Vauxhall Workshop Service and Repair Manuals

Repair engine using a short-block

Warning:   When working on the common rail system, wait one minute after switching off the engine. The system relieves the pressure itself.

Important:   Cleanliness is absolutely essential when working on the fuel system because even small dirt particles can lead to disruption of engine operation or the fuel system. On opening fuel system connectors, seal them with appropriate sealing plugs 1) . Sealing plugs are only designed to be used once.

  Remove

2.	Detach manual transmission from engine

3.   Remove starter •   Detach 2 wiring harnesses – Unscrew 2 nuts •   Unscrew 2 bolts (1)

4.	Remove thrust plate and clutch disc

5.   Lock crankshaft •   Insert EN-46778 (1) into cylinder block through flywheel (2)

9.   Detach transmission bracket (2) •   Detach cylinder block from base plate – Unscrew 4x bolt (1) Note:   Note differing bolt lengths!

10.   Remove oil pan (2) •   Unscrew 13x bolt •   Unscrew 2 nuts Note:   Carefully separate oil pan (2) from base plate using KM-J-37228 (1)

Important:   After disconnecting the pressure lines, seal the openings of the injectors, high-pressure pump and accumulator with protective caps (these can be ordered from the Opel parts catalogue, catalogue no. 45 06 154 / part no. 92 01 697) 16.   Remove high-pressure lines •   Detach 4 accumulator high pressure lines (1) at injectors – Unscrew 8 union nuts •   Detach high pressure pump line (2) at accumulator – Unscrew 2 union nuts •   Unclip leak oil line (3)

17.   Detach accumulator (2) with bracket •   Disconnect 2 wiring harness plugs (1) and (3) •   Detach fuel return line from high-pressure pump to accumulator at connection (5) – Release clamp •   Detach oil leak line from connection (6) •   Unscrew 3x bolt (7) Note:   Remove engine transport shackle •   Detach fuel return line from connection (4) – Disconnect quick-release coupling with KM-796-A – Seal using KM-807

18.   Detach exhaust gas recirculation valve (1) with radiator EGR •   Detach exhaust gas recirculation pipe from intake manifold – Release clamp •   Detach coolant hose from thermostat housing – Release clamp •   Unscrew 2 bolts

19.   Detach oil dipstick guide tube (1) with oil dipstick (2) •   Remove bolt (3)

20.   Detach engine vent oil separator (1) •   Detach engine vent hose from timing case – Release clamp – Unclip from bracket •   Detach engine vent hose from flange – Release clamp •   Unscrew 2 bolts

21.   Detach cylinder block ventilation exhaust connector (1) •   Unscrew 6 bolts

22.   Remove fuel distributor pipe (1) •   Detach from heat exchanger – Unscrew 2 bolts •   Detach from cylinder block – Remove bolt •   Unclip 2 wiring harnesses •   Detach coolant hose – Release clamp

23.   Detach thermostat housing (1) from cylinder head •   Unscrew 2 bolts

24.   Remove coolant pipe (1) •   Unscrew 2 bolts (2) •   Release clamp

25.   Detach oil filter housing (1) •   Unscrew 4 bolts

26.   Remove crankshaft sensor (1) •   Remove bolt

27.   Detach right-hand engine damping block adapter (1) •   Unscrew 4 bolts

28.	Remove ribbed V-belt tensioner

29.   Remove torsional vibration damper (1) •   Unscrew 4 bolts Note:   Counterhold at torsional vibration damper flange bolt (2)

30.   Remove coolant pump (1) •   Unscrew 4 nuts

31.   Detach torsional vibration damper flange Note:   Left hand thread •   Remove bolt (1) – Counterhold with KM-662-C (2) – Tighten 2 bolts

32.   Remove timing case •   Detach engine vent hose (2) from timing case – Release clamp •   Unscrew 15x bolts (arrows) •   Unscrew 3x nut (1) •   Remove gasket.

33.   Remove 2 closure bolts from camshaft housing

35.   Lock camshafts •   Screw in 2 camshaft reference drifts EN-46781 (1) •   Check for proper installation position Note:   The fixing reference drift must be fitted in a horizontal position. Put guide marks on the reference drifts (arrows). •   Turn the camshaft back and forth at camshaft drive pinion bolt until EN-46781 engages in both camshafts

36.   Remove timing chain tensioner •   Tighten timing chain tensioner. Lock in pretensioned position using KM-955 •   Unscrew 2 bolts (2)

39.   Undo camshaft drive gear •   Remove bolt •   Counterhold at camshaft drive gear with KM-6347 (1) and KM-956-1 (2)

41.   Detach timing chain oil spray nozzle (1) •   Unscrew 2 bolts (2)

42.   Detach oil leak line (1) •   Disengage 4 clamps (2) in direction of arrow

43.   Detach injectors •   Remove 2 injector brackets (3) – Unscrew 2 nuts (1) Note:   The injectors (2) can only be removed in pairs with the bracket (cylinders 1 and 2 or cylinders 3 and 4) •   Remove 4x seal ring

44.   Remove camshaft housing (3) •   Unscrew 16x bolt (2) Note:   Note differing bolt lengths! •   Unscrew and remove 2x stud bolt (1) •   Remove gasket (4)

45.   Remove 16 roller cam followers (1) with hydraulic valve lifters (2) Note:   Put down in order of removal

46.   Remove 2 x camshaft housing centring pins (1)

47.   Loosen cylinder head •   Unscrew 10 bolts Note:   Undo bolts in order shown

  Install

54.   Push rear crankshaft seal ring onto EN-46777-10 •   Push on EN-46777-10 (1) Note:   Coat crankshaft seal ring with silicone grease (white) •   Slide crankshaft seal ring (3) over EN-46777-10 •   Remove EN-46777-10

55.   Install rear crankshaft seal ring (1) with EN-46777-10 (2)

57.   Check cylinder head for plane surface •   Use straight edge and feeler gauge to check length and breadth of cylinder block sealing surfaces for torsion

58.   Set cylinder 1 to TDC •   Insert MKM-571-B in KM-301 •   Place KM-301 with MKM-571-B in position on cylinder block •   Place probe of MKM-571-B on piston head •   Set dial to zero – Note pretension. •   Turn engine in its direction of rotation Note:   Determine highest point of cylinder 1 by turning the crankshaft. 59.   Measure piston projection •   Place probe of MKM-571-B in position on cylinder block •   Set dial to zero Note:   Note pretension. – Determine high point by turning crankshaft •   Measure piston projection – Measure on all 4 pistons – Carry out measurement on two different locations (3 and 4) or (5 and 6)

60.   Lock crankshaft •   Insert EN-46778 (1) into cylinder block through flywheel (2)

61.   Check cylinder head for plane surface •   Use straight edge and feeler gauge to check length and breadth of cylinder head sealing surfaces for torsion •   Maximum deflection is 0,10 mm 62.   Measure the height of the cylinder head •   Sealing surface to sealing surface •   Dimension l: = 105.45 –105.55 mm

66.   Align cylinder head •   Use straight edge to align cylinder head (2) with cylinder block (3)

67.   Fasten cylinder head •   Tighten 10 cylinder head bolts 40 Nm + 90°+ 90° Note:   Note tightening sequence.

70.   Align camshaft housing (1) •   Using straight edge (2), align with cylinder head

71.   Tighten camshaft housing •   Tighten 2 stay-bolts (M8) (2) and (11) 25 Nm •   Tighten 16 (M7) bolts 18 Nm Note:   Note longer bolt (14). Comply with tightening sequence.

72.   Clean 4 injector seats with EN-47632 •   Loosen dirt with brush side (1) •   Remove dirt with sponge side (2)

73.   Install 4 injectors •   Fit 4 new seal rings to injector shaft •   Replace 4 injector seal rings (1) •   Tighten 2 nuts 20 Nm

Important:   The timing case must be installed within 10 minutes of applying the silicone sealant. 81.   Insert timing case gasket •   Apply silicone sealant (grey) to the transitions between the cylinder head and camshaft housing (1) and the cylinder block and cylinder head (2)

82.   Attach timing case. •   Centre timing case with EN-46775 (1) – Screw in 2 nuts (2) – Tighten 14 bolts 9 Nm – Tighten 3x nuts 9 Nm •   Remove EN-46775 •   Attach engine vent hose to timing case – Fasten clamp

83.   Push crankshaft seal ring front (2) onto seal ring flange torsional vibration damper (1).

84.   Install flange torsional vibration damper (2) with front crankshaft seal ring (1). •   Carefully tighten bolt to crankshaft stop. •   Remove bolt •   Remove torsional vibration damper flange.

85.   Press in seal ring with flat side of EN-46775 (2) •   Tighten bolt (1) carefully until EN-46775 lies on timing case (arrow).

95.	Attach ribbed V-belt tensioner

114.   Apply sealing compound Note:   Apply a bead of silicone sealant (grey) to the oil pan sealing surface

119.	Install thrust plate with clutch disk

121.	Attach transmission to engine