Vauxhall Workshop Service and Repair Manuals

Repair engine using a short block (Z 14 XE without AC, LHD, Z 16 YNG)

(Engine removed and transmission detached)

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

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

4.   Detach alternator •   Unclip wiring harness (1) •   Detach alternator shackle – Remove 2 bolts •   Disconnect alternator wiring harness – Remove 2 nuts (2) – Remove cable ties.

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

8.   Remove wiring harness for engine management •   Disconnect wiring harness plug – Coolant temperature sensor (9), camshaft sensor (1), throttle body module (2), knock sensor (4), intake pipe pressure sensor (3), exhaust recirculation valve (arrow), top engine control unit (7), ignition module (6), crankshaft sensor, combination connector (8) •   Unscrew ground cable (5) •   Remove cable ties.

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

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

12.   Remove camshaft sensor (1) •   Remove 2 bolts (2)

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

14.   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) 15.   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.

16.   Remove ignition module •   Remove 4 bolts Important:   Do not tilt •   Extract using KM-6009 (1)

17.   Remove cylinder head cover •   Detach engine vent hose •   Remove 10 bolts •   Remove gasket.

18.   Remove camshaft sprockets •   Remove KM-852 •   Remove 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) •   Remove 3 bolts 22.   Remove toothed belt tension roller •   Remove bolt (4)

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

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

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

34.   Remove coolant pump •   Remove 3 bolts (arrows)

36.   Remove crankshaft sensor (arrow) •   Turn engine (180°) •   Remove bolt

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

49.   Install crankshaft front seal ring •   Coat seal lip with grease •   Attach KM-417 to crankshaft journal (1) •   Slide seal ring over KM-417 •   Remove KM-417 •   Install crankshaft front seal ring – With KM-417 (4), bolt (2) and crankshaft ribbed V-belt pulley washer (3)

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

54.   Install coolant pump •   Coat sealing surface with silicon grease •   Replace seal ring Note:   Mark on cylinder block must align with mark on coolant pump (arrow). •   Tighten bolts 8 Nm

59.   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 134.90 - 135.10 mm (Dimension I)

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

67.   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.

68.   Install right engine bracket •   Renew bolts •   Tighten bolts ( 65 Nm + 45° + 15° ) Note:   The rotating angle to be applied must be set by eye. •   Note tightening sequence.

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

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

76.   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)

78.   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.   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 81.   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

87.   Attach cylinder head cover •   Replace gasket Important:   Complete installation work within 10 minutes •   Apply sealant to sealing surfaces(1) •   Tighten bolts 8 Nm •   Attach engine vent hose