Vauxhall Workshop Service and Repair Manuals

Remove and refit timing case (Z 10 XE, Z 10 XEP, with air conditioning, LHD)

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

  Remove

3.   Drain coolant Note:   With model variant "ECO" - remove lower engine compartment cover •   Place collecting basin underneath. •   Open drain bolt (arrow)

4.   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) •   On Z 10 XEP: Remove air intake hose – Release clamp •   Remove bolt (arrow)

5.   Detach throttle body preheater hose (1) •   Release clamp 6.   Detach heater supply hose (6) from coolant pump •   Release clamp 7.   Remove engine management wiring harness •   Disconnect 3 wiring harness plugs – oil pressure switch (3), coolant temperature sensor (4) and camshaft sensor (5) •   Unclip wiring trough (2) •   Set wiring harness to one side

8.   Remove upper radiator hose (1) •   Release 2x clamp 9.   Detach lower radiator hose (2) from coolant pump •   Release clamp

10.   Remove ignition module •   Remove ignition module cover – Move to the right •   Disconnect wiring harness plug •   Unscrew 2 bolts •   Extract using KM-6009 (1) Note:   Do not tilt 11.   Remove cylinder head cover •   Detach engine vent hose – Release clamp •   Unscrew 13x bolt 12.   Detach front right wheel •   Loosen 4 bolts 13.   Raise vehicle 14.   Remove right front wheel •   Unscrew 4 bolts 15.   Raise vehicle

16.   Remove ribbed V-belt cover Note:   With model variant "ECO" - remove lower engine compartment cover •   Unscrew 3 bolts (1) •   Remove clip (arrow)

Important:   Angular dislocations of the flexpipe as small as 5 to 10 degrees offset from the intended installation position can cause damage and subsequent complete failure of the flexpipe. 19.   Loosen exhaust system Note:   When removing the centre muffler, a catalytic converter, an exhaust manifold or an exhaust manifold with catalytic converter, the exhaust system piece remaining in the vehicle must be secured to prevent it sagging uncontrollably. The exhaust system piece with the flex pipe inside it can be fastened to the vehicle underbody with suitable materials such as wire. •   Detach oxygen sensor (catalytic converter control) wiring harness plug (1) •   Detach 2x damper rings (arrows) •   Unbolt front exhaust pipe (2) – Unscrew 3 nuts •   Suspend front exhaust pipe from left front axle body

21.   Detach alternator wiring harness (1) •   Unscrew 2x nuts •   Remove cable ties.

22.   Remove ribbed V-belt •   Tension ribbed V-belt tensioner in direction of arrow with KM-6131 •   Fit KM-6130 (2) 23.   Remove ribbed V-belt tensioner Note:   Ensure that the ribbed V-belt tensioner is positioned correctly (arrow pointing upwards). If this cannot be guaranteed the ribbed V-belt tensioner must be bled. At least 5 strokes must be performed (tensile/pressure load), whereby the load speed should be constant and the application of load even. Damage to the tensioning element must be avoided! •   Tension ribbed V-belt tensioner with KM-6131 •   Remove KM-6130 (2) •   Release ribbed V-belt tensioner •   Unscrew 2 bolts (1)

24.   Remove alternator •   Detach 2x screw connections (1)

25.   Remove oil pan •   Transmission – Unscrew 3 bolts (1) •   Crankshaft bearing bridge – Unscrew 14 bolts

26.   Attach KM-6169-2 to transmission •   Tighten 2x bolts 95 Nm

27.   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, Fig. III) •   Tighten 8 bolts

28.   Install support •   An KM-6169 – Adjust bracket (2) for support •   Screw on nut (1) 29.   Adjust supports •   Transmission side – Turn spindles until mounts (3) are positioned at 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)

30.   Loosen right engine bracket •   Loosen lower bolt (1) 31.   Lower vehicle

32.   Remove compressor Note:   The air conditioning system remains closed •   Disconnect wiring harness plug (arrow) •   Unscrew 3 bolts (1) •   Hang compressor aside 33.   Lower vehicle

34.   Remove right engine bracket •   Loosen engine damping block – Unscrew 2 bolts (1) •   Unscrew 2x bolt (arrows)

35.   Remove coolant pump ribbed V-belt pulley •   Unscrew 3 bolts 36.   Detach ribbed V-belt tensioner •   Remove bolt 37.   Detach coolant connection •   Unscrew 3 bolts

38.   Set no.1 cylinder to TDC •   Remove closure bolt for crankshaft bearing bridge (1) •   Insert KM-952 (2) Note:   Crankshaft belt pulley (4) must line up with lug (3) on timing case – Turn crankshaft uniformly until KM-952 engages

39.   Insert KM-953 (1) Note:   KM-953 must engage in camshaft groove 40.   Remove KM-953

42.   Detach crankshaft ribbed V-belt pulley (1) •   Unscrew 6 bolts •   Counterhold at crankshaft hub bolt 43.   Loosen crankshaft hub bolt Note:   Second person required •   Remove KM-952 •   Attach KM-956-1 / KM-956-2 (3) •   Counterhold KM-956-1 / KM-956-2 44.   Remove crankshaft hub (2) Note:   Pay attention to installation position •   Insert KM-952 •   Remove bolt •   Remove with KM-956-1 / KM-956-2

45.   Unscrew timing case at bottom Note:   Note dissimilar bolt lengths •   Unscrew 2x bolts (3) (M10) •   Unscrew 14x bolts (M6) (arrows) 46.   Lower vehicle 47.   Remove coolant pump Note:   Note guide bushings during removal •   Place another collecting basin underneath •   Unscrew 4 bolts (2) Note:   Note dissimilar bolt lengths 48.   Remove timing case •   Unscrew 4x bolt (1) Note:   Note dissimilar bolt lengths

49.   Remove chain drive •   Undo 2x camshaft sprocket bolts – Counterhold camshafts at hexagonal section •   Lock chain tensioner (1) – Insert KM-955-1 (2) •   Detach sliding rail (3), guide rail (5), tension rail (7) and camshaft sprockets •   Remove timing chain (4) with drive sprocket (6) •   Remove timing case gasket.

  Install

51.   Clean sealing surfaces •   Timing case, cylinder block, cylinder head, crankshaft bearing bridge, oil pan, cylinder head cover, coolant pump, thermostat housing •   If present, remove sealing compound from vicinity of cylinder head gasket 52.   Inspect components Note:   If cylinder head is to be checked and overhauled : Remove all outer attaching parts from cylinder head •   Chain drive, timing case, cylinder block, cylinder head, crankshaft bearing bridge, oil pan, cylinder head cover, coolant pump, thermostat housing 53.   When replacing components, note the different designs! Ensure the part and list numbers are correct. 54.   Replace crankshaft front seal ring (1) •   Coat sealing lips with silicon grease (white) •   Slide onto KM-960 (2) •   Drive in until flush using KM-960

55.   Replace timing case gasket •   Apply silicone sealant to joint between cylinder block and crankshaft bearing bridge Note:   Complete assembly operations within 10 minutes •   Cut off excess elastomer of cylinder head gasket (1) and replace with a 2 mm thick bead of silicone sealant (2) Note:   If no excess elastomer is present, the bead of silicone sealant can be applied directly

56.   Attach timing chain Note:   Ensure that guide sleeves are correctly seated (arrows) •   Attach KM-953 •   Renew bolts •   Fit drive sprocket (5) •   Attach exhaust camshaft sprocket – Bolt in bolt •   Install timing chain (3) •   Insert intake camshaft sprocket with phase sensor disc in timing chain – Bolt in bolt Note:   It must be possible to rotate phase sensor disk by hand

57.   Attach timing chain tension rail (6) •   Tighten bolt 20 Nm Note:   Ensure that timing chain is correctly seated 58.   Attach timing chain guide rail (4) Note:   Ensure that timing chain is correctly seated •   Tighten bolt 8 Nm 59.   Attach timing chain sliding rail (2) •   Tighten 2 bolts 8 Nm 60.   Remove KM-955-1 (1)

61.   Attach coolant pump Note:   Ensure that guide sleeves are correctly seated (arrows) •   Replace gasket (1) •   Attach using short bolts (2) •   Tighten 3x bolts 8 Nm

62.   Attach timing case. Note:   Note tightening sequence. •   Screw in 21x bolts •   Tighten 5x bolts (1) (M6) 8 Nm •   Tighten 14x bolts (2) (M6) 8 Nm •   Tighten 2x bolts (3) (M10) 35 Nm 63.   Install coolant connection •   Replace gasket •   Tighten 3x bolts 8 Nm

66.   Attach crankshaft hub (1) Note:   Note crankshaft hub installation position - mark must point upwards •   Replace bolt 67.   Tighten crankshaft hub bolt Note:   Second person required •   Counterhold with KM-956-1 / KM-956-2 (2) •   Tighten bolt 150 Nm + 45° •   Detach KM-956-1 / KM-956-2 68.   Attach crankshaft ribbed V-belt pulley •   Tighten 6x bolts 8 Nm •   Counterhold at crankshaft hub bolt

71.   Attach KM-954 (1) •   Rotate phase sensor disk (2) until KM-954 can be attached to timing case

72.   Fasten camshaft sprockets Note:   First tighten intake camshaft sprocket bolt •   Tighten 2x bolts (2) 10 Nm Note:   Tightening torque of 10 Nm is used to secure the camshaft sprockets and the phase sensor disk – Counterhold camshafts at hexagonal section (1) 73.   Remove retaining tools Note:   Retaining tools must not be used for counterholding •   KM-952 , KM-953 , KM-954 74.   Fasten camshaft sprockets Note:   Second person required •   Tighten bolts 50 Nm + 60° Note:   First tighten intake camshaft sprocket bolt – Counterhold camshafts at hexagonal section

94.	Install ribbed V-belt cover Note:   With "ECO" model variant - install lower engine compartment cover •   Tighten 3 bolts •   Install clip

99.   Attach cylinder head cover (1) Note:   Complete assembly operations within 10 minutes •   Replace gasket (2) •   Apply sealant (dimension I = 2 mm) •   Tighten 13 bolts 8 Nm •   Attach engine vent hose 100.   Install ignition module •   Unscrew KM-6009 •   Tighten 2 bolts 8 Nm •   Connect wiring harness plug •   Fit ignition module cover 101.   Connect wiring harness for engine management •   Route wiring harness •   Clip-in wiring trough •   Connect 3 wiring harness plugs 102.   Connect lower radiator hose •   Fasten clamp 103.   Install upper radiator hose •   Secure 2x clamp 104.   Attach heater supply hose •   Fasten clamp 105.   Attach preheater hose for throttle body •   Fasten clamp

108.	Fill and bleed cooling system