Vauxhall Workshop Service and Repair Manuals

Engine Using A Short Block, Repair (Z 18 XE, without Air Conditioning, LHD)

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

  Remove

2.	Detach manual transmission from engine

4.   Detach alternator •   Unclip wiring harness •   Detach ground cable – Unscrew nut •   Detach alternator shackle – Unscrew bolt, stud •   Disconnect alternator wiring harness – Unscrew 2 nuts (1) – Remove cable ties.

5.   Remove wiring harness for starter •   Unscrew 2 nuts (1) •   Unclip wiring harness

7.   Remove wiring harness for engine management •   Disconnect 11x wiring harness plugs – Throttle valve module (8), engine control unit (4), knock sensor (6), combination plug (7), EGR valve (3), ignition module (2), coolant temperature sensor (arrow), camshaft sensor, mixture regulation heated oxygen sensor (1), crankshaft sensor •   Detach ground cable (5) •   Unclip wiring harness – 3 brackets •   Remove wiring trough – Unscrew from engine transport shackle

8.   Remove fuel distributor pipe •   Unscrew 2 bolts (arrows) •   Pull out fuel distributor pipe with injectors and engine management wiring harness

10.   Detach crankshaft ribbed V-belt pulley •   Block flywheel using KM-652 (1) •   Remove bolt

11.   Remove camshaft sensor (1) •   Unscrew 2 bolts (2)

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

13.   Set 1st cylinder to TDC of combustion stroke •   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) – Use KM-852 (II) 14.   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.

15.   Remove ignition module •   Unscrew 5 bolts Important:   Do not tilt •   Extract using KM-6009 (1)

17.   Detach cylinder head cover •   Unscrew 10 bolts •   Remove seal

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

19.   Remove intake side toothed belt guide roller •   Remove bolt (1) 20.   Remove exhaust side toothed belt guide roller •   Remove bolt (2) 21.   Remove right engine bracket (3) •   Unscrew 3 bolts 22.   Remove toothed belt tension roller •   Remove bolt (4)

24.   Remove rear toothed belt cover •   Unscrew 4 bolts (arrows)

26.   Detach flywheel •   Unscrew 6 bolts •   Remove KM-652 (1)

29.   Remove coolant pump •   Place another collecting basin underneath •   Unscrew 3 bolts (arrows)

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

39.   Remove oil intake pipe (1) •   Unscrew 3 bolts •   Remove seal ring

  Install

50.   Install crankshaft front seal ring •   Coat seal lip with grease •   Attach KM-6010 to crankshaft journal (1) •   Slide seal ring over KM-6010 •   Remove KM-6010 •   Install crankshaft front seal ring – With KM-6010 (4), bolt (2) and crankshaft ribbed V-belt pulley washer (3)

52.   Attach oil pan Important:   Complete installation work within 10 minutes •   Apply sealant •   Screw in 15 bolts •   At cylinder block – Tighten 12x bolts 10 Nm •   At oil pump – Tighten 3x bolts 10 Nm

58.   Check for plane surface •   cylinder head Important:   Cylinder head must not be resurfaced. •   With straightedge, feeler gauge •   Measure cylinder head height – Sealing surface to sealing surface 135.85 - 136.00 (dimension I)

61.   Fasten cylinder head •   Replace cylinder head bolts – Screw in 10x bolts •   Tighten 10 cylinder head bolts 25 Nm + 90°+ 90°+ 90° + 45° Note:   Note tightening sequence.

63.   Install coolant pump •   Coat sealing surface with silicon grease •   Replace seal ring Note:   Ensure that the lug of the oil pump (1) engages in the groove of the coolant pump •   Tighten 3x bolts (arrows) 8 Nm

68.   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.

69.   Attach right engine bracket •   Renew bolts •   Tighten 3x bolts 65 Nm + 45° + 15° •   Note tightening sequence.

74.   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 75.   Lock crankshaft •   Set crankshaft to mark. – Turn crankshaft evenly Note:   Marks on drive gear toothed belt and rear toothed belt cover must align (III).

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

77.   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)

79.   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) 80.   Remove KM-852

81.   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 82.   Check toothed belt tension •   Turn crankshaft (720°) Note:   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

89.   Attach cylinder head cover •   Replace gasket (2) Important:   Complete installation work within 10 minutes •   Apply sealant (1) •   Tighten 10x bolts 8 Nm

98.	Attach manual transmission to engine

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