

116. Attach camshaft bearing caps

• Note! Apply surface sealant (green) to sealing surfaces of 1st camshaft bearing cap (3)
• 5 off
• Install nuts, stud bolts, bolts

117. Tighten camshaft bearing caps

• Caution! Tighten in sequence illustrated in steps of 1/2 to 1 turn
• Tighten nuts M8 (21.6 Nm / 16 lbf. ft.)
• Tighten nuts M10 (43.1 Nm / 31.8 lbf. ft.)
• Tighten stud bolts M10 (43.1 Nm / 31.8 lbf. ft.)
• Remove KM-955-2

118. Install intake camshaft seal ring (1)

• Replace seal ring
• Coat seal lips with grease
• Slide onto camshaft
• Drive in until flush using KM-656 (2)

122. 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

124. Rotate crankshaft

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

126. Insert adjustment shim

• Insert new shim (7), coat with engine oil, and insert in cup tappet with identification mark facing downwards
• Note! Valve clearances must be checked again for all adjusted valves

127. Rotate 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

139. Install right engine damping block

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

140. Install 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.)