Vauxhall Workshop Service and Repair Manuals

Remove and install crankshaft (Z 10 XE, Z 10 XEP, with air conditioning)

  Remove

2.	Remove and install manual transmission from engine

6.   Remove exhaust manifold •   Unscrew 7x nuts •   Remove gasket. 7.   Attach KM-412-18 (1) •   Tighten 4 bolts 8.   Fit engine to KM-412 (2) Note:   Second person required •   Tighten 8 bolts

9.   Drain engine oil •   Place collecting basin underneath. •   Remove oil drain bolt •   Remove oil filter housing cover •   Remove oil filter element 10.   Remove clutch (1) - see operation "Remove and install thrust plate and clutch disk" in group "K" 11.   Detach flywheel •   Attach KM-652 (2) •   Unscrew 6 bolts •   Remove KM-652 12.   Detach right engine bracket •   Unscrew 3x bolts 13.   Install oil drain screw •   Replace seal ring •   Tighten bolt 10 Nm

14.   Remove ribbed V-belt Note:   Mark running direction. 15.   Detach coolant pump ribbed V-belt pulley •   Unscrew 3 bolts 16.   Detach crankshaft ribbed V-belt pulley •   Unscrew 6 bolts •   Counterhold at crankshaft hub bolt 17.   Detach ribbed V-belt tensioner •   Tension ribbed V-belt tensioner in direction of arrow •   Remove KM-6130 (1) •   Release ribbed V-belt tensioner •   Unscrew 2 bolts (arrows)

18.   Detach alternator wiring harness (1) •   Unscrew 2 nuts 19.   Detach alternator •   Unscrew 2 bolts

20.   Remove wiring harness for engine management •   Disconnect wiring harness plug – Oil pressure switch (2), coolant temperature sensor (3), camshaft sensor (4) ignition module (1), crankshaft sensor (5) •   Unclip wiring trough 21.   Detach 3x coolant hoses from coolant pump •   Release 3x clamp

22.   Detach coolant pump (1) Note:   Note guide bushings during removal •   Place collecting basin underneath. •   Unscrew 9 bolts Note:   Pay attention to different bolt lengths (arrows = short bolts)

23.   Remove ignition module •   Remove ignition module cover – Move to the right •   Unscrew 2 bolts •   Extract using KM-6009 (1) Note:   Do not tilt 24.   Unscrew 3x spark plugs with KM-194-E 25.   Detach cylinder head cover •   Detach engine vent hose – Release clamp •   Unscrew 13x bolt

26.   Loosen crankshaft hub bolt (1) Note:   Second person required •   Attach KM-956-1 / KM-956-2 (2) •   Counterhold KM-956-1 / KM-956-2

27.   Adjust camshafts •   Uniformly rotate crankshaft in direction of engine rotation with KM-956-1 / KM-956-2 until KM-953 (1) engages in camshaft groove as far as it will go 28.   Remove crankshaft hub Note:   Pay attention to installation position •   Remove bolt •   Remove with KM-956-1 / KM-956-2 29.   Detach oil pan •   Turn engine (180°) •   Unscrew 14 bolts •   Remove oil pan seal

30.   Remove camshaft sensor (1) •   Turn engine (90°) 31.   Remove timing case •   Unscrew 15x bolts (arrows) – Pay attention to bolt lengths •   Lever out timing case seal ring Note:   Do not damage sealing surface

32.   Remove chain drive •   Loosen camshaft sprocket bolts – Counterhold camshafts at hexagonal section •   Lock chain tensioner – Insert KM-955-1 (2) •   Detach sliding rail (3), guide rail (5), tension rail (7) and camshaft sprockets •   Remove timing chain (4) with drive sprocket (6) •   Remove timing case gasket.

33.   Remove oil baffle plate (1) •   Turn engine (90°) •   Unscrew 6 bolts 34.   Remove crankshaft sensor •   Remove bolt Important:   Crankshaft must only be carefully rotated to the left or right within a range of 45°, otherwise the valves and pistons could become damaged 35.   Remove con-rod bearing cap •   Mark 3x con-rod bearing caps (2) Note:   Observe cylinder sequence •   Unscrew 6 bolts Important:   The mating surfaces of the cod-rods and con-rod bearing caps form an individual fit and must not be damaged or interchanged. Do not lay on mating surfaces. •   Remove 3x con-rod bearing caps

36.   Remove crankshaft •   Remove crankshaft bearing bridge Note:   Prise off evenly – Unscrew 18x bolts •   Remove crankshaft rear seal ring •   Place crankshaft on wooden blocks 37.   Remove crankshaft bearing shells Note:   Observe order •   Mark crankshaft bearing shells 38.   Remove con-rod bearing shells Note:   Observe order •   Mark con-rod bearing shells 39.   Remove crankshaft pulse pickup disc (1) •   Unscrew 3 bolts

40.   Remove oil intake pipe (1) •   Unscrew 4 bolts •   Detach seal ring (2) 41.   Clean sealing surfaces •   Cylinder block, cylinder head, cylinder head cover, crankshaft bearing bridge, chain drive, timing case, oil pan, coolant pump, exhaust manifold 42.   Inspect components Note:   If cylinder head is to be checked and overhauled : Remove all outer attaching parts from cylinder head 43.   Check whether crankshaft bearing bridge is level using a straightedge and a feeler gauge

  Install

44.   Attach crankshaft pulse pickup disc •   Tighten 3x bolts 15 Nm 45.   Insert con-rod bearing shells •   In con-rod, con-rod bearing cap – Coat with engine oil 46.   Insert crankshaft bearing shells Note:   Note position of axial bearing (arrow) •   Insert crankshaft bearing bridge into cylinder block – Coat with engine oil 47.   Insert crankshaft Note:   Note DTC installation position •   Coat crankshaft journal with engine oil

48.   Attach crankshaft bearing bridge Note:   Complete installation work within 10 minutes •   Renew bolts •   Apply sealant to outer edge of groove (dimension I = 2 mm) Note:   Do not apply sealant in groove •   Tighten 8x bolts (M8) 25 Nm + 60° •   Tighten 10x bolts (M6) 10 Nm + 60° •   Remove excess sealant

49.   Install rear crankshaft seal ring (1) •   Coat sealing lip with silicon grease (white) •   Position KM-235-6 (2) on crankshaft journal •   Slide seal ring onto KM-235-6 •   Drive in until flush using KM-658-1 (3)

50.   Attach con-rod bearing cap Note:   Bead on con-rod bearing cap should face transmission side •   Renew bolts •   Tighten 6x bolts (M6) 10 Nm + 60° + 15° – From engine number 19P13554 13 Nm + 60° + 15° (M6.5) 51.   Lock crankshaft •   Remove closure bolt (1) •   Insert KM-952 (2) – Turn crankshaft uniformly until KM-952 engages 52.   Attach oil baffle plate •   Tighten 6x bolts 8 Nm

53.   Replace timing case gasket Note:   Complete assembly operations within 10 minutes •   Turn engine (90°) •   Apply sealant – Cut off excess elastomer of cylinder head gasket (1) and replace with a 2 mm thick bead of silicone sealant Note:   If no excess elastomer is present, the bead of silicone sealant can be applied directly – Apply silicone sealant to joint between cylinder block and crankshaft bearing bridge

54.   Attach timing chain Note:   Ensure that guide sleeves are correctly seated (arrows) •   Fit drive sprocket (5) •   Renew bolts •   Position exhaust camshaft – Bolt in bolt •   Install timing chain (3) •   Insert intake camshaft sprocket with phase sensor disc in timing chain – Bolt in bolt Note:   It must be possible to rotate phase sensor disk by hand

55.   Attach timing chain tension rail (6) Note:   Ensure that timing chain is correctly seated •   Tighten bolt 20 Nm 56.   Attach timing chain guide rail (4) Note:   Ensure that timing chain is correctly seated •   Tighten bolt 8 Nm 57.   Attach timing chain sliding rail (2) •   Tighten bolt 8 Nm 58.   Release tension of chain tensioner •   Remove KM-955-1 (1)

59.   Attach coolant pump Note:   Ensure that guide sleeves are correctly seated (arrows) •   Replace gasket (1) •   Attach using short bolts (2) – Tighten 3x bolts 8 Nm •   Remove thermostat housing cover – Unscrew 3 bolts

60.   Attach timing case. •   Screw in bolts •   Tighten 5x bolts (1) (M6) 8 Nm •   Tighten 14x bolts (2) (M6) 8 Nm •   Tighten 2x bolts (3) (M10) 35 Nm •   Attach thermostat housing cover – Replace seal ring – Tighten 3x bolts 8 Nm

61.   Replace front crankshaft seal ring (1) •   Coat sealing lips with silicon grease •   Slide onto KM-960 (2) •   Drive in until flush using KM-960 62.   Remove KM-952 Note:   Retaining tools must not be used for counterholding

63.   Attach crankshaft hub Note:   Note crankshaft hub installation position (2). Mark must point upwards •   Replace bolt •   Counterhold with holder KM-956-1 / KM-956-2 (3) Note:   Second person required •   Tighten bolt 150 Nm + 45° •   Detach KM-956-1 / KM-956-2 64.   Attach crankshaft ribbed V-belt pulley (1) •   Tighten 6x bolts 8 Nm •   Counterhold at crankshaft hub bolt 65.   Insert KM-952 •   Turn engine (90°)

66.   Attach KM-954 (1) •   Rotate phase sensor disk (2) until KM-954 can be attached to timing case

67.   Fasten camshaft sprockets Note:   Tightening torque of 10 Nm is used to secure camshaft sprockets and phase sensor disk •   Tighten 2x bolts (2) 10 Nm Note:   First tighten intake camshaft sprocket bolt – Counterhold camshafts at hexagonal section (1) 68.   Remove retaining tools •   KM-952 , KM-953 , KM-954 69.   Fasten camshaft sprockets Note:   Second person required •   Tighten 2x bolts 50 Nm + 60° Note:   First tighten intake camshaft sprocket bolt – Counterhold camshafts at hexagonal section

76.   Attach cylinder head cover (1) Note:   Complete assembly operations within 10 minutes •   Turn engine (180°) •   Renew gasket (2) and seal rings •   Apply sealant (dimension I = 2 mm) •   Tighten 13 bolts 8 Nm •   Attach engine vent hose – Fasten clamp 77.   Install 3 sparkplugs •   Tighten using KM-194-E 25 Nm 78.   Attach ignition module •   Tighten 2 bolts 8 Nm 79.   Attach camshaft sensor •   Replace seal ring •   Tighten bolt 6 Nm