Vauxhall Workshop Service and Repair Manuals

Remove and install all pistons with con-rods (Z 12 XE, Z 12 XEP, Z 14 XEP, with air conditioning, LHD)

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

  Remove

1.   Open bonnet 2.   Disconnect battery Note:   On vehicles as of model year 04 with ESP - the steering angle sensor loses its basic adjustment each time the battery is disconnected. It must be recalibrated. •   Detach ground cable 3.   Remove oil filter housing cover 4.   Release upper front panelling •   Unscrew 3 bolts (1) 5.   Raise vehicle

6.   Release lower front panelling •   Disconnect wiring harness connector. •   Remove 3 clips (2) •   Unscrew 4x bolt (1) •   Unscrew 2x nut (3) 7.   Detach front panelling Note:   Second person required •   Remove and close the hose – high-pressure – Headlamp washer system 8.   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. 9.   Loosen exhaust system Note:   When removing the centre muffler, a catalytic converter, an exhaust manifold or 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) •   Detach front exhaust pipe (2) – Unscrew 3 nuts •   Suspend front exhaust pipe from left front axle body 10.   Drain engine oil •   Place collecting basin underneath. •   Remove drain bolt

11.   Unclip engine management wiring harness from intake manifold •   2 clips (arrows)

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

13.   Remove ribbed V-belt •   Tension ribbed V-belt tensioner in direction of arrow with KM-6131 •   Use KM-6130 (1) •   Remove ribbed V-belt from compressor ribbed V-belt pulley

14.   Install engine oil drain bolt •   Replace seal ring •   Tighten bolt 10 Nm 15.   Remove oil pan •   Transmission – Unscrew 3 bolts (1) •   Crankshaft bearing bridge – Unscrew 16 bolts

16.   If present: detach oil baffle plate •   Unscrew 8 bolts

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

18.   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

19.   Install support •   An KM-6169 – Adjust bracket (2) for support •   Screw on nut (1) 20.   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)

21.   Loosen right engine bracket •   Loosen lower bolt (1) 22.   Lower vehicle

23.   Drain coolant •   Place collecting basin underneath. •   Open drain bolt (arrow) 24.   Lower vehicle

25.   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) •   For Z 12 XEP, Z 14 XEP: detach air intake hose – Release clamp •   Remove bolt (arrow)

26.   Remove throttle body preheater hoses (1) •   Detach from throttle valve pipe, coolant pump – Release 2x clamp 27.   Detach heater supply hose (2) from coolant pump •   Release clamp •   Lay hose aside 28.   Detach heater return hose from exhaust gas recirculation coolant flange •   Unclip wiring harness •   Lay hose aside

Important:   Observe safety precautions and national regulations 31.   Reduce fuel pressure •   Unscrew test connection protective cap (2) Note:   Test connection is on top of fuel rail in Z 10 XEP •   Attach KM-J-34730-91 to fuel rail (1)

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

33.   Detach intake pipe (1) •   Remove bolt (2) •   Pull suction pipe from bracket

35.   Detach upper coolant hose (2) from coolant connection •   Release clamp 36.   Detach coolant connection (1) •   Unscrew 3 bolts

37.   Remove right engine bracket •   Remove right engine damping block – Unscrew 2 bolts (2) •   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 (1)

40.   Remove wiring harness for engine management •   For Z 12 XEP, Z 14 XEP: remove fuel rail cover – Unscrew 2 bolts •   Disconnect 12 wiring harness plugs – Oil pressure switch (5), coolant temperature sensor (6), camshaft sensor (1), injectors (2), throttle valve adjuster (3), engine control unit (7), combination plug (8), exhaust gas recirculation valve (9), ignition module (4) •   Detach 3 ground cables (arrows) •   Unclip wiring harness – 3 brackets •   Remove cable ties. •   Unclip wiring trough •   Set wiring harness to one side

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 crankshaft bearing bridge closure bolt (1) •   Insert KM-952 (2) Note:   Mark on 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 12 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 52.   Remove camshaft sprockets Note:   Mark camshaft sprockets 53.   Remove KM-952 54.   Raise vehicle

55.   Remove con-rod bearing cap 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. •   Cylinder 2, cylinder 3 Note:   Observe cylinder sequence •   Mark con-rods with con-rod bearing caps •   Unscrew 4 bolts •   Push piston with con-rod upwards 56.   Lower vehicle

60.   Remove con-rod bearing cap 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. •   Cylinder 1, cylinder 4 •   Mark con-rods with con-rod bearing caps •   Unscrew 4 bolts •   Push piston with con-rod upwards 61.   Lower vehicle 62.   Remove piston •   2 off 63.   Remove con-rod bearing shells •   Mark con-rod bearing shells Note:   Observe order

  Install

64.   Inspect components •   Crank drive, cylinder block, cylinder head, timing case, exhaust manifold, oil filter housing, thermostat housing, cylinder head cover 65.   Insert con-rod bearing shells •   In con-rod, con-rod bearing cap •   Coat with engine oil 66.   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)

67.   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 68.   Raise vehicle

73.   Attach con-rod bearing cap Note:   Bead on con-rod bearing cap faces transmission side •   Coat con-rod journal with engine oil •   Renew bolts •   Tighten 4 bolts 10 Nm + 60° + 15° (M6) – From engine number 19P13554 ( 13 Nm + 60° + 15° ) (M6.5) 74.   Lower vehicle 75.   Lock crankshaft Note:   Second person required •   Insert KM-952 •   Pull timing chain upwards •   Turn crankshaft uniformly until KM-952 engages

76.   Detach 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) 77.   Clean sealing surfaces •   Cylinder block, cylinder head, timing case, exhaust manifold, oil filter housing, thermostat housing, cylinder head cover

78.   Check for plane surface •   Cylinder head, cylinder block •   With straightedge, feeler gauge 79.   Insert camshaft sprockets

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

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

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

83.   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 84.   Fasten cylinder head •   Replace cylinder head bolts – Screw in bolts by several threads •   Attach timing case. – Tighten 3 bolts (1) 8 Nm •   Position cylinder head by tapping with rubber mallet in direction of timing case •   Tighten 12 cylinder head bolts 25 Nm + 60° + 60° + 60° – Note tightening sequence.

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

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

87.   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 88.   Attach sliding rail •   Tighten 2 bolts 8 Nm 89.   Remove KM-955-1 •   Replace seal ring •   Tighten chain tensioner closure bolt 50 Nm 90.   Attach KM-954 •   Rotate phase sensor disk until KM-954 (1) can be attached to timing case

91.   Fasten camshaft sprockets Note:   Tightening torque of 10 Nm is used to secure the camshaft sprockets and the phase sensor disk •   Tighten 2 bolts (2) 10 Nm Note:   First tighten intake camshaft sprocket bolt – Counterhold camshafts at hexagonal section (1) 92.   Remove retaining tools Note:   Retaining tools must not be used for counterholding •   KM-952 , KM-953 , KM-954 93.   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

94.   Timing, Check •   Turn crankshaft (720°) •   Insert KM-952 •   Insert KM-953 •   Attach KM-954 95.   Remove retaining tools •   KM-952 , KM-953 , KM-954 96.   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