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Vauxhall Workshop Manuals

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Remove and install cylinder head (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:   In vehicles as of model year 04 onwards with ESP - the steering angle sensor loses its basic adjustment each time the battery is disconnected, and must be recalibrated
•   Detach ground cable
3.   Release upper front panelling
•   Unscrew 3 bolts (1)
Object Number: 2410625  Size: DEFAULT


4.   Raise vehicle
5.   Release lower front panelling
•   Disconnect wiring harness connector.
•   Remove 3 clips (2)
•   Unscrew 4x bolt (1)
•   Unscrew 2x nut (3)
6.   Detach front panelling
Note:   Second person required
•   If present: Detach and seal headlamp washer system high-pressure hose
Object Number: 2410626  Size: DEFAULT


7.   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.
8.   Detach front exhaust pipe (1) from catalytic converter
•   Unscrew 3 nuts
•   Affix the front exhaust pipe to the vehicle underbody with wire
9.   Remove ribbed V-belt cover
•   Unscrew 3 bolts (1)
•   Remove clip (arrow)
Object Number: 2410600  Size: DEFAULT


10.   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)
Object Number: 2410376  Size: DEFAULT


11.   Remove compressor
Note:   The air conditioning system remains closed
•   Disconnect wiring harness plug (arrow)
•   Unscrew 3 bolts (1)
•   Suspend compressor
Object Number: 2411030  Size: DEFAULT


12.   Unclip wiring harness for engine management
•   Open 2 clips (arrows)
Object Number: 2410392  Size: DEFAULT


13.   Attach KM-6169-2 to transmission
•   Tighten 2 bolts 95 Nm
Object Number: 2411401  Size: DEFAULT


14.   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
Object Number: 2409770  Size: DEFAULT


Object Number: 2411021  Size: DEFAULT

15.   Install support
•   An KM-6169
Adjust bracket (2) for support
•   Screw on nut (1)
16.   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)

17.   Loosen right engine bracket
•   Loosen lower bolt (1)
18.   Lower vehicle
Object Number: 2410431  Size: DEFAULT


19.   Drain coolant
•   Place collecting basin underneath.
•   Open drain bolt (arrow)
20.   Lower vehicle
Object Number: 2410656  Size: DEFAULT


21.   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)
Object Number: 2410646  Size: DEFAULT


22.   Detach throttle valve module preheater return hose (1)
•   Release clamp
23.   Remove throttle valve module preheater feed hose (1)
•   Release clamp
24.   Detach heater return hose (2) from coolant pump
•   Release clamp
•   Lay hose aside
25.   Detach heater return hose from exhaust gas recirculation coolant flange
•   Release clamp
•   Lay hose aside
Object Number: 2411033  Size: DEFAULT


26.   Detach brake servo vacuum line (4)
27.   Pull fuel evaporation hose (3) from intake manifold
Object Number: 2410606  Size: DEFAULT


Important:   Observe safety precautions and national regulations
28.   Release fuel pressure with KM-J-34730-91
•   Unscrew test connection protective cap (2) from fuel rail (1)
Note:   Test connection is on top of fuel rail in Z 12 XEP and Z 14 XEP
Object Number: 2410591  Size: DEFAULT


29.   Detach fuel rail (arrow) with KM-796-A
•   Unclip fuel line
•   Seal using KM-807
Object Number: 2410636  Size: DEFAULT


30.   Remove intake pipe (1)
•   Remove bolt (2)
•   Remove oil dipstick
Object Number: 2410640  Size: DEFAULT


31.   Remove exhaust manifold gasket or replace exhaust manifold

Remove exhaust manifold gasket

Z 12 XE, Z 14 XEP with air conditioning LUREF_1.gif

Replace exhaust manifold

Z 12 XEP, Z 14 XEP Combo

32.   Remove oil filter housing cover
33.   Remove oil filter housing (1)
•   Place another collecting basin underneath
•   Unscrew 3 bolts (2)
34.   Remove upper radiator hose
•   Release 2x clamp
Object Number: 2410647  Size: DEFAULT


35.   Detach coolant connection
•   Unscrew 3 bolts
Object Number: 2410616  Size: DEFAULT


36.   Remove right engine bracket
•   Remove right engine damping block
Unscrew 2 bolts (1)
•   Remove engine bracket
Unscrew 2 bolts (arrows)
37.   Remove ribbed V-belt
Note:   Mark running direction.
38.   Remove coolant pump ribbed V-belt pulley
•   Unscrew 3 bolts
Object Number: 2411032  Size: DEFAULT


Object Number: 2410667  Size: DEFAULT

39.   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
Open 3 brackets
•   Remove cable ties.
•   Unclip wiring trough
•   Set wiring harness to one side

40.   Remove timing case fastening bolts
•   Coolant pump
Unscrew 4x bolt (1)
•   Timing case
Unscrew 5 bolts (arrows)
Object Number: 2399514  Size: DEFAULT


41.   Remove ignition module
•   Remove ignition module cover
Move to the right
•   Unscrew 2 bolts
•   Extract using KM-6009 (1)
Note:   Do not tilt
42.   Remove cylinder head cover
•   Detach engine vent hose
Release clamp
•   Unscrew 13x bolt
Object Number: 2410639  Size: DEFAULT


Object Number: 2410668  Size: DEFAULT

43.   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

Object Number: 2410671  Size: DEFAULT

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

46.   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)
Object Number: 2399429  Size: DEFAULT


Object Number: 2399410  Size: DEFAULT

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

49.   Remove cylinder head bolts
Note:   Undo bolts in order shown
•   Unscrew 10 bolts
Loosen bolts (90°)
Loosen bolts (180°)
50.   Remove cylinder head
Note:   Second person required
•   Guide chain tensioner past tensioning rail
•   Place cylinder head on wooden blocks
•   Remove cylinder head gasket
Object Number: 2399430  Size: DEFAULT


  Install

Object Number: 2399431  Size: DEFAULT

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

53.   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
54.   Check for plane surface
•   Cylinder head, cylinder block
•   With straightedge, feeler gauge
Object Number: 2410435  Size: DEFAULT


Object Number: 2399433  Size: DEFAULT

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

Object Number: 2399434  Size: DEFAULT

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

Object Number: 2399435  Size: DEFAULT

57.   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

58.   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
59.   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.
Object Number: 2399436  Size: DEFAULT


60.   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
Object Number: 2399514  Size: DEFAULT


Object Number: 2399432  Size: DEFAULT

61.   Adjust camshafts
•   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
Object Number: 2410436  Size: DEFAULT


66.   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)
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
Object Number: 2399406  Size: DEFAULT


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
Object Number: 2410670  Size: DEFAULT


72.   Attach ignition module
•   Unscrew KM-6009
•   Tighten 2 bolts 8 Nm
•   Attach ignition module cover
73.   Attach wiring harness for engine management
•   Route wiring harness
•   Clip-in wiring trough
•   Connect wiring harness for engine management
Connect 14 wiring harness plugs
Screw on 3 ground cables
•   Fasten cable tie
•   For Z 12 XEP, Z 14 XEP: attach fuel rail cover
Tighten 2 bolts
74.   Attach coolant pump ribbed V-belt pulley
•   Screw in 3 bolts
75.   Install ribbed V-belt
Note:   Note running direction
•   Tension ribbed V-belt tensioner with KM-6131
•   Remove KM-6130
•   Release ribbed V-belt tensioner
76.   Fasten coolant pump ribbed V-belt pulley
•   Tighten 3 bolts 20 Nm
77.   Raise vehicle
78.   Fit compressor
•   Release compressor
•   Tighten 3 bolts 20 Nm
•   Connect wiring harness plug
79.   Install right engine bracket
•   Insert lower bolt
•   Tighten 2 upper bolts 60 Nm
•   Fasten engine damping block
Tighten 2 bolts 40 Nm
80.   Install coolant connection
•   Replace gasket
•   Tighten 3 bolts 8 Nm
81.   Attach upper radiator hose
•   Fasten clamp
82.   Install oil filter housing
•   Replace gasket
•   Tighten 3 bolts 20 Nm
•   Attach oil filter housing cover
Replace seal ring
Tighten cover 10 Nm
83.   Remove exhaust manifold gasket or replace exhaust manifold

Remove exhaust manifold gasket

Z 12 XE, Z 14 XEP with air conditioning LUREF_1.gif

Replace exhaust manifold

Z 12 XEP, Z 14 XEP Combo

84.   Raise vehicle
85.   Close coolant drain bolt
86.   Fasten right engine bracket
•   Tighten lower bolt 60 Nm
87.   Detach supports
•   Engine timing side
•   Transmission side
88.   detach KM-6169
89.   Detach KM-6169-2
90.   Attach closure bolt of crankshaft bearing bridge
•   Replace seal ring
•   Tighten bolt 50 Nm
91.   Fasten engine management wiring harness
•   Open 2 brackets
•   Route wiring harness
•   Close 2 brackets
92.   Install ribbed V-belt
Note:   Note running direction
•   Tension ribbed V-belt tensioner with KM-6131
•   Remove KM-955-2
•   Release ribbed V-belt tensioner
93.   Fasten coolant pump ribbed V-belt pulley
•   Tighten 3 bolts 20 Nm
94.   Attach exhaust system
•   Replace gasket
•   Replace nuts
•   Tighten 3 nuts 25 Nm
•   Install damping rings
•   Connect oxygen sensor (catalytic converter control) wiring harness plug.
95.   Install ribbed V-belt cover
•   Tighten 3 bolts
•   Install clip
96.   Lower vehicle
97.   Position front panelling
Note:   Second person required
•   Install high-pressure headlamp washer hose
98.   Fasten lower front panelling
•   Install 3 clips
•   Tighten 4 bolts
•   Tighten 2 nuts
•   Connect wiring harness plug
99.   Lower vehicle
100.   Fasten upper front panelling
•   Tighten 3 bolts
101.   Install intake pipe
•   Install in upper front
Tighten bolt
•   Insert oil dipstick
102.   Attach brake servo vacuum line
•   Connection must audibly engage
103.   Attach fuel evaporation hose
104.   Attach fuel line
•   Remove KM-807
•   Attach fuel line
Connection must audibly engage
•   Attach fuel line
105.   Attach heater return hose
106.   Attach heater supply hose
107.   Install throttle valve module preheater supply hose
108.   Attach throttle valve module preheater return hose
109.   Install air cleaner housing
•   Tighten bolt
•   Attach suction pipe
Replace seal ring
Tighten 2 nuts
•   For Z 12 XEP, Z 14 XEP: attach air intake hose
Tighten clamp 3.5 Nm
•   Attach engine vent hose
•   Clip in tank vent valve
•   Connect 2 wiring harness plugs
110.   Connect battery
111.   Calibrate steering angle sensor
•   Switch on ignition
•   Rotate the steering wheel one time from its right-hand to its left-hand stop
112.   Top up and bleed cooling system – see operation "Cooling System, Top up and Bleed"
113.   Check engine oil level and correct if necessary
114.   Program volatile memory
115.   Close bonnet

J Engine and Engine Aggregates > DOHC Petrol Engine > Cylinder Head > Repair Instructions > Remove and install cylinder head (Z 12 XE, Z 12 XEP, Z 14 XEP, with air conditioning, LHD)

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