Repair Engine Using Part Engine Opel Vectra C

Important: Extreme cleanliness is important when working on the fuel system, since even minute dirt particles can cause engine or fuel system problems. Open fuel connections must be sealed with suitable sealing plugs from the Opel parts catalogue (catalogue number: 45 06 154 / part number: 9201697). Sealing plugs are determined for one-off use.

Remove

1. 1. Remove manual transmission from engine
2. 2. Remove clutch
3. 3. Detach KM-6263 • Turn rotating spindle back to its initial position • Remove the centring pin • Unscrew 4x bolt • Remove KM-6263
4. 4. Attach EN-46792 (1) • Tighten bolt
5. 5. Remove flywheel • Unscrew 6x bolt (2) • Detach EN-46792 – Remove bolt

6. 6. Remove heat shield • Unscrew 2x bolt
7. 7. Detach vacuum reservoir (1) with retaining plate • Detach 2x vacuum hoses • Unscrew 2x bolt (2) • Remove bolt (3)

Note. If fitted

8. 8. Remove cooler, exhaust gas recirculation (1) • Unscrew bolt, nut (arrows) • Detach metal pipe, EGR valve – Release clamp • Detach coolant hose – Release clamp

9. 9. Detach thermostat housing (1) • Disconnect wiring harness connector. • Unscrew 2x bolt • Remove gasket. • Detach coolant hose – Release clamp

10. 10. Detach vacuum pump (1) • Detach vacuum hose • Unscrew 3x bolt (2) • Remove gasket.

11. 11. Remove compressor • Disconnect wiring harness plug (2) • Unscrew 3x bolt (1)

12. 12. Detach compressor retaining bracket from engine block • Unscrew 4x bolt (1)

Note. Note guide bushings

Note. Remove with ribbed V-belt deflecting roller (2)

13. 13. Remove 2x holders for compressor wiring harness (2) • Unscrew 2x bolt • Set wiring harness (1) to one side

14. 14. Detach coolant pipe assembly (1) • Unscrew 6x bolt (2) • Remove gasket.

15. 15. Remove torsional vibration damper (1) • Unscrew 4x bolt

Note. Counterhold at toothed belt drive gear bolt (2)

16. 16. Detach ribbed V-belt upper guide roller (1) • Remove bolt

17. 17. Remove toothed belt cover • Unscrew 6x bolts (arrows) • Unclip 4x camshaft sensor wiring harness

18. 18. Remove engine damping block adapter (1) • Unscrew 5x bolt

Note. Note dissimilar bolt lengths

19. 19. Set cylinder 1 to ignition TDC. • Mark on camshaft sprocket (1) must align with mark on camshaft housing cover (2).

20. 20. Detach toothed belt (1) • Release toothed belt tension roller – Loosen bolt (2)

Note. Mark direction of rotation.

21. 21. Detach toothed belt tension roller • Remove bolt
22. 22. Detach vacuum line • Unscrew 2x bolt (arrows)

Important. After removing the high pressure lines, seal openings on injectors and pressure reservoir using protective caps 1)

23. 23. Remove 4x leakage oil line (2) from injectors • Unclip 2x leakage oil line (1) • Release 4x locking clips (3) on injector in direction of arrow – Detach oil leak line

Note. Leakage oil line must not be separated from fuel return vaporisation housing else it must be replaced

24. 24. Remove wiring harness (1) from engine • Detach wiring harness bracket from camshaft housing cover – Unscrew 2x bolt • Unclip 5x wiring harness • Disconnect 11x wiring harness plug – 4x injectors – Throttle valve module – EGR valve – Sensor, pressure reservoir – High pressure pump – Intake air temperature sensor – Camshaft sensor – Pressure regulator

Important. After removing the high pressure lines, seal openings on injectors and pressure reservoir using protective caps 1)

25. 25. Remove fuel return vaporizer housing (1) with leakage oil line • Unscrew 2x bolt • Remove 2x hoses – Release 2x clamp

Note. Leakage oil line must not be separated from fuel return vaporisation housing else it must be replaced

Important. After removing the high pressure lines, seal openings on injectors and pressure reservoir using protective caps 1)

26. 26. Detach high pressure line (1), pressure reservoir to high pressure pump • Unscrew 2x union nut

Important. When releasing the lock nut on the injector, counterhold at high pressure pump with open-ended wrench

Important. After removing the high pressure lines, seal openings on injectors and pressure reservoir using protective caps 1)

27. 27. Remove 4x high pressure lines from pressure reservoir to injector • Unscrew 8x lock nut (1)

Important. When releasing the lock nut, counterhold at injector with open-ended wrench

28. 28. Detach pressure reservoir (1) • Unscrew 2x nut (arrows)

29. 29. Remove 4x injectors • Unscrew 4x nut

Note. If the injectors cannot be removed manually, use KM-328-B . Fit suitable plugs 1) to removed injectors (arrows).

30. 30. Detach wiring harness, sheathed glow plug (arrows) • Disconnect 4x wiring harness plug for glow plugs • Unclip wiring harness

31. 31. Detach 4x sheathed glow plugs (1) with EN-48389

32. 32. Release high pressure pump wheel • Counterhold it with KM-6347 (1) together with KM-956-1 (2) • Unscrew nut

Note. This requires a second person

33. 33. Detach high pressure pump wheel • Attach EN-46790 (1) – Screw in 2x bolt • Remove high pressure pump drive wheel – Counterhold with open-ended wrench (2)

34. 34. Remove high pressure pump • Unscrew 3x nut (1)

35. 35. Detach high pressure pump bracket (1) • Remove coolant pipe holder from high pressure pump bracket – Remove bolt • Unscrew 6x bolt

Note. Observe different bolt lengths

36. 36. Remove intake manifold (1) • Unscrew 9x nut • Detach gasket

Note. Remove with throttle valve module and EGR valve

37. 37. Detach alternator bracket (1) • Unscrew 2x bolt (2)

Note. Observe different bolt lengths

38. 38. Detach crankshaft pulse pickup (1) • Unscrew bolts (2) with EN-47631

39. 39. Detach breather hose for cylinder head cover (1) • Release clamp
40. 40. Detach crankcase breather hose (1) • Release 2x clamp

41. 41. Detach charge air pipe bracket (1) • Remove bolt (2)

42. 42. Attach engine transport shackle. • Tighten bolt
43. 43. Suspend engine on workshop crane.
44. 44. Remove engine from KM-412 • Unscrew 8x bolt • Lower engine
45. 45. Detach KM-412-36-1 and KM-412-36-2 from the engine block. • Unscrew 7x bolt
46. 46. Unhook engine from workshop crane
47. 47. Detach engine transport shackle, • Remove bolt

Install

48. 48. Attach engine transport shackle. • Tighten bolt
49. 49. Suspend engine on workshop crane.
50. 50. Attach KM-412-36-1 and KM-412-36-2 to the engine block. • Tighten 7x bolt
51. 51. Attach engine to KM-412 • Tighten 8x bolt
52. 52. Unhook engine from workshop crane
53. 53. Detach engine transport shackle, • Remove bolt
54. 54. Install charge air pipe bracket • Tighten bolt
55. 55. Attach crankcase breather hose • Secure 2x clamp
56. 56. Attach breather hose for cylinder head cover • Fasten clamp
57. 57. Install crankshaft pulse pickup • Coat sealing ring with special grease (white) • Tighten bolt 9 Nm
58. 58. Attach alternator bracket • Tighten 2x bolt

Note. Observe different bolt lengths

59. 59. Install intake manifold • Replace gasket • Tighten 9x new nuts 25 Nm
60. 60. Attach high pressure pump bracket • Tighten 6x bolt 25 Nm • Attach coolant pipe holder to high pressure pump bracket – Tighten bolt

Note. Observe different bolt lengths

61. 61. Fit high pressure pump • Tighten 3x nuts 25 Nm
62. 62. Attach high pressure pump wheel • Screw in nut
63. 63. Fasten high pressure pump wheel • Tighten nut 50 Nm • Counterhold it with KM-6347 together with KM-956-1

Note. This requires a second person

64. 64. Attach 4x sheathed glow plugs • Tighten 4x sheathed glow plugs with EN-48389 , 8 Nm
65. 65. Attach wiring harness, sheathed glow plug • Connect 4x wiring harness plugs for glow plugs • Attach wiring harness
66. 66. Clean injector seat • To clean the injector seats, insert EN-47632 with coarse fleece into the injector shaft and roughly clean by twistiing the injector seat. Then clean with fine fleece.

67. 67. Attach 4x injectors • Detach sealing plugs • Replace 4x seal ring • Tighten 4x nut 32 Nm
68. 68. Attach pressure reservoir • Tighten 2x nut 25 Nm
69. 69. Fit 4x new high pressure lines from pressure reservoir to injector • Detach sealing plugs • Tighten 4x lock nuts (M14) 23 Nm • Tighten 4x lock nuts (M12) 23 Nm

Important. Pressure lines may only be installed once. When fastening the lock nuts, counterhold at the injector with an open-ended wrench.

70. 70. Attach new high pressure line, pressure reservoir to high pressure pump • Detach sealing plugs • Tighten lock nuts (M14) 23 Nm • Tighten lock nuts (M12) 23 Nm

Important. Pressure lines may only be installed once. When fastening the lock nuts, counterhold at the high pressure pump with an open-ended wrench.

71. 71. Install fuel return vaporizer housing with leakage oil line • Tighten 2x bolt – Attach wiring harness bracket to fuel return vaporizer housing • Attach 2x hose – Secure 2x clamp

Note. Leakage oil line must not be separated from fuel return vaporisation housing else it must be replaced

72. 72. Attach 4x leakage oil line to injectors • Detach sealing plugs • Clip 4x leakage oil line to injectors
73. 73. Attach wiring harness to engine • Clip in 5 wiring harnesses • Connect 11x wiring harness plugs – 4x injectors – Throttle valve module – EGR valve – Sensor, pressure reservoir – High pressure pump – Intake air temperature sensor – Camshaft sensor – Pressure regulator • Clip in 2x leakage oil line • Attach wiring harness bracket to camshaft housing cover – Tighten 2x bolt
74. 74. Attach vacuum line • Tighten 2x bolts 9 Nm
75. 75. Attach toothed belt tension roller • Insert tension roller in guide • Screw in bolt

Note. Insert bolt with locking compound (red). The maximum installation time including the torque check is 10 min.

76. 76. Set cylinder 1 to ignition TDC. • Mark on camshaft sprocket (1) must align with mark on camshaft housing cover (2).

77. 77. Check crankshaft position with EN-46788 • Unscrew oil pan bolt (arrow) • Tighten stud bolt (1) EN-46788 • Attach positioning disk (4) EN-46788 – Screw in bolt (3) – Screw in nut (2) • Detach positioning disk EN-46788

78. 78. Attach toothed belt • Note specified running direction • Position toothed belt

Important. Tensioned side (1) must be taut

79. 79. Tension toothed belt • Screw in bolt (6) • Tension toothed belt tension roller • Tighten bolt, toothed belt tension roller (3) 25 Nm

Note. Using a screwdriver (5) push adjusting lever in direction of arrow until pointer (4) of toothed belt tension roller is in line with mark (2).

80. 80. Check crankshaft position with EN-46788 • Attach positioning disk EN-46788 – Screw in bolt – Screw in nut • Detach positioning disk EN-46788
81. 81. Timing, Check • Rotate crankshaft 720° in direction of engine rotation • Check camshaft setting – Camshaft wheel marking must align with marking on cylinder head cover
82. 82. Check crankshaft position with EN-46788 • Attach positioning disk EN-46788 – Screw in bolt – Screw in nut • Remove positioning disk and stud bolt EN-46788 • Tighten oil pump bolt 9 Nm

Note. If EN-46788 cannot be attached, the toothed belt positioning procedure must be repeated

83. 83. Install engine damping block adapter • Tighten 3x bolts (M10) 50 Nm • Tighten 2x bolts (M8) 25 Nm

Note. Note dissimilar bolt lengths

84. 84. Fit toothed belt cover • Tighten 4 bolts (M6) 9 Nm • Tighten 2x bolts (M8) 25 Nm • Clip in 4x camshaft sensor wiring harness
85. 85. Attach ribbed V-belt upper guide roller • Tighten bolt 50 Nm
86. 86. Install torsional vibration damper • Tighten 4x bolt 25 Nm

Note. Note installation position.

Note. Counterhold at toothed belt drive gear bolt

87. 87. Attach coolant pipe assembly • Replace gasket • Tighten 6x bolt 9 Nm
88. 88. Attach 2x holders for compressor wiring harness • Tighten 2x bolt
89. 89. Attach compressor retaining bracket to engine block • Tighten 4x bolt 50 Nm

Note. Note guide bushings

90. 90. Attach compressor to compressor support • Tighten 3x bolt 22 Nm • Connect wiring harness plug
91. 91. Clean sealing surface
92. 92. Attach vacuum pump • Replace gasket • Tighten 3x bolt 20 Nm • Attach vacuum hose
93. 93. Clean sealing surface
94. 94. Attach thermostat housing • Replace seal ring • Attach coolant hose. – Fasten clamp • Tighten 2x bolt 25 Nm • Connect wiring harness plug
95. 95. Fit cooler, exhaust gas recirculation • Tighten bolt 25 Nm • Tighten nuts 9 Nm • Attach metal pipe, EGR valve – Tighten clamp • Attach coolant hose. – Fasten clamp
96. 96. Attach vacuum reservoir with retaining plate • Tighten 3x bolt 25 Nm • Attach 2x vacuum hoses

Note. If fitted

97. 97. Install heat shield
98. 98. Clean 6x thread
99. 99. Install flywheel • Attach EN-46792 – Tighten bolt • Tighten 6x new bolts 160 Nm • Detach EN-46792 – Remove bolt
100. 100. Attach KM-6263 • Tighten 4x bolt • Insert clutch pin KM-6263-30 with KM-6263-22

Important. KM-6263 to engine block only, not to oil pan

101. 101. Install clutch
102. 102. Attach manual transmission to engine

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) Protective caps are available in the Opel parts catalogue under number: 45 06 154 / Part number 9201697