Vauxhall Workshop Service and Repair Manuals

Remove and install cylinder head (Z 10 XE, Z 10 XEP, with 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

15.   Detach catalytic converter from bracket Note:   Only necessary for version with sheet metal manifold •   Unscrew 2x bolts (1)

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. 16.   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)

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

20.   Remove compressor Note:   The air conditioning system remains closed •   Disconnect wiring harness plug (arrow) •   Unscrew 3 bolts (1) •   Suspend compressor

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

22.   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

23.   Install support •   An KM-6169 – Adjust bracket (2) for support •   Screw on nut (1) 24.   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)

25.   Loosen right engine bracket •   Loosen lower bolt (1) 26.   Lower vehicle

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

28.   Remove heated oxygen sensor for mixture regulation •   Disconnect wiring harness plug •   Unscrew carefully using KM-6129 (1) 29.   Detach left engine transport shackle (2) •   Remove bolt 30.   Remove exhaust manifold heat shield •   Unscrew 2 bolts

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

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

35.   Remove right engine bracket •   Remove right engine damping block – Unscrew 2 bolts (1) •   Remove engine bracket – Unscrew 2 bolts (arrows) 36.   Remove ribbed V-belt Note:   Mark running direction.

37.   Remove coolant pump ribbed V-belt pulley •   Unscrew 3 bolts 38.   Detach coolant connection •   Unscrew 3 bolts

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

40.   Remove ignition module •   Remove ignition module cover – Move to the right •   Unscrew 2 bolts •   Extract using KM-6009 (1) Note:   Do not tilt 41.   Remove cylinder head cover •   Detach engine vent hose – Release clamp •   Unscrew 13x bolt

42.   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

43.   Insert KM-953 (1) Note:   KM-953 must engage in camshaft groove 44.   Remove KM-953

45.   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)

46.   Remove sliding rail (1) •   Unscrew 2 bolts 47.   Detach camshaft sprockets •   Unscrew 2 bolts (2) – Counterhold camshafts at hexagonal section (3) •   Remove phase sensor disc

48.   Remove cylinder head bolts Note:   Undo bolts in order shown •   Unscrew 10 bolts – Loosen bolts (90°) – Loosen bolts (180°) 49.   Remove cylinder head Note:   Second person required •   Guide chain tensioner past tensioning rail •   Place cylinder head on wooden blocks •   Remove cylinder head gasket

  Install

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

52.   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 53.   Check for plane surface •   Cylinder head, cylinder block •   With straightedge, feeler gauge

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

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

56.   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

57.   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 58.   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.

59.   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

60.   55. Adjust camshafts 61.   @ Insert KM-953 (1) "Turn" the camshafts at hexagonal section (arrows)

62.   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 63.   Attach sliding rail •   Tighten 2 bolts 8 Nm 64.   Remove KM-955-1 •   Replace seal ring •   Tighten chain tensioner closure bolt 50 Nm 65.   Attach KM-954 •   Rotate phase sensor disk until KM-954 (1) can be attached to timing case

66.   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) 67.   Remove retaining tools Note:   Retaining tools must not be used for counterholding •   KM-952 , KM-953 , KM-954 68.   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

69.   Timing, Check •   Turn crankshaft (720°) •   Insert KM-952 •   Insert KM-953 •   Attach KM-954 70.   Remove retaining tools •   KM-952 , KM-953 , KM-954 71.   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

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