Vauxhall Workshop Service and Repair Manuals

Remove and install all pistons with con-rods (Z 10 XE, Z 10 XEP, without air conditioning, LHD)

Note:   On vehicles as of model year 04 with ESP - every time the battery is disconnected, the steering angle sensor loses its basic setting. It must be recalibrated.

  Remove

3.   Drain coolant Note:   With model variant "ECO" - remove lower engine compartment cover •   Place collecting basin underneath. •   Open drain bolt (arrow)

4.   Remove air cleaner housing (1) •   Disconnect 2 wiring harness plugs – Hot film mass air flow sensor (3), tank vent valve (2) •   Unclip tank vent valve •   Remove suction pipe (4) – Unscrew 2 nuts – Detach engine vent hose (5) •   On Z 10 XEP: Remove air intake hose – Release clamp •   Remove bolt (arrow)

5.   Remove intake pipe (1) •   Remove bolt (2) •   Withdraw oil dipstick

6.   Remove preheater hoses for throttle body (1) •   Detach from throttle valve pipe, coolant pump – Release 2x clamp 7.   Detach heater supply hose (2) from coolant pump •   Release clamp •   Lay hose aside 8.   Remove brake servo vacuum line (3)

9.   Detach heater return hose from exhaust gas recirculation coolant flange •   Unclip wiring harness •   Lay hose aside

Important:   Observe safety precautions and national regulations 10.   Reduce fuel pressure •   Unscrew test connection protective cap (2) Note:   Test connection for Z 10 XEP at upper fuel rail •   Fit KM-J-34730-91 to fuel rail (1)

11.   Detach fuel line (arrow) with KM-796-A •   Unclip fuel line •   Seal using KM-807

12.   Detach fuel evaporation hose (1) •   Detach hose from intake manifold and set to one side

13.   Disconnect engine management wiring harness plug •   On Z 10 XEP: Remove fuel rail cover – Unscrew 2 bolts •   Disconnect 11x wiring harness plugs – Oil pressure switch (5), coolant temperature sensor (6), camshaft sensor (1), injectors (2), throttle valve adjuster (3), engine control unit (8), combination plug (9), exhaust gas recirculation valve (10), ignition module (4) •   Detach 3x ground cables (arrows) •   Unclip wiring harness – 2 brackets •   Unclip wiring trough (7) •   Set wiring harness to one side 14.   Raise vehicle

Important:   Angular dislocations of the flexpipe as small as 5 to 10 degrees offset from the intended installation position can cause damage and subsequent complete failure of the flexpipe. 15.   Loosen exhaust system Note:   When removing the centre muffler, a catalytic converter, an exhaust manifold or an exhaust manifold with catalytic converter, the exhaust system piece remaining in the vehicle must be secured to prevent it sagging uncontrollably. The exhaust system piece with the flex pipe inside it can be fastened to the vehicle underbody with suitable materials such as wire. •   Detach oxygen sensor (catalytic converter control) wiring harness plug (1) •   Detach 2x damper rings (arrows) •   Unscrew front exhaust pipe (2) – Unscrew 3 nuts •   Tie front exhaust pipe to left front axle body

17.   Remove ribbed V-belt cover •   Unscrew 3 bolts (1) •   Remove clip (arrow)

18.   Remove wiring harness for engine management •   Detach starter wiring harness – Unscrew 2 nuts (1) – Release cable ties •   Open 2x brackets (arrows)

20.   Remove oil pan •   Transmission – Unscrew 3 bolts (1) •   Crankshaft bearing bridge – Unscrew 14 bolts

21.   Detach oil baffle plate •   Unscrew 6 bolts

22.   Remove ribbed V-belt •   Tension ribbed V-belt tensioner in direction of arrow with KM-6131 •   Insert KM-955-2 (1) •   Release ribbed V-belt tensioner

23.   Attach KM-6169-2 to transmission •   Tighten 2x bolts 95 Nm

24.   Attach KM-6169 (1) •   Attach KM-6169 to left of front axle body (arrows, illus. I) – Guide pin must be seated in bore in front axle body •   Attach both right holders on the front axle body (arrows, Illus. II). – Guide pin must be seated in bore in front axle body (arrow, Fig. III) •   Tighten 8 bolts

25.   Install support •   An KM-6169 – Adjust bracket (2) for support •   Screw on nut (1) 26.   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)

27.   Loosen right engine bracket •   Loosen lower bolt (1) 28.   Lower vehicle

29.   Remove oil dipstick guide tube •   Remove bolt (arrow) •   Turn oil dipstick guide tube towards the front

30.   Remove heated oxygen sensor for mixture regulation •   Disconnect wiring harness plug •   Unscrew carefully using KM-6129 (1) 31.   Detach left engine transport shackle (2) •   Remove bolt 32.   Remove exhaust manifold heat shield •   Unscrew 2 bolts

33.   Remove exhaust manifold •   Unscrew 7x nuts •   Remove gasket.

35.   Remove oil filter housing (1) •   Place another collecting basin underneath •   Unscrew 3 bolts (2)

37.   Remove right engine bracket •   Remove right engine damping block – Unscrew 2 bolts (1) •   Remove engine bracket – Unscrew 2 bolts (arrows) 38.   Remove ribbed V-belt Note:   Mark running direction.

39.   Remove coolant pump ribbed V-belt pulley •   Unscrew 3 bolts 40.   Detach coolant connection •   Unscrew 3 bolts

41.   Remove timing case fastening bolts •   Coolant pump – Unscrew 4x bolt (1) •   Timing case – Unscrew 5 bolts (arrows)

42.   Remove ignition module •   Remove ignition module cover – Move to the right •   Unscrew 2 bolts •   Extract using KM-6009 (1) Note:   Do not tilt 43.   Remove cylinder head cover •   Detach engine vent hose – Release clamp •   Unscrew 13x bolt

44.   Set no.1 cylinder to TDC •   Remove closure bolt for crankshaft bearing bridge (1) •   Insert KM-952 (2) Note:   Crankshaft belt pulley (4) must line up with lug (3) on timing case – Turn crankshaft uniformly until KM-952 engages

45.   Insert KM-953 (1) Note:   KM-953 must engage in camshaft groove 46.   Remove KM-953

47.   Lock chain tensioner •   Remove closure bolt (1) •   Load intake camshaft in direction of arrow via hexagonal section using an open-ended spanner •   Insert KM-955-1 (2)

48.   Remove sliding rail (1) •   Unscrew 2 bolts 49.   Detach camshaft sprockets •   Unscrew 2 bolts (2) – Counterhold camshafts at hexagonal section (3) •   Remove phase sensor disc

50.   Remove cylinder head bolts Note:   Undo bolts in order shown •   Unscrew 10 bolts – Loosen bolts (90°) – Loosen bolts (180°) 51.   Remove cylinder head Note:   Second person required •   Guide chain tensioner past tensioning rail •   Place cylinder head on wooden blocks •   Remove cylinder head gasket

53.   Raise vehicle 54.   Remove con-rod bearing caps for no.2 cylinder (1) 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. •   Mark con-rods with con-rod bearing caps •   Unscrew 2 bolts •   Push piston with con-rod upwards 55.   Lower vehicle 56.   Remove piston 57.   Turn crankshaft •   Pull timing chain upwards •   Set cylinder no.3 piston to BDC 58.   Raise vehicle

59.   Remove con-rod bearing caps for no.3 cylinder (1) 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. •   Mark con-rods with con-rod bearing caps •   Unscrew 2 bolts •   Push piston with con-rod upwards 60.   Lower vehicle 61.   Remove piston 62.   Turn crankshaft 63.   Turn crankshaft •   Pull timing chain upwards •   Set cylinder no.1 piston to BDC 64.   Raise vehicle

65.   Remove con-rod bearing caps for no.1 cylinder (1) 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. •   Mark con-rods with con-rod bearing caps •   Unscrew 2 bolts •   Push piston with con-rod upwards 66.   Lower vehicle 67.   Remove piston 68.   Remove con-rod bearing shells •   Mark con-rod bearing shells Note:   Observe order

  Install

69.   Inspect components Note:   If cylinder head is to be checked and overhauled : Remove all outer attaching parts from cylinder head 70.   Insert con-rod bearing shells •   In con-rod, con-rod bearing cap •   Coat with engine oil 71.   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)

72.   Install piston for no.1 cylinder Note:   Arrow on bottom of piston points to engine timing side. Bead (1) on con-rod should face transmission side •   Coat piston and cylinder bore with engine oil •   Compress piston rings with piston ring tensioner •   Insert piston 73.   Raise vehicle

87.   Remove timing case gasket •   Cut through elastomer sealing lips (dimension I and II) from inside outwards flush to cylinder block •   Carefully bend gasket at designated break points (arrows) 88.   Clean sealing surfaces •   Cylinder block, cylinder head, timing case, exhaust manifold, oil filter housing, thermostat housing, cylinder head cover

89.   Inspect components Note:   If cylinder head is to be checked and overhauled : Remove all outer attaching parts from cylinder head •   Cylinder block, cylinder head, timing case, exhaust manifold, oil filter housing, thermostat housing, cylinder head cover 90.   Check for plane surface •   Cylinder head, cylinder block •   With straightedge, feeler gauge

91.   Replace cylinder head gasket •   Cut off protruding elastomer (dimension I) on timing case side

92.   Apply sealant (dimension I = 2 mm) Note:   Complete assembly operations within 10 minutes •   Attach cylinder head gasket – OBEN/TOP mark must point upwards.

93.   Fit timing case upper gasket (1) •   Apply sealant (dimension I = 2 mm) •   Insert 2x upper fastening bolts into timing case (arrows) Note:   Fastening screws are used to fix the upper timing case gasket in position •   Attach gasket Note:   Push on in vicinity of sealant

94.   Attach cylinder head Note:   Second person required •   Guide KM-955-1 through aperture in timing case •   Guide chain tensioner past tensioning rail •   Insert pin in guide rail 95.   Fasten cylinder head •   Replace cylinder head bolts – Screw in bolts by several threads •   Attach timing case. – Tighten 3x bolts (1) 8 Nm •   Position cylinder head by tapping with rubber mallet in direction of timing case •   Tighten 10x cylinder head bolts 25 Nm + 60° + 60° + 60° – Note tightening sequence.

96.   Install timing case fastening bolts Undo lower 3 bolts of cylinder head again (previously installed bolts) Coolant pump Tighten 4x bolts (1) 8 Nm Timing case Tighten 5x bolts (arrows) 8 Nm

97.   Adjust camshafts •   Insert KM-953 (1) – "Turn" the camshafts at hexagonal section (arrows)

98.   Attach camshaft sprockets •   Renew bolts •   Attach intake camshaft sprocket with phase sensor disc (2) – Bolt in bolt Note:   It must be possible to rotate phase sensor disk by hand •   Attach exhaust camshaft sprocket – Bolt in bolt 99.   Attach sliding rail •   Tighten 2 bolts 8 Nm 100.   Remove KM-955-1 •   Replace seal ring •   Tighten chain tensioner closure bolt 50 Nm 101.   Attach KM-954 •   Rotate phase sensor disk until KM-954 (1) can be attached to timing case

102.   Fasten camshaft sprockets Note:   Tightening torque of 10 Nm is used to secure the camshaft sprockets and the phase sensor disk •   Tighten 2x bolts (2) 10 Nm Note:   First tighten intake camshaft sprocket bolt – Counterhold camshafts at hexagonal section (1) 103.   Remove retaining tools Note:   Retaining tools must not be used for counterholding •   KM-952 , KM-953 , KM-954 104.   Fasten camshaft sprockets Note:   Second person required •   Tighten 2 bolts (2) 50 Nm + 60° Note:   First tighten intake camshaft sprocket bolt – Counterhold camshafts at hexagonal section

105.   Timing, Check •   Turn crankshaft (720°) •   Insert KM-952 •   Insert KM-953 •   Attach KM-954 106.   Remove retaining tools •   KM-952 , KM-953 , KM-954 107.   Attach cylinder head cover (1) •   Renew gasket (2) and seal rings •   Apply sealant (dimension I = 2 mm) Note:   Complete assembly operations within 10 minutes •   Tighten 13 bolts 8 Nm •   Attach engine vent hose – Fasten clamp

131.	Install ribbed V-belt cover Note:   With "ECO" model variant - install lower engine compartment cover •   Tighten 3 bolts •   Install clip