Vauxhall Workshop Service and Repair Manuals

Engine Using A Short Block, Repair (Z 17 DTH, With Air Conditioning, LHD)

  Remove

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

2.	Detach manual transmission from engine

4.   Remove air intake pipe (1) •   Unscrew 2 bolts •   Release clamp •   Detach engine vent hose •   Unclip wiring harness

5.   Detach connection hose (1) from intercooler for intake pipe •   Release clamp

6.   Detach EGR cooler (1) •   Release 2 clamps (arrows) •   Unscrew 7 bolts •   Remove 2 gaskets

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

8.   Detach turbocharger oil return line (3) •   Release clamp 9.   Disconnect vacuum line, turbocharger control (2) 10.   Detach turbocharger oil supply line (1) from turbocharger •   Unscrew banjo bolt •   Remove 2x seal ring

11.   Remove exhaust manifold (1) with turbocharger •   Unscrew 2 bolts •   Unscrew 7x nuts •   Remove 2 gaskets

15.   Remove vacuum pump (2) oil return line •   Release clamp 16.   Remove oil supply line, vacuum pump (1) •   Unscrew banjo bolt •   Remove 2x seal ring 17.   Detach alternator wiring harness bracket •   Disconnect dynamic oil level check sensor wiring harness plug (3) •   Unscrew 2 bolts

18.   Remove alternator support •   Unscrew 4 bolts

19.   Remove coolant pipe •   Remove bolt (1) •   Detach coolant hose (arrow) – Release clamp

21.   Remove starter alternator wiring harness •   Detach starter – Remove bolt – Unscrew 2 nuts •   Unclip vacuum line (4) •   Detach wiring trough (5) – Remove bolt (3) – Unclip wiring trough •   Disconnect camshaft sensor wiring harness plug (2) •   Expose wiring harness and remove

22.   Remove engine control unit •   Release wiring harness plug in direction of arrow •   Unscrew 2 bolts •   Unscrew 2 nuts

25.   Remove bracket of engine control unit bracket •   Unscrew 2 bolts

31.   Detach charge air pipe (1), intake manifold •   Unscrew 4 bolts •   Unscrew 2 nuts •   Unscrew 2 bolts •   Remove 2 gaskets

33.   Remove oil filter housing cover (1) •   Place collecting basin underneath. •   Remove oil filter element

34.   Detach oil filter housing/heat exchanger •   Detach coolant hose – Release clamp •   Remove bolt (1)

37.   Detach 4x injection line (1) •   Unscrew 8 nuts •   Use KM-6098

38.   Detach fuel return line (1) •   Unscrew 2x banjo bolt (2) •   Remove 4x seal ring •   Unscrew nut •   Unclip 4x retaining clamp

Important:   Be sure not to damage the high pressure line (2) 39.   Detach high pressure line (1) from high pressure pump at accumulator •   Remove from bracket – Remove bolt •   Remove union nut from accumulator using KM-812 and from high pressure pump using KM-6098 – Unscrew 2 union nuts •   Seal connection of high pressure pump

40.   Detach accumulator (4) •   Unscrew 2 bolts (3) Note:   Note different lengths of bolts (3) and spacer sleeves (1) •   Detach fuel return line from connection (2)

41.   Remove crankshaft sensor (1) •   Remove bolt (2)

42.   Detach right engine bracket (1) •   Unscrew 3 bolts •   With right engine bracket adapter

Important:   Take care not to damage the increment counter on the camshaft sprocket when removing the upper toothed belt cover 43.   Remove upper toothed belt cover (3) •   Unscrew 8 bolts Note:   Note dissimilar bolt lengths.

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

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

48.   Remove coolant pump (1) •   Unscrew 5 bolts •   Remove gasket and plastic insert

49.   Remove camshaft sensor (1) •   Remove bolt (2)

50.   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

51.   Remove toothed belt •   Mark running direction •   Loosen toothed belt tension roller (1) – Loosen bolt (2) •   Pretension tension roller toothed belt approx. 90° anticlockwise •   Secure toothed belt tension roller in pretensioned position – Tighten bolt

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

54.   Remove high pressure pump drive gear •   Unscrew nut – Counterhold with KM-6603 (1) Note:   Allow KM-6603 to lie in position (2) against toothed belt drive gear Important:   Note woodruff key •   Disengage high pressure pump drive gear using KM-6602 (4) – Counterhold with KM-6603 Note:   Allow KM-6603 to lie in position (3) against toothed belt drive gear

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

56.   Remove oil pump drive gear (1) •   Remove bolt – Counterhold with socket wrench

58.   Remove crankshaft toothed belt drive gear (1) •   Attach KM-662-C •   Remove bolt •   Remove KM-662-C •   Attach KM-161-B (2)

60.   Remove high pressure pump (3) •   Disconnect fuel lines – 2x from return line connection (1) – From feed line connection (2) •   Unscrew 3 nuts

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

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

Important:   Do not damage components 64.   Remove camshaft housing cover (1) •   Unscrew and remove 10x screw, nut, bolt •   Remove gasket.

65.   Remove 4 injectors Note:   Mark the injectors (1). If the heat insulation sleeve (5) is pulled out together with the injector during removal, the gaskets (3) must be replaced and the heat insulation sleeve driven into the cylinder head. •   Remove 4x bracket (2) – Unscrew 4 bolts •   Remove 4x copper ring

66.   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

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

69.   Unscrew 10 cylinder head bolts Note:   Loosen bolts in stages of 1/2 to 1 turn in a spiral in the order shown

75.   Detach flywheel •   Unscrew 8 bolts •   Use KM-652 (1)

77.   Detach lower part of oil pan •   Unscrew 15 bolts •   Use KM-J-37228

79.   Remove oil intake pipe •   Remove bolt (1)

82.   Remove oil pump cover (1) •   Unscrew 9 bolts Note:   Note different bolt lengths •   Remove inner rotor together with outer rotor (2) •   Remove front crankshaft seal ring and oil pump seal ring

  Install

94.   Fit rear crankshaft seal ring •   Attach KM-658-2 to crankshaft journal •   Slide sealing ring onto KM-658-2 •   Drive in until flush using KM-658-1 (1)

95.   Remove oil pump cover seal rings Important:   Do not damage sealing surfaces. •   Prise out front crankshaft seal rings (1) and oil pump seal ring (2)

Important:   The application of silicone sealing compound and installation of the oil pump housing, including torque test, must be completed within 10 minutes 96.   Install oil pump cover (2) •   Insert inner rotor together with outer rotor – Coat with engine oil •   Replace sealing ring (1) •   Apply sealant •   Install oil pump cover Note:   Note guide sleeves and different bolt lengths – Tighten 9 bolts 9.8 Nm

97.   Install oil pump seal ring •   Insert seal ring (1) in oil pump cover •   Drive in as far as stop using KM-657

98.   Install front crankshaft seal ring •   Insert seal ring in oil pump cover •   Drive in as far as stop using KM-656 (1)

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

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

Important:   The largest piston projection found determines the selection of the cylinder head gasket with appropriate identification. 115.   Replace cylinder head gasket •   Lay cylinder head gasket in place 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

117.   Fasten cylinder head •   Tighten 10 new bolts 39.2 Nm + 60° + 60° Note:   Use MKM-610 and KM-470-B to tighten in the order illustrated in a spiral from inside outwards.

119.   Install camshaft housing •   Replace gasket Note:   Note tightening sequence and guide sleeves – 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. 127.   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 128.   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

129.   Pretension toothed belt tension roller •   Pretension tension roller toothed belt (1) approx. 180° anticlockwise •   Secure toothed belt tension roller in pretensioned position – Tighten bolt (2)

130.   Rotate crankshaft to 1st cylinder TDC •   Mark on toothed belt drive gear (3) must align with cast lug (2) on oil pump cover

131.   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

132.   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

133.   Turn crankshaft •   Turn crankshaft until cam pairs (1) and (2) point upwards 134.   Check valve clearance •   Using feeler gauge Note:   The valve play is checked on a cold engine at room temperature – Test values: Intake valves/Exhaust valves (0.35 – 0.45 mm) 135.   Adjust valve clearance •   Turn cup tappet until tappet groove points outwards Important:   Make sure that the valves are not set when the piston is in "TDC". The valves could strike the piston head •   Press down cup tappets Note:   Note different tool versions for intake and exhaust valves – Use KM-6090 – Mark – IN = Intake side – Mark – EX = Exhaust side •   Remove adjustment shim

137.   Insert adjustment shim •   Coat new shim (7) with engine oil and insert in cup tappet with identification mark facing downwards 138.   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

139.   Replace 8 injector seals •   4 O-rings (1) •   4 copper seal rings (2)

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

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

Important:   The application of silicone sealing compound and installation of the camshaft housing cover, including torque test, must be completed within 10 minutes 148.   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 •   Screw, nut, bolt

150.   Fit 4 injector connection seals Note:   Coat with engine oil •   Replace 4 gaskets Note:   Note installation position (arrow) •   Tighten 8 bolts

165.   Insert oil filter element (1) •   Install 3 new gaskets (2) and (3)

197.	Attach manual transmission to engine

200.	Reset service interval using TECH 2