Vauxhall Workshop Service and Repair Manuals

Engine maintenance using a section engine

Warning:   When working on the Common Rail system, wait for one minute after switching off the engine. The system reduces the pressure automatically.

Important:   When working on the fuel system, pay strict attention to cleanliness as even the smallest particle of dirt may lead to malfunctions in engine operation or the fuel system. Seal opened fuel connections with suitable closure plugs 1) . Closure plugs are intended for single use.

  Remove

3.   Detach starter •   Detach 2x wiring harness – Unscrew 2x nuts •   Unscrew 2x bolts (1)

4.	Remove thrust plate with clutch disc

5.   Lock crankshaft •   Insert EN-46778 (1) through flywheel (2) into cylinder block

9.   Remove transmission bracket (2) •   Detach from cylinder block base plate – Unscrew 4x bolts (1) Note:   Note different bolt lengths!

10.   Remove oil pan (2) •   Unscrew 13x bolts •   Unscrew 2x nuts Note:   Carefully detach oil pan (2) from cylinder block base plate using KM-J-37228 (1).

Important:   After detaching the pressure lines, seal the openings of the injectors, the high-pressure pump and the accumulator using protective caps (select suitable protective caps from the spare parts catalogue). 16.   Detach high pressure lines •   Detach 4x high pressure line (1) from accumulator to injector – Unscrew 8x union nut •   Remove high pressure line (2) from high pressure pump to accumulator – Unscrew 2x union nut •   Unclip oil leak line (3)

17.   Remove accumulator (2) with accumulator bracket •   Disconnect 2x wiring harness plug (1) and (3) •   Deatch fuel return line (high pressure to accumulator) from connection (5) – Release clamp •   Detach oil leak line from connection (6) •   Unscrew 3x bolts (7) Note:   Remove engine transport tab. •   Detach fuel return line from connection (4) – Undo quick-release fitting with KM-796-A – Seal with KM-807

18.   Deatch EGR valve (1) with EGR cooler •   Detach EGR pipe from intake manifold – Release clamp •   Detach coolant hose from thermostat housing – Release clamp •   Unscrew 2x bolts

19.   Detach oil dipstick guide tube (1) with oil dipstick (2) •   Unscrew bolt (3)

20.   Detach oil separator (1) for engine ventilation •   Detach engine vent hose from timing case – Release clamp – Unclip from bracket •   Detach engine vent hose from flange – Release clamp •   Unscrew 2x bolts

21.   Detach exhaust port for cylinder block ventilation (1) •   Unscrew 6x bolts

22.   Detach coolant feed pipe (1) •   Detach from heat exchanger – Unscrew 2x bolts •   Detach from cylinder block – Unscrew bolt •   Unclip 2x wiring harness bracket •   Detach coolant hose – Release clamp

23.   Detach thermostat housing (1) from cylinder head •   Unscrew 2x bolts

24.   Remove coolant pipe (1) •   Unscrew 2x bolts (2) •   Release clamp

25.   Detach oil filter housing (1) •   Unscrew 4x bolts

26.   Remove crankshaft sensor (1) •   Unscrew bolt

27.   Remove right engine damping block adapter (1) •   Unscrew 4x bolts

28.	Remove ribbed V-belt tensioner

29.   Remove torsional vibration damper (1) •   Unscrew 4x bolts Note:   Counterhold against bolt, torsional vibration damper flange (2).

30.   Remove coolant pump (1) •   Unscrew 4x nuts

31.   Detach torsional vibration damper flange Note:   Left-handed thread •   Unscrew bolt (1) – Counterhold with KM-662-C (2) – Tighten 2x bolts

32.   Remove timing case •   Detach engine vent hose (2) from timing case – Release clamp •   Unscrew 15x bolts (arrows) •   Unscrew 3x nuts (1) •   Remove gasket

33.   Remove 2x closure bolt from camshaft housing

35.   Lock camshafts •   Screw in 2x camshaft reference drift EN-46781 (1) •   Ensure correct installation position Note:   Fixing for reference drift must be installed in the horizontal position. To do this, apply marking to reference drift as an aid (arrows). •   Turn camshafts at camshaft drive gear bolt back and forth until EN-46781 engages in both camshafts

36.   Detach timing chain tensioner •   Apply tension to chain tensioner, lock in pre-tensioned position with KM-955 •   Unscrew 2x bolts (2)

39.   Slacken camshaft drive gear •   Unscrew bolt •   Counterhold with KM-6347 (1) and KM-956-1 (2) on camshaft drive gear

41.   Detach timing chain oil spray nozzle (1) •   Unscrew 2x bolts (2)

42.   Remove oil leak line (1) •   Release 4x clamp (2) in direction of arrow

43.   Remove injectors •   Detach 2x injector bracket (3) – Unscrew 2x nuts (1) Note:   Injectors (2) can only be removed in pairs (cylinder 1 and 2 or 3 and 4) with bracket. •   Remove 4x seal rings

44.   Detach camshaft housing (3) •   Unscrew 16x bolt (2) Note:   Note different bolt lengths! •   Unscrew 2x stud bolt (1) •   Remove gasket (4)

45.   Remove 16x roller cam followers (1) with hydraulic valve lifters (2) Note:   Set aside in the order removed!

46.   Remove 2x camshaft housing centring pin (1)

47.   Slacken cylinder head •   Unscrew 10x bolt Note:   Undo bolts in order shown.

  Install

54.   Place rear crankshaft seal ring on EN-46777-10 •   Insert EN-46777-10 (1) •   Push crankshaft seal ring (3) over EN-46777-10 •   Remove EN-46777-10

55.   Install rear crankshaft seal ring (1) with EN-46777-10 (2)

57.   Cylinder Block, Check for Plane Surface •   Check cylinder block with straightedge and feeler gauge on the sealing surfaces for distortion along their length and diagonals

58.   Adjust TDC combustion stroke - cylinder 1 •   Insert MKM-571-B (1) in KM-301 (2) •   Place KM-301 with MKM-571-B on cylinder block •   Place probe of MKM-571-B on piston head •   Set dial to zero – Note pre-tension! •   Turn engine in direction of rotation Note:   Determine highest point of cylinder 1 by turning the crankshaft. 59.   Measure piston projection •   Place probe of MKM-571-B on cylinder block •   Set dial to zero Note:   Note pre-tension! – Determine highest point by turning the crankshaft •   Measure piston projection – Measure on all 4 pistons – Perform measurements at two different points (3 and 4) or )5 and 6)

60.   Lock crankshaft •   Insert EN-46778 (1) through flywheel (2) into cylinder block

61.   Cylinder Head, Check for Plane Surface •   Check cylinder head with straightedge and feeler gauge on the sealing surfaces for sag along their length and in the diagonals for distortion •   Maximum sag is 0.10 mm 62.   Measure height of cylinder head •   Sealing surface to sealing surface •   Measurement I: = 105.45 - 105.55 mm

66.   Align cylinder head •   Align cylinder head (2) with cylinder block (3) using a straightedge (1)

67.   Fasten cylinder head •   Tighten 10x cylinder head bolt 40 Nm + 90° + 90° Note:   Note correct tightening sequence!

70.   Align camshaft housing (1) •   Align with cylinder head using straightedge (2)

71.   Tighten camshaft housing •   Tighten 2x stud bolt (M8) (2) and (11) 25 Nm •   Tighten 16x bolt (M7) 18 Nm Note:   Note longer bolt lengths (14). Note correct tightening sequence!

72.   Clean 4x injector seat with EN-47632 •   Loosen dirt with the brush side (1) •   Remove dirt with the sponge side (2)

73.   Install 4x injector •   Replace 4x injector shaft seal ring •   Replace 4x injector seal ring (1) •   Tighten 2x nut 20 Nm

Important:   The timing case must be fitted within 10 minutes of applying the silicone sealing compound! 81.   Insert timing case gasket •   Apply silicone sealant to the transitions between the cylinder head and camshaft housing (1) and the cylinder block and cylinder head (2) Note:   Select a suitable silicone sealing compound from the spare parts catalogue.

82.   Attach timing case. •   Centre timing case with EN-46775 (1) – Screw in 2x nut (2) – Tighten 14x bolt 9 Nm – Tighten 3x nuts 9 Nm •   Remove EN-46775 •   Attach engine vent hose to timing case – Fasten clamp

83.   Install front crankshaft seal ring with EN-46776 (1)

92.	Attach ribbed V-belt tensioner

110.   Apply sealing compound Note:   Apply a bead of silicone sealant on the sealing surface of the oil pan. Note:   Select a suitable silicone sealing compound from the spare parts catalogue.

115.	Install thrust plate with clutch disc