Vauxhall Workshop Service and Repair Manuals

Replace valve stem seal (Z 12 XE, Z 12 XEP, Z 14 XEP, with air conditioning, LHD)

  Remove

2.   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)

3.   Remove wiring harness for engine management •   Disconnect 4 wiring harness plugs – Oil pressure switch (2), coolant temperature sensor (3), camshaft sensor (4) and ignition module (1) •   Unclip wiring trough (5) •   Set wiring harness to one side

4.   Remove ignition module •   Remove ignition module cover – Move to the right •   Unscrew 2 bolts •   Extract using KM-6009 (1) Note:   Do not tilt 5.   Remove cylinder head cover •   Detach 2 engine vent hoses •   Unscrew 13x bolt 6.   Raise vehicle

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

8.   Make guide mark on crankshaft belt pulley (arrow) •   180° offset to no.1 cylinder TDC mark

9.   Remove closure bolt for crankshaft bearing bridge (1) 10.   Lower vehicle 11.   Set no.1 cylinder to TDC •   Insert KM-952 (2) •   Turn crankshaft uniformly until KM-952 engages – Mark on crankshaft belt pulley (4) must line up with lug (3) on timing case

12.   Insert KM-953 (1) •   KM-953 must engage in camshaft groove •   Remove KM-953

13.   Lock crankshaft •   5. Engage gear •   Apply parking brake – Wheels must be in contact with ground •   Remove KM-952

14.   Lock chain tensioner •   Unscrew closure bolt (1) •   Load intake camshaft in direction of arrow via hexagonal section using an open-ended spanner •   Insert KM-955-1 (2)

15.   Remove sliding rail (1) •   Unscrew 2 bolts 16.   Detach camshaft sprockets •   Unscrew 2 bolts (2) – Counterhold camshafts at hexagonal section (3) •   Remove phase sensor disc

17.   Remove exhaust camshaft •   Remove camshaft bearing cap – Note identification •   Release camshaft bearing cap working in inward spiral from outside in steps of 1/2 to 1 turn – Camshaft must be evenly released from the bearing seats 18.   Remove intake camshaft •   Remove camshaft bearing cap – Note identification •   Release camshaft bearing cap working in inward spiral from outside in steps of 1/2 to 1 turn – Camshaft must be evenly released from the bearing seats

19.   Remove 16x roller cam follower Note:   Observe allocation. 20.   Unscrew 4x spark plugs with KM-194-E

21.   Complete automatic valve spring compressor •   Adjust supports – Position support heads (1) in centre of support bases (2) and tighten •   Complete lever arm – Using joint, removal head •   Insert assembly head MKM-6086-200 Note:   Comply with manufacturer's instructions – Insert thrust piece -5a (3)

22.   Attach automatic valve spring compressor •   Attach supports (1) – Insert installation shaft in supports – Line up assembly shaft in central position above spark plug hole – Tighten 4 bolts •   Install Lever Arm (2) Note:   Removal head must point to intake side •   Secure installation shaft – Tighten 2 bolts 23.   Install compressed air adapter •   Screw into spark plug thread of 1st cylinder •   Apply compressed air to 1st cylinder

24.   Remove 2x cylinder no.1 intake valve springs •   Carefully push valve spring down with lever arm (1) – Removal head (2) must be vertically above the valve stem •   Remove valve keepers Important:   Observe allocation. •   Remove valve head, valve spring Note:   Do not use magnetised tools

25.   Replace 2x valve stem seals •   Remove using KM-840 •   Attach new valve stem seal to valve stem •   Drive in to stop using KM-958

26.   Install intake valve springs for cylinder no.1 •   Insert valve spring, valve head •   Insert valve keepers in assembly head MKM-6068-200 (1) – Push plastic clamping sleeve (2) towards lever arm mounting – Insert valve keepers with taper facing the valve – Push plastic clamping sleeve towards valve

27.   Install valve keepers •   Attach assembly head (1) to lever arm Important:   Assembly head must be vertically above the valve stem. Valve keepers (2) must audibly engage. •   Carefully push valve spring down with lever arm (arrow) Important:   Do not make 2nd attempt without checking that both valve keepers are in the assembly head 28.   Check installation position •   Check seat of valve keepers •   Ensure that pressure is being applied

  Install

55.   Insert roller cam follower Note:   Observe allocation. •   Coat sliding surfaces with MoS2 lubricating paste 56.   Install intake camshaft •   Coat sliding surfaces with MoS2 lubricating paste •   Insert camshaft, camshaft bearing cap Note:   Observe installation position and allocations •   Install camshaft bearing cap – Tighten camshaft bearing caps in stages in spiral pattern from inside to outside 8 Nm 57.   Install exhaust camshaft •   Coat sliding surfaces with MoS2 lubricating paste •   Insert camshaft, camshaft bearing cap Note:   Observe installation position and allocations •   Install camshaft bearing cap – Tighten camshaft bearing caps in stages in spiral pattern from inside to outside 8 Nm

58.   Adjust camshafts •   Insert KM-953 (1) – "Turn" the camshafts at hexagonal section (arrows)

59.   Attach camshaft sprockets •   Renew bolts •   Attach intake camshaft sprocket with phase sensor disc (2) Note:   It must be possible to rotate phase sensor disk by hand – Bolt in bolt •   Attach exhaust camshaft sprocket – Bolt in bolt 60.   Attach sliding rail •   Tighten 2 bolts 61.   Remove KM-955-1 •   Replace seal ring •   Tighten chain tensioner closure bolt 50 Nm 62.   Attach KM-954 Note:   Rotate phase sensor disk (2) until KM-954 (1) can be attached to timing case

63.   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) 64.   Remove retaining tools Note:   Retaining tools must not be used for counterholding •   KM-952 , KM-953 , KM-954 65.   Fasten camshaft sprockets Note:   Second person required •   Tighten 2 bolts 50 Nm + 60° Note:   First tighten intake camshaft sprocket bolt – Counterhold camshafts at hexagonal section 66.   Timing, Check •   Turn crankshaft (720°) •   Insert KM-952 •   Insert KM-953 •   Insert KM-954 67.   Remove retaining tools •   KM-952 , KM-953 , KM-954 68.   Raise vehicle 69.   Attach closure bolt of crankshaft bearing bridge •   Replace seal ring •   Tighten bolt 60 Nm 70.   Install ribbed V-belt cover •   Tighten 3 bolts •   Install clip 71.   Lower vehicle

72.   Attach cylinder head cover (1) •   Renew gasket (2) and seal rings •   Apply sealant (dimension l = 2 mm) Note:   Complete assembly operations within 10 minutes •   Tighten 13 bolts 8 Nm •   Attach engine vent hose 73.   Install ignition module •   Unscrew KM-6009 •   Tighten 2 bolts •   Attach ignition module cover 74.   Install engine management wiring harness •   Route wiring harness •   Clip-in wiring trough •   Connect 4 engine management wiring harness plugs