Vauxhall Workshop Service and Repair Manuals

J340100 Engine, Remove and Install (Z 14 XE, Z 16 YNG without AC, LHD)

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

Warning:   When using vehicles running on natural gas, observe the particular procedures and method of use, warning instructions and safety regulations. 1. Open bonnet Important:   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.

2. Disconnect battery

• Detach ground cable

3. Install steering intermediate shaft (1)

• Remove lower clamp pin (2)
• Unscrew nut (3)
• Steering in straight ahead position
• Engage steering lock
• Remove steering intermediate shaft
• Caution: Do not alter steering wheel position

4. Loosen front wheels

• Loosen 8 bolts

5. Release upper front panelling Remove 3 bolts (1)

6. Raise vehicle

7. Remove front wheels

8. Release lower front panelling Disconnect wiring harness plug Remove 3 clips (2) Remove 4 bolts (1) Remove 2 nuts (3)

9. Detach front panelling

• Note: 2 people
• Remove and close the hose – high-pressure – Headlamp washer system

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

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

12. Lower vehicle

13. Remove engine cover Unscrew oil filler pipe cap Remove 2 bolts Screw on oil filler pipe cap

14. 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)

15. Detach throttle body module preheater return hose (1) From throttle valve module

16. Detach heater fluid hoses (2)

• From heater core

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

18. Remove fuel line

• Close off fuel line

19. Unclip brake servo vacuum line (1) Side release

20. Remove catalytic converter control oxygen sensor wiring harness plug (2)

• Slide from bracket

21. Detach fuel evaporation hose From throttle valve module

22. Detach pressure line for central release (2)

• Remove cover of brake fluid reservoir
• Top up brake fluid reservoir to "MAX" marking
• Attach MKM-558-10
• Disengage retaining clip (1) with a screwdriver
• Suspend pressure line for central release
• Note: Collect escaping brake fluid
• Clamp retaining clip

23. Remove upper radiator hose (1)

24. Remove lower radiator hose (3)

• From coolant pipe

25. Detach hose for coolant compensation tank (2)

26. Remove wiring harness for engine management Disconnect wiring harness plug Combination plug (1) Lower wiring harness plug for engine control unit (2) Reversing light switch (3) Unclip wiring harness and lay aside

27. Detach engine wiring harness Remove rubber seal Lift water deflector Detach ground cable from battery. Detach battery positive cable Remove positive terminal Disconnect combination plug (1) Unclip wiring harness Close clip (arrow) Remove cable harness and lay aside

28. Attach radiator

29. Raise vehicle

30. Close coolant drain bolt

31. Detach axle shafts Remove protective caps (1) Remove split pin (2) Attach KM-468-B (4) At front wheel hub Use wheel bolts Unscrew nut (3) Hold with KM-468-B Remove discs

32. Detach tie rods From steering knuckle Remove 2 nuts Press off tie rods Use KM-507-C (1)

33. Remove pendulum From spring strut support tube Remove 2 nuts Note: Counterhold with open-ended wrench

34. Detach guide joints From steering knuckle Remove 2 nuts (1) Remove bolts

35. Press out axle shafts

• From wheel hub

36. Raise vehicle

37. Remove exhaust system. Remove silencer Release clamp Detach 3 damping rings Remove front exhaust pipe Remove 3 nuts Remove wiring harness for oxygen sensor, catalytic converter control Remove 2 cable ties

38. Remove exhaust system

• Detach exhaust system
• 2 damping rings
• Note: 2 people

39. Remove shift linkage.

• Loosen bolt (1)

40. Attach KM-6169 (1) Place left of KM-6169 onto 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

41. Install support To KM-6169 Adjust bracket (2) for support Screw on nut (1)

42. Adjust supports

• Transmission side
• Note: Turn spindles until the 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)

43. Lower vehicle

44. Remove adapter for right engine bracket Remove 2 bolts (1)

45. Remove left engine bracket adapter Remove 2 bolts (arrows)

46. Raise vehicle

47. Insert hydraulic jack Use KM-904 (1)

48. Attach KM-6168 (2)

• Apply KM-6168
• On KM-904
• Note: Lower bodywork positioning pins (3)
• Position KM-6168
• Without play under front axle body
• Note: Note centring points in front axle body

49. Detach front axle body Remove 4 bolts (arrows) Caution: The removal of the front axle body with an impulse or impact screwdriver is not permitted

50. Lower drive unit

• Note: 2 people
• Caution: Carefully lower front axle body with engine and transmission downwards out of engine compartment
• Do not damage attaching parts

51. Pull out drive unit

52. Check thread of clamping nut

• 4 off
• Caution: Before installing front axle body, the threads of the clamping nuts must be checked for free movement, replace clamping nut if necessary.

53. Push in drive unit

• Note: Secure bodywork positioning pins in upper position

54. Raise drive unit

• Note: 2 people
• Caution: Carefully move front axle body with engine and transmission upwards into the engine compartment
• Do not damage attaching parts
• Insert body positioning pins in body positioning holes

55. Attach front axle body

• Renew bolts
• Tighten bolts (90 Nm / 70 lbf. ft. + 45° + 15°.)

56. Remove hydraulic jack

57. Lower vehicle

58. Fasten left engine bracket adapter

• Renew bolts
• Tighten bolts (80 Nm / 59 lbf. ft. + 45° + 15°)

59. Attach adapter for right engine bracket

• Renew bolts
• Tighten bolts (60 Nm / 44 lbf. ft. + 30° + 15°.)

60. Release radiator

61. Raise vehicle

62. Detach supports

• Engine timing side
• Transmission side

63. Detach KM-6169

64. Install shift linkage.

65. Attach exhaust system

• Note: 2 people

66. Attach exhaust system

• Replace gasket
• Replace nuts
• Tighten nuts (25 Nm / 18 lbf. ft.)
• Install damping rings
• Attach rear muffler
• Connect oxygen sensor (catalytic converter control) cable harness plug.

67. Lower vehicle

68. Install axle shafts

69. Attach guide joints

• Replace nuts
• Tighten bolts (60 Nm / 44.5 lbf. ft.)

70. Attach pendulum.

• Replace nuts
• Tighten nuts (65 Nm / 48 lbf. ft.)
• Note: Counterhold with open-ended wrench

71. Attach tie rods

• Replace nuts
• Tighten nuts (35 Nm / 26 lbf. ft.)

72. Attach axle shafts

• Replace nuts
• Install discs
• Attach KM-468-B
• Tighten nuts (120 Nm / 89 lbf. ft.)
• Hold with KM-468-B
• Loosen nuts
• Tighten nuts (20 Nm / 15 lbf. ft. + 90°)
• Hold with KM-468-B
• Replace split pins
• Note: If necessary, turn nut back until one split pin hole aligns with the next castellated nut groove
• Install protective caps

73. Install ribbed V-belt cover

• Screw in bolts
• Install clip

74. Position front panelling

• Note: 2 people
• Install high-pressure headlamp washer hose

75. Fasten lower front panelling

• Install clips
• Tighten bolts
• Tighten nuts
• Connect wiring harness plug.

76. Attach front wheels

• Screw in bolts

77. Lower vehicle

78. Fasten upper front panelling

• Tighten bolts

79. Fasten front wheels

• Tighten bolts (110 Nm / 81 lbf. ft.)

80. Attach engine wiring harness

• Route wiring harness
• Connect wiring harness plug.
• Install positive terminal
• Attach positive cable
• Connect ground cable.
• Fasten cable harness
• Install rubber seal

81. Attach wiring harness for engine management

• Route wiring harness
• Connect wiring harness plug.
• 3 off
• Attach wiring harness

82. Attach pressure line for central release

• Note: Pressure line must engage audibly
• Detach MKM-558-10
• Bleed hydraulic clutch actuation – see operation "Hydraulic Clutch Actuation, Bleed " in group "K".
• Screw on cover of brake fluid reservoir

83. Connect lower radiator hose

84. Connect hose for coolant compensation tank

85. Install upper radiator hose

86. Connect heater fluid hoses

87. Attach preheater return hose for throttle valve module

88. Connect wiring harness plug for oxygen sensor, catalytic converter control

• Insert in bracket

89. Attach fuel line

90. Attach brake servo vacuum line

• Note: Connection must engage audibly

91. Connect fuel evaporation hose

92. Install air cleaner housing

• Tighten bolt
• Install air intake hose.
• Attach engine vent hose
• Install air intake pipe
• Clip in tank vent valve
• Connect wiring harness plug.
• 2 off

93. Install engine cover

• Unscrew oil filler pipe cap
• Insert retaining lugs
• Tighten bolts (8 Nm / 6 lbf. ft.)
• Screw on oil filler pipe cap
• Note: Note cable routing

94. Install steering intermediate shaft Note: Wheels in straight-ahead position Release steering lock Push on steering intermediate shaft Note: Bore hole for clamp bolt must be on the flat-milled side of the steering journal Insert clamp pin Replace nut (2) Adjust length compensator Fasten with KM-6181 (1) Tighten nut (22 Nm / 16 lbf. ft.) Remove KM-6181

95. Arrest transmission shift linkage

Unclip manual shift lever cover Arrest shift lever and shift lever housing Use KM-527-A (1) Engage locking pin (1) in adjustment bore in shift cover by turning shift rod to the left (direction of 3rd gear)

96. Raise vehicle

97. Fasten clamp

• Tighten bolt (12 Nm / 9 lbf. ft. + 90° + 90° to + 90° + 90° + 45°)

98. Lower vehicle

99. Check transmission shift linkage

• Detach KM-527-A
• Note: Locking pin in adjustment bore is released automatically when first shifting towards "R"
• Engage all gears
• Clip in manual shift lever cover

100. Top up coolant

• Note: Top up and bleed cooling system – see operation "Cooling System, Top Up and Bleed".
• Observe specified coolant quantity

101. Connect battery

102. Calibrate steering angle sensor

• Switch on ignition

Note:   Rotate the steering wheel one time from its right-hand to its left-hand stop.

103. Program volatile memories

104. Close bonnet