Vauxhall Workshop Service and Repair Manuals

J608200 Coolant Connection, Remove and Install (Z 18 XE, with Air Conditioning, LHD)

  Remove

1.   Open bonnet 2.   Disconnect battery Note:   In vehicles from 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.   Remove engine cover. •   Unscrew oil filler pipe cap •   Unscrew 2 bolts •   Screw on oil filler pipe cap 4.   Remove air cleaner housing (1) •   Disconnect wiring harness plug – Hot film mass air flow meter (4), tank vent valve (2) •   Unclip tank vent valve •   Detach intake hose •   Detach engine vent hose (3) •   Remove bolt (arrow) 5.   Raise vehicle

6.   Remove right-hand air duct •   Unscrew 3 bolts (arrows) 7.   Remove ribbed V-belt cover •   Unscrew 3 bolts (1) •   Remove clip (2)

8.   Remove ribbed V-belt Note:   Mark running direction. •   Tension ribbed V-belt tensioner in direction of arrow with KM-913-A (2) •   Use KM-6130 (1)

9.   Remove wiring harness for engine management •   Disconnect wiring harness plug – Catalytic converter control oxygen sensor (1), oil pressure switch (2), crankshaft sensor (3) •   Unclip wiring harness – 3 brackets

10.   Release alternator •   Release alternator support – Unscrew 2 upper bolts (1) •   Release nut (2)

11.   Detach intake manifold support •   Unscrew upper bolt •   Loosen lower bolt 12.   Lower vehicle

13.   Drain coolant •   Place collecting basin underneath. •   Open drain bolt (arrow) 14.   Lower vehicle 15.   Disconnect camshaft sensor wiring harness plug •   Unclip from bracket •   Disconnect wiring harness connector.

16.   Remove alternator shackle •   Remove ground cable (1) – Unscrew nut (2) •   Unscrew studs (3) •   Unscrew 2x bolts (4, 5) •   Swing alternator backwards.

Important:   Observe safety precautions and national regulations 17.   Release fuel pressure with KM-J-34730-91 •   Unscrew protective cap of test connection on fuel distributor pipe

18.   Detach fuel line (1) from fuel distributor pipe 19.   Detach engine vent hose from cylinder head cover 20.   Pull fuel evaporation hose from throttle valve module

21.   Remove wiring harness for engine management •   Disconnect 9 wiring harness plugs – Throttle valve module (8), engine control unit (4), knock sensor (6), combination plug (7), EGR valve (3), ignition module (2), mixture regulation heated oxygen sensor (1), coolant temperature sensor (arrow) •   Detach ground cable (5) •   Remove 6x cable ties •   Remove wiring trough – Unscrew from engine transport shackle •   Set wiring harness to one side

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

23.   Release preheater line - throttle valve module (1) •   Detach preheater hose from throttle valve module •   Unscrew 2 bolts (arrows) 24.   Detach preheater return hose for throttle valve module (2) from throttle valve module 25.   Detach heating return hose (3) from intake manifold 26.   Remove right rear engine transport shackle (4) •   Remove bolt

27.   Remove intake manifold •   Unscrew 7x nuts (arrows) •   Remove brake servo vacuum line

28.   Unclip knock sensor cable from coolant pipe 29.   Detach heating supply hose (2) from coolant pipe 30.   Detach coolant hose, coolant compensation tank (3) from coolant pipe 31.   Detach lower radiator hose (1) from coolant pipe 32.   Remove coolant pipe •   Remove bolt (arrow) •   Detach from centre coolant hose

33.   Remove centre coolant hose (1) •   Detach coolant hose from coolant pump connection, coolant flange 34.   Remove coolant flange (2) •   Unscrew 2x bolt (arrows)

  Install