Vauxhall Workshop Service and Repair Manuals

Remove and install all pistons with con-rods (Z 14 XE, Z 16 YNG with air conditioning, RHD)

Warning:   When using vehicles running on natural gas, observe the particular procedures and method of use, warning instructions and safety regulations.

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.

3.   Drain coolant •   Place collecting basin underneath. •   Open drain bolt (arrow)

5.   Remove air cleaner housing (1) •   Disconnect wiring harness plug – Intake air temperature sensor (4), tank vent valve (2) •   Unclip tank vent valve •   Remove air intake pipe – From throttle valve module •   Detach engine vent hose (5) •   Remove air intake hose •   Remove bolt (3)

6.   Remove ignition module •   Disconnect wiring harness plug •   Remove 4 bolts Important:   Do not tilt •   Extract using KM-6009 (1)

8.   Remove coolant temperature sensor wiring harness plug (arrow) •   Release from rear of toothed belt cover

9.   Remove cylinder head cover •   Detach engine vent hose – 2 off •   Disconnect wiring harness plug for mixture regulating heated oxygen sensor – Unclip cable •   Remove 10 bolts •   Remove seal

10.   Remove catalytic converter control oxygen sensor wiring harness plug •   Disconnect wiring harness plug •   Remove from bracket

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

18.   Remove ribbed V-belt •   Tension ribbed V-belt tensioner in direction of arrow – Using KM-913-A (2) (SW 15) •   Use KM-6130 (1) •   Mark running direction.

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

20.   Detach crankshaft ribbed V-belt pulley •   Lever out front closure plug – From oil pan •   Use KM-911 •   Remove bolt •   Remove KM-911

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

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

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

27.   Attach KM-6169-3 •   Tighten bolts 95 Nm

28.   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, Illus. III). •   Tighten bolts

29.   Install support •   An KM-6169 – Adjust bracket (2) for support •   Screw on nut (1) 30.   Adjust supports •   Transmission side Note:   Turn spindles until mounts (3) are positioned at the 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)

32.   Remove right engine damping block •   Loosen engine bracket adapter – Remove 2 bolts (1) •   Loosen engine damping block – Remove 2 bolts (2) 33.   Remove upper part of toothed belt cover •   Remove 3 bolts (arrows) •   Unclip from rear toothed belt cover

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

36.   Set 1st cylinder to TDC of combustion stroke •   Install crankshaft V-belt pulley bolt •   Set crankshaft to mark. – Turn crankshaft evenly Note:   Marks on drive gear toothed belt 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) – Use KM-852 (II) 37.   Remove toothed belt •   Release toothed belt tension roller (IV) Note:   Mark running direction. – 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.

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

39.   Remove intake side toothed belt guide roller •   Remove bolt (1) 40.   Remove exhaust side toothed belt guide roller •   Remove bolt (2) 41.   Remove right engine bracket (3) •   Remove 3 bolts 42.   Remove toothed belt tension roller •   Remove bolt (4)

44.   Remove rear of toothed belt cover •   Remove 4 bolts (arrows)

45.   Remove alternator shackle (1) •   Remove 3 bolts •   Swing alternator backwards.

46.   Reduce fuel pressure Important:   Observe safety measures and national legislation. •   With KM-J-34730-91 •   Unscrew test connection protective cap •   To fuel manifold pipe

48.   Remove wiring harness for engine management •   Disconnect wiring harness plug – Throttle body module (2), knock sensor (1), intake pipe pressure sensor (3), exhaust recirculation valve (4), engine control unit (5), combination plug (6) •   Remove ground cable (7) •   Remove cable ties.

49.   Remove fuel distributor pipe •   Remove 2 bolts (arrows) •   Remove wiring harness for engine management together with injectors

50.   Remove intake manifold •   Remove brake servo vacuum line (3) •   Unclip wiring harness (1) •   Remove tank vent valve line (2) •   Remove 5 bolts (arrows)

52.   Detach coolant hoses •   2 off (arrows)

53.   Remove engine vent flange •   From engine control unit bracket

54.   Remove heated oxygen sensor for mixture regulation •   Using KM-6179 (1)

56.   Remove exhaust manifold •   Remove 9 nuts •   Remove gasket.

57.   Remove cylinder head bolts •   Remove 10 bolts Note:   Undo bolts in order shown. – Loosen bolts (90°) – Loosen bolts (180°)

60.   Remove con-rod bearing cap Note:   Observe cylinder order. •   Cylinder 2, cylinder 3 •   Mark con-rods with con-rod bearing caps •   Remove 4 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. •   Push piston with con-rod upwards

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 •   Coat piston and cylinder bores with engine oil – Cylinder 1, cylinder 4 Important:   Arrow (1) on bottom of piston points to engine timing side. Bead (2) on con-rod should face transmission side •   Compress piston rings with piston ring tensioner •   Insert piston

82.   Check for plane surface •   Cylinder head, cylinder block •   With straightedge, feeler gauge •   Measure cylinder head height – Sealing surface to sealing surface 134.90 - 135.10 mm (I)

86.   Fasten cylinder head •   Replace cylinder head bolts – Screw in bolts by several threads •   Tighten cylinder head bolts ( 25 Nm + 90°+ 90°+ 90° + 45° ) Note:   Note tightening sequence.

100.   Install toothed belt tension roller Important:   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.

101.   Install right engine bracket •   Renew bolts •   Insert bolts with locking compound (red) •   Tighten bolts ( 65 Nm + 45° - 60° ) Note:   The rotating angle to be applied must be set by eye. •   Note tightening sequence (1 - 3).

106.   Fix camshaft sprockets in position. Note:   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 107.   Lock crankshaft •   Set crankshaft to mark. – Turn crankshaft evenly Note:   Marks on drive gear toothed belt and rear toothed belt cover must align (III).

108.   Install toothed belt Note:   Pay attention to direction of travel and timing marks. •   Position toothed belt Note:   Tensioned side must be taut (I).

109.   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)

111.   Timing, Check •   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). •   Use KM-852 (II) Note:   Marks must be opposite one another and aligned with the top edge of the cylinder head (I)

113.   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 114.   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

126.   Install oil pan •   Apply sealant Important:   Complete installation work within 10 minutes •   Screw in bolts •   At cylinder block – Tighten bolts 10 Nm •   At oil pump – Tighten bolts 10 Nm •   On transmission – Tighten bolts 40 Nm •   Insert rear closure plug

137.   Install cylinder head cover •   Replace gasket •   Apply sealant (1) Important:   Complete installation work within 10 minutes •   Tighten bolts 8 Nm •   Attach engine vent hose – 2 off •   Connect cable harness plug of oxygen sensor, mixture regulation, heated