Vauxhall Workshop Service and Repair Manuals

J330100 All Pistons with Con-rod, Remove and Install (Z 18 XE, with Air Conditioning, LHD)

Note:   KM-6394 must be used as of model year 04 instead of KM-6169-1 .

Note:   The customer should be informed of the choice between ECOService and ECOService-Flex before the oil change.

  Remove

4.   Remove air cleaner housing (1) •   Disconnect 2 wiring harness plugs – Hot film mass air flow meter (4), tank vent valve (2) •   Unclip tank vent valve •   Detach intake hose •   Detach engine vent hose (3) •   Remove bolt (arrow)

5.   Remove upper part of toothed belt cover •   Unscrew 3 bolts (arrows) •   Unclip from rear toothed belt cover

6.   Raise vehicle 7.   Remove right-hand air duct •   Unscrew 3 bolts (arrows) 8.   Remove ribbed V-belt cover •   Unscrew 3 bolts (1) •   Remove clip (2) 9.   Lower vehicle

10.   Detach front right wheel •   Loosen 4 bolts 11.   Raise vehicle 12.   Remove right front wheel. •   Unscrew 4 bolts 13.   Raise vehicle 14.   Remove ribbed V-belt •   Tension ribbed V-belt tensioner in direction of arrow with KM-913-A (2) •   Use KM-6130 (1)

15.   Remove ribbed V-belt tensioner •   Tension ribbed V-belt tensioner. •   Remove KM-6130 (2) •   Release ribbed V-belt tensioner •   Remove bolt (1)

16.   Detach crankshaft ribbed V-belt pulley •   Prise front closure plug out of oil pan •   Use KM-911 •   Remove bolt •   Remove KM-911

17.   Release lower part of toothed belt cover •   Remove bolt (arrow) •   Unclip from rear toothed belt cover

20.   Release shift guide (3) •   Remove retaining clip (2) 21.   Release rear reaction member (4) •   Remove bolt (1)

22.   Remove front reaction member •   Undo bolted connection •   Unscrew 2 bolts 23.   Lower vehicle

24.   Use MKM-883-1 (1) Note:   Second person required 25.   Fasten MKM-883-1 Note:   Observe manufacturer's instructions 26.   Attach engine •   To right engine transport shackle (3) •   To front left engine transport shackle (2) Note:   The front left engine transport shackle is used only to stabilise the engine

27.   Detach right engine damping block •   Unscrew 2 bolts (1) 28.   Lift engine •   Carefully raise the engine approx. 40 mm on the timing side with MKM-883-1 Note:   Observe manufacturer's instructions 29.   Raise vehicle

30.   Remove oil pan •   Lever out rear sealing plug (1) •   Transmission – Unscrew 3 bolts (2) •   Oil pump – Unscrew 3 bolts (arrows) •   Cylinder Block – Unscrew 12 bolts 31.   Lower vehicle

32.   Lower engine Note:   When lowering pay attention to the shift guide and rear reaction member 33.   Raise vehicle 34.   Fasten rear reaction member •   Tighten bolt 80 Nm 35.   Install front reaction member •   Tighten 2 bolts 95 Nm •   Tighten bolted connection 60 Nm 36.   Attach KM-6169 (1) •   Attach KM-6169 to left of 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, Fig. III) •   Tighten 8 bolts

37.   Install support to KM-6169 •   Adjust bracket (2) for support •   Screw on nut (1) 38.   Adjust supports •   Transmission side – Turn spindles until mounts (3) are positioned at 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) 39.   Lower vehicle

40.   Drain coolant •   Place collecting basin underneath. •   Open drain bolt (arrow) 41.   Lower vehicle 42.   Release MKM-883-1 43.   Remove MKM-883-1 Note:   Second person required

44.   Remove right engine damping block •   Loosen engine bracket adapter – Unscrew 2 bolts (1)

45.   Remove preheater line for throttle valve module •   Unscrew 2 bolts •   Disconnect wiring harness plug for coolant temperature sensor – Remove cable ties. •   Detach 2x hoses 46.   Remove upper part of toothed belt cover •   Unscrew 3 bolts •   Unclip from rear toothed belt cover 47.   Remove camshaft sensor (2) •   Unscrew 2 bolts •   Unclip from bracket •   Disconnect wiring harness plug (1) 48.   Remove lower part of toothed belt cover •   Unclip from rear toothed belt cover •   Remove downwards

49.   Set 1st cylinder to TDC of combustion stroke •   Install crankshaft V-belt pulley bolt •   Set crankshaft to mark. – Turn crankshaft evenly – Marks on drive gear toothed belt and rear toothed belt cover must align (III). •   Fix camshaft sprockets in position. – Marks must be opposite one another and aligned with the top edge of the cylinder head (I) – Use KM-852 (II) 50.   Remove toothed belt Note:   Mark running direction. •   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. •   Remove toothed belt.

51.   Remove ignition module •   Disconnect wiring harness plug (2) •   Unscrew 5 bolts •   Extract using KM-6009 (1) Note:   Do not tilt 52.   Remove cylinder head cover •   Detach engine vent hose •   Unscrew 10 bolts •   Remove seal •   Unclip wiring harness of mixture regulation heated oxygen sensor

53.   Remove camshaft sprockets •   Remove KM-852 •   Unscrew 2 bolts – Counterhold camshafts at hexagonal section

54.   Remove exhaust side toothed belt guide roller •   Remove bolt (2) 55.   Remove intake side toothed belt guide roller •   Remove bolt (1) 56.   Remove right engine bracket (3) •   Unscrew 3 bolts 57.   Remove toothed belt tension roller •   Remove bolt (4) 58.   Raise vehicle 59.   Remove toothed belt drive pulley •   Use KM-911 •   Unscrew crankshaft ribbed V-belt pulley bolt •   Remove KM-911 60.   Release rear toothed belt cover •   Unscrew 2 bolts

61.   Release alternator •   Release alternator support – Unscrew 2 upper bolts (1) •   Release nut (2)

62.   Detach intake manifold support •   Unscrew upper bolt •   Loosen lower bolt

63.   Remove wiring harness for engine management •   Disconnect 2 wiring harness plugs – Oil pressure switch (1), crankshaft sensor (arrow) •   Unclip wiring harness – 3 brackets

64.   Lower vehicle 65.   Remove rear of toothed belt cover •   Unscrew 2 bolts 66.   Pull fuel evaporation hose from throttle valve module

67.   Remove alternator shackle •   Remove ground cable (1) – Unscrew nut (2) •   Unscrew studs (3) •   Unscrew 2x bolts (4, 5) •   Swing alternator backwards.

Important:   Observe safety precautions and national regulations 68.   Release fuel pressure with KM-J-34730-91 on fuel distributor pipe •   Unscrew test connection protective cap

69.   Detach fuel line (1) from fuel distributor pipe

70.   Remove wiring harness for engine management •   Disconnect 7x wiring harness plugs – Throttle valve module (1), engine control unit (3), knock sensor (4), combination plug (5), EGR valve (6), mixture regulation oxygen sensor (2) •   Detach ground cable •   Remove 6x cable ties •   Remove wiring trough – Unscrew from engine transport shackle (arrow) •   Set wiring harness to one side

71.   Remove fuel distributor pipe •   Unscrew 2x bolt (arrows) •   Pull out fuel distributor pipe with injectors and engine management wiring harness 72.   Detach preheater return hose for throttle valve module from throttle valve module 73.   Detach heating return hose from intake manifold 74.   Remove right rear engine transport shackle •   Remove bolt

75.   Remove intake manifold •   Unscrew 7x nuts (arrows) •   Remove brake servo vacuum line

76.   Detach coolant pipe. •   Remove bolt (arrow) 77.   Detach centre coolant hose from coolant pump connection, coolant flange 78.   Detach upper radiator hose from thermostat housing

79.   Remove intake pipe •   Remove bolt (arrow) •   Pull intake pipe out of bracket

80.   Remove heated oxygen sensor for mixture regulation •   Remove cable ties. •   Screw out carefully using KM-6129 (1) 81.   Remove exhaust manifold heat shield •   Unscrew 3 bolts 82.   Detach oil dipstick guide tube •   Remove bolt •   Swivel the oil dipstick guide tube to one side

83.   Remove exhaust manifold •   Unscrew 10x nut – Remove engine transport shackle •   Remove gasket.

84.   Remove cylinder head bolts Note:   Undo bolts in order shown •   Unscrew 10 bolts – Loosen 10x bolts (90 °) – Loosen 10x bolts (180 °) 85.   Remove cylinder head Note:   Second person required •   Place cylinder head on wooden blocks •   Remove cylinder head gasket

86.   Raise vehicle 87.   Remove con-rod bearing cap (1) Note:   Observe cylinder sequence •   Mark con-rods with con-rod bearing caps – Cylinder 2, cylinder 3 •   Unscrew 4 bolts Note:   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. •   Push piston with con-rod upwards 88.   Lower vehicle 89.   Remove 2 pistons 90.   Raise vehicle 91.   Rotate crankshaft in direction of engine rotation (180°)

  Install

96.   Inspect crank drive components 97.   Insert con-rod bearing shells into con-rods and con-rod bearing caps •   Coat with engine oil 98.   Adjust piston ring gaps •   Turn piston rings – Upper rings in position (1) – Middle rings in position (4) •   Turn oil scraper ring – Intermediate ring in position (5) – Steel band rings in position (2) or (3)

99.   Install piston Note:   Arrow (1) on bottom of piston points to engine timing side. Bead (2) on con-rod should face transmission side •   Coat piston and cylinder bores with engine oil – Cylinder 1, cylinder 4 •   Compress piston rings with piston ring tensioner •   Insert piston 100.   Raise vehicle 101.   Attach con-rod bearing cap Note:   Bead on con-rod bearing cap should face transmission side •   Coat con-rod journal with engine oil •   Renew bolts •   Tighten 4x bolts 25 Nm + 30°

107.   Lower vehicle 108.   Clean sealing surfaces •   Cylinder block, crankshaft bearing bridge, oil pan, cylinder head, timing case, exhaust manifold, oil filter housing, thermostat housing, cylinder head cover 109.   Check for plane surface •   Cylinder head, cylinder block •   With straightedge, feeler gauge

110.   Attach cylinder head •   Attach cylinder head gasket – OBEN/TOP mark must point upwards. 111.   Install cylinder head bolts Note:   Note tightening sequence. •   Renew bolts •   Tighten 10x bolts 25 Nm + 90° + 90° + 90° + 45°

112.   Install exhaust manifold •   Replace gasket •   Replace nuts •   Position engine transport shackle •   Tighten 10x nuts 12 Nm + 12 Nm Note:   The nuts must be tightened in two stages in accordance with the tightening sequence – Note tightening sequence. •   Attach bracket for engine control unit wiring harness – Tighten nut 12 Nm

131.   Install toothed belt tension roller •   Detent lever (1) of toothed belt tension roller must engage in guide web (2) of oil pump. •   Bolt in bolt Note:   Adjust toothed belt tension before tightening bolt.

132.   Install right engine bracket •   Renew bolts •   Insert bolts with locking compound (red) •   Tighten bolts 65 Nm + 45° - 60° Note:   Note tightening sequence (1 - 3).

136.   Fix camshaft sprockets in position. •   Marks must be opposite one another and aligned with the top edge of the cylinder head (I) •   Use KM-852 (II) – Turn the camshafts at hexagonal section 137.   Lock crankshaft •   Install crankshaft V-belt pulley bolt •   Set crankshaft to mark. – Turn crankshaft evenly – Marks on drive gear toothed belt and rear toothed belt cover must align (III).

138.   Install toothed belt Note:   Note running direction •   Position toothed belt Note:   Tensioned side must be taut (I)

139.   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) 140.   Remove KM-852

141.   Timing, Check •   Turn crankshaft in direction of engine rotation at the crankshaft ribbed V-belt pulley bolt (720°) •   Set crankshaft to mark. – Marks on drive gear toothed belt and rear toothed belt cover must align (III). •   Use KM-852 (II) – Marks must be opposite one another and aligned with the top edge of the cylinder head (I) 142.   Remove KM-852

143.   Adjust toothed belt tension •   Release toothed belt tension roller – Loosen bolt •   Turn adjustment eccentric in direction of arrow (clockwise) until tension roller toothed belt pointer (1) is aligned with notch mark (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 144.   Check toothed belt tension •   Turn crankshaft (720°) •   Pointer 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

145.   Install lower part of toothed belt cover •   Clip to rear of toothed belt cover •   Tighten bolt 4 Nm 146.   Install camshaft sensor •   Insert bolts with locking compound •   Tighten 2x bolts 8 Nm 147.   Install upper part of toothed belt cover •   Clip to rear of toothed belt cover •   Tighten 3x bolts 4 Nm 148.   Install cylinder head cover •   Replace gasket (2) •   Apply sealant (1) Note:   Complete assembly operations within 10 minutes •   Tighten 10x bolts 8 Nm •   Attach engine vent hose •   Clip in cable for mixture regulation heated oxygen sensor

164.   Install oil pan •   Apply sealant Note:   Complete assembly operations within 10 minutes •   Screw in bolts •   At cylinder block – Tighten 12x bolts 10 Nm •   On transmission – Tighten 3x bolts 10 Nm •   At oil pump – Tighten 3 bolts 40 Nm •   Insert rear closure plug

202.	Top up and bleed cooling system

203.	Reset service interval using TECH 2 Note:   If the customer decides to have ECOService - connect TECH2 and reprogram engine control unit