Vauxhall Workshop Service and Repair Manuals

Replace front crankshaft seal ring (Z 14 XE LHD, Z 16 YNG)

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

4.   Remove air cleaner housing (1) •   Disconnect wiring harness plug – Intake air temperature sensor (4), tank vent valve (2) •   Unclip tank vent valve •   Detach intake hose •   Detach engine vent hose (5) •   Remove bolt (3)

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

10.   Remove ribbed V-belt •   Tension ribbed V-belt tensioner in direction of arrow – Using KM-913-A (2) (SW 15) •   Use KM-6130 (1) •   Mark running direction.

11.   Remove ribbed V-belt tensioner •   Tension ribbed V-belt tensioner. •   Remove KM-6130 (2) •   Release ribbed V-belt tensioner •   Remove bolt (1)

12.   Detach crankshaft ribbed V-belt pulley •   Lever out front closure plug – From oil pan •   Use KM-911 •   Remove bolt •   Remove KM-911

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

14.   Attach KM-6169-3 •   Tighten bolts 95 Nm

15.   Attach KM-6169 (1) •   Attach KM-6169 to left of 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

16.   Install support •   An KM-6169 – Adjust bracket (2) for support •   Screw on nut (1) 17.   Adjust supports •   Transmission side Note:   Turn spindles until 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)

19.   Remove right engine damping block •   Loosen engine bracket adapter – Remove 2 bolts (1) •   Loosen engine damping block – Remove 2 bolts (2) 20.   Remove upper part of toothed belt cover •   Remove 3 bolts (arrows) •   Unclip from rear toothed belt cover

23.   Set 1st cylinder to TDC of combustion stroke •   Install crankshaft V-belt pulley bolt •   Set crankshaft to mark. – Turn crankshaft evenly Note:   Marks on drive gear toothed belt 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) 24.   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.

27.   Remove front crankshaft seal ring (1) Important:   Do not damage sealing surface. •   Lever out seal ring 28.   Clean sealing surfaces •   Oil pump 29.   Inspect components •   Ribbed V-belt, ribbed V-belt tensioner, ribbed V-belt pulleys, toothed belt drive 30.   Install front crankshaft seal ring •   Coat seal lip with grease •   Attach KM-6010 to crankshaft journal (2) •   Slide seal ring over KM-6010 •   Remove KM-6010 •   Pull in front crankshaft seal ring – With KM-6010 (4), bolt (3) and crankshaft ribbed V-belt pulley washer (5)

34.   Install toothed belt Note:   Note running direction. •   Position toothed belt Note:   Tensioned side must be taut (I).

35.   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)

37.   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) 38.   Remove KM-852

39.   Adjust toothed belt tension •   Release toothed belt tension roller – Loosen bolt •   Turn adjustment eccentric in direction of arrow (clockwise) until tension roller toothed belt pointer (1) is aligned with notch mark (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 40.   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