Vauxhall Workshop Service and Repair Manuals

Remove and install crankshaft (Z 14 XE without air conditioning, Z 16 YNG)

1. Remove engine Note: See operation "J340100 Engine, Remove and Install"

2. Remove manual transmission from engine

• Note: See operation "J340100 007 Manual Transmission, Detach and Reattach from Engine"

3. Drain engine oil

• Place collecting basin underneath.
• Unscrew oil drain bolt

4. Remove upper part of toothed belt cover

• Remove 3 bolts
• Unclip from rear toothed belt cover

5. Detach crankshaft ribbed V-belt pulley Block flywheel Using KM-652 (1) Remove bolt

6. Remove camshaft sensor (2) Unclip from bracket Disconnect wiring harness plug (1) Remove 2 bolts

7. Remove lower part of toothed belt cover

• Remove bolt
• Unclip from rear toothed belt cover

8. Set 1st cylinder to TDC Set crankshaft to mark. Turn crankshaft evenly Note: Marks on crankshaft ribbed V-belt pulley and rear toothed belt cover must align (III) Fix camshaft sprockets in position. Note: Marks must be opposite one another and aligned with the top edge of the cylinder head (I) Insert KM-852

9. Remove toothed belt

• Release toothed belt tension roller (IV)
• Loosen bolt
• Turn adjusting eccentric in direction of arrow (clockwise) until pointer (1) of the toothed belt tension roller is located just before left stop.
• Note: Mark running direction
• Remove toothed belt.

10. Remove camshaft sprocket on exhaust side Use KM-6347 (1), KM-956-1 (2) Attach KM-6347, KM-956-1 Note:   Loosen the clamping screws (3) of KM-6347 and insert KM-6347 connected to KM-956-1 in the camshaft sprocket. The notches on KM-6347 must engage in the camshaft sprocket (arrows). Ensure that it engages properly. Turn KM-6347 in the direction of the arrow using KM-956-1 Tighten clamping screws Loosen camshaft sprocket bolt (4) Remove KM-6347, KM-956-1 Loosen clamping screws Unscrew camshaft sprocket bolt

11. Remove camshaft sprocket on intake side

• Use KM-6347, KM-956-1
• Attach KM-6347, KM-956-1

Note:   Loosen the clamping screws of KM-6347 and insert KM-6347 connected to KM-956-1 in the camshaft sprocket. The notches on KM-6347 must engage in the camshaft sprocket. Ensure that it engages properly.

• Turn KM-6347 in the direction of the arrow using KM-956-1
• Tighten clamping screws

• Loosen camshaft sprocket bolt
• Remove KM-6347, KM-956-1
• Loosen clamping screws

• Unscrew camshaft sprocket bolt

12. Remove intake side toothed belt guide roller Remove bolt

13. Remove exhaust side toothed belt guide roller

• Remove bolt

14. Remove right engine bracket (2)

• Remove 3 bolts

15. Remove toothed belt tension roller

• Remove bolt

16. Remove toothed belt drive pulley (3)

• Unscrew crankshaft ribbed V-belt pulley bolt
• Remove toothed belt drive pulley

17. Remove rear toothed belt cover

• Remove 4 bolts (1, 4)

18. Remove clutch

Note:   See operation "Remove and install thrust plate and clutch disc (without SAC)" in group "K"

19. Detach flywheel Remove 6 bolts Detach KM-652

20. Install oil drain bolt

• Replace seal ring
• Tighten bolt (10 Nm / 7.5 lbf. ft.)

21. Remove crankshaft sensor

• Turn engine (180°)
• Disconnect wiring harness plug (arrow)
• Remove bolt

22. Detach oil pan Oil pump Remove 3 bolts (arrows) Cylinder Block Remove 12 bolts

23. Remove oil intake pipe (1) Remove 3 bolts Remove seal ring

24. Remove oil pump Remove 7 bolts

25. Detach con-rod bearing cap Mark con-rod bearing cap (1) Note: Observe cylinder sequence Set piston to BDC position 4 off Remove 8 bolts Caution: 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

26. Remove crankshaft Remove crankshaft bearing cap. Mark crankshaft bearing cap Note: Observe cylinder sequence 5 off Remove 10 bolts Remove crankshaft rear seal ring Note: Place crankshaft on wooden blocks

27. Remove crankshaft bearing shells

• Mark crankshaft bearing shells
• Note: Observe cylinder sequence

28. Remove con-rod bearing shells

• Mark con-rod bearing shells
• Note: Observe cylinder sequence

29. Detach crankshaft pulse pick-up disc (1) Remove 3 bolts

30. Clean sealing surfaces

• Cylinder block, cylinder head, cylinder head cover, oil pan, oil pump, crankshaft rear bearing cap

31. Inspect components

• Cylinder block, cylinder head, cylinder head cover, oil pan, oil intake pipe, oil pump, ribbed V-belt, ribbed V-belt tensioner assembly, ribbed V-belt pulleys, toothed belt drive

32. Rework threads

• Into cylinder block
• Oil pump

33. Attach crankshaft pulse pick-up disc

• Tighten bolts (15 Nm / 11 lbf. ft.)

34. Insert con-rod bearing shells

• Caution: Note mark and allocation
• In con-rod, con-rod bearing cap
• Coat with engine oil

35. Insert crankshaft bearing shells

• Caution: Note mark and allocation
• In cylinder block, crankshaft bearing cap
• Coat with engine oil
• Caution: Note position of axial bearing

36. Insert crankshaft

• Coat crankshaft journal with engine oil

37. Install crankshaft bearing cap Caution: Note mark and allocation. Apply sealant in groove of rear crankshaft bearing cap. Complete assembly operations within 10 minutes Renew bolts Tighten bolts (50 Nm / 37 lbf. ft. + 45° + 15°) Note: Observe tightening sequence Remove excess sealant

38. Attach con-rod bearing cap Renew bolts Caution: Note mark and allocation. Bead (1) on con-rod bearing cap points towards the transmission side Tighten bolts (25 Nm / 18.5 lbf. ft. + 30°)

39. Install rear crankshaft seal ring Coat seal lip with grease Position KM-235-6 (1) on crankshaft journal Push seal ring (2) onto KM-235-6 Drive in until flush using KM-658-1 (3)

40. Remove front crankshaft seal ring Lever out seal ring (1) Caution: Do not damage sealing surface

41. Install oil pump

• Replace gasket
• Note: Insert bolts with locking compound
• Tighten bolts (8 Nm / 6 lbf. ft.)

42. Install front crankshaft seal ring

• Coat seal lip with grease
• Position KM-417 on crankshaft journal (2)
• Push seal ring onto KM-417
• Remove KM-417
• Install crankshaft front seal ring
• With KM-417 (4), bolt (3) and crankshaft ribbed V-belt pulley (5)

43. Install oil intake pipe Replace seal ring Note: Insert bolts with locking compound Tighten bolts (8 Nm / 6 lbf. ft.)

44. Attach oil pan

• Apply sealant
• Caution: Complete assembly operations within 10 minutes
• Screw in bolts
• At cylinder block
• Tighten bolts (10 Nm / 7.5 lbf. ft.)
• At oil pump
• Tighten bolts (10 Nm / 7.5 lbf. ft.)

45. Install crankshaft sensor

• Replace seal ring
• Tighten bolt (10 Nm / 7.5 lbf. ft.)
• Connect wiring harness plug.

46. Rework threads

• In crankshaft

47. Attach flywheel

• Turn engine (180°)
• Renew bolts
• Tighten bolts (35 Nm / 26 lbf. ft. + 30° + 15°)
• Lock with KM-652

48. Install clutch

Note:   See operation "Remove and install thrust plate and clutch disc (without SAC)" in group "K"

49. Attach rear toothed belt cover

• Tighten bolts (6 Nm / 4.4 lbf. ft.)

50. Install toothed belt drive gear

• Install crankshaft V-belt pulley bolt

51. Install toothed belt tension roller Caution: Detent lever (1) of toothed belt tension roller must engage in guide web (2) of oil pump Bolt in bolt Note: Only tighten bolt after adjusting toothed belt tension

52. Attach right engine bracket

• Renew bolts
• Insert bolts with locking compound (red)
• Tighten bolts (65 Nm + 45° - 60°)

53. Install intake side toothed belt guide roller

• Tighten bolt (25 Nm / 18.5 lbf. ft.)
• Caution: Toothed belt guide roller with larger diameter is installed on intake side

54. Install exhaust side toothed belt guide roller

• Tighten bolt (25 Nm / 18.5 lbf. ft.)

55. Fix camshaft sprockets in position Note: Marks must be opposite one another and aligned with the top edge of the cylinder head (I) Insert KM-852 (II) Turn the camshafts at hexagonal section 56. Lock crankshaft Set crankshaft to mark. Turn crankshaft evenly Note: Marks on drive gear toothed belt and rear toothed belt cover must align (III)

57. Install toothed belt Note: Note running direction and timing marks Position toothed belt Note: Tensioned side must be taut (I)

58. Tension toothed belt Tension toothed belt tension roller Turn adjusting eccentric in direction of arrow (anticlockwise) until pointer of the toothed belt tension roller is located just before left stop Fasten toothed belt tension roller bolt (1)

59. Remove KM-852

60. Check timing Turn crankshaft (720°) At crankshaft ribbed V-belt pulley bolt Note: In direction of engine rotation Set crankshaft to mark. Note: Marks on drive gear toothed belt and rear toothed belt cover must align (III) Insert KM-852 (II) Note: Marks must be opposite one another and aligned with the top edge of the cylinder head (I)

61. Remove KM-852

62. Adjust toothed belt tension Release toothed belt tension roller Loosen bolt Turn adjustment eccentric in the direction of the arrow (clockwise) until pointer (1) is aligned with the notch mark at the toothed belt tension roller (2). Adjust used toothed belts to the marking USED Adjust new toothed belts to the marking NEW Tighten toothed belt tension roller bolt (20 Nm / 15 lbf. ft.)

63. Check toothed belt tension

• Turn crankshaft (720°)
• Note: Pointers on the toothed belt tension roller and notch mark must align
• Adjust used toothed belts to the marking USED
• Adjust new toothed belts to the marking NEW

64. Rework threads

• Camshaft sensor to cylinder head

65. Install camshaft sensor

• Note: Insert bolts with locking compound
• Tighten bolts (8 Nm / 6 lbf. ft.)

66. Install lower part of toothed belt cover

• Clip to rear of toothed belt cover
• Tighten bolt (4 Nm / 3 lbf. ft)

67. Install upper part of toothed belt cover

• Clip to rear of toothed belt cover
• Tighten bolts (4 Nm / 3 lbf. ft)

68. Attach crankshaft ribbed V-belt pulley

• Block flywheel
• With KM-652
• Replace bolt
• Tighten bolt (95 Nm / 70 lbf. ft. + 30° + 15°.)
• Detach KM-652

69. Connect wiring harness plug of camshaft sensor

• Connect wiring harness plug.
• Clip to bracket

70. Attach manual transmission to engine

• Note: See operation "J 3401 00 007 Manual Transmission, Remove and Install from Engine"

71. Install engine

• Note: See operation "J 3401 00 Engine, Remove and Install"