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

6. 6. For vehicles with automatic transmission: Fit EN-46792 (2) • Tighten bolt
7. 7. For vehicles with automatic transmission: detach drive disk • Unscrew 6 bolts (1) • Detach EN-46792 – Remove bolt

8. 8. Remove heat shield • Unscrew 2x bolt
9. 9. Detach engine vent hose (2) • Release 2x clamp • Unclip from bracket (1)

10. 10. Detach vacuum line (1) • Separate 4x vacuum hose • Unscrew 3x bolt

Note. Mark vacuum hose

11. 11. Detach oil separator/vacuum reservoir bracket (1) • Release 2x clamp • Detach engine vent hose – Fast closure • Unclip wiring harness bracket • Unscrew 3x bolt • Unscrew 2x nut

Note. If fitted

12. 12. Disconnect wiring harness plug (2) from coolant temperature sensor (1)

13. 13. Detach thermostat housing (1) • Detach 4x coolant hose – Release 4x clamp • Unscrew 2x bolt (2)

14. 14. Detach 3x coolant hose • Detach coolant hose (1) from top coolant pipe – Release clamp • Detach coolant hose (3) from bottom coolant pipe – Release clamp • Detach coolant hose (2) from exhaust gas recirculation cooler – Release clamp

15. 15. Detach metal pipe for exhaust gas recirculation (3) from EGR valve • Detach from EGR valve – Unscrew 2x bolt • Detach exhaust gas recirculation on cooler – Release clamp
16. 16. Detach EGR cooler (2) • Unscrew 2x bolt

Note. Remove with exhaust gas recirculation metal pipe (1)

17. 17. Detach intake connector (1) from throttle valve module • Unscrew 2x bolt (2)

18. 18. Detach engine oil filler port (1) • Unscrew 3x bolt

19. 19. Detach vacuum pump (2) • Detach vacuum hose (1) • Unscrew 4x bolt • Remove gasket.

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

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

Note. Note guide bushings

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

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

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

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

24. 24. Remove toothed belt cover • Unscrew 5x bolts (1) with EN-47631 • Unscrew 2x bolt (2)

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

Note. Note dissimilar bolt lengths

26. 26. Detach engine vent pipe (2) • Detach engine vent hose (3) from engine vent pipe – Release clamp • Unscrew 2x bolt (1)

27. 27. Install EN-46789 (1) in camshaft housing • Unscrew exhaust camshaft closure bolt • Screw in EN-46789
28. 28. Set cylinder 1 to ignition TDC. • Rotate crankshaft in direction of engine rotation until reference drift EN-46789 audibly engages in exhaust camshaft

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

Note. Mark direction of rotation.

30. 30. Detach toothed belt tension roller • Remove bolt
31. 31. Detach vacuum line from cable duct • Detach 2x vacuum hoses • Unclip 3x clips

32. 32. Remove wiring harness bracket for compressor • Remove bolt – Set wiring harness to one side

33. 33. Detach wiring harness for engine management (1) • Disconnect wiring harness connector. – Actuator drive for twist valve – Boost pressure sensor – EGR valve – Coolant temperature sensor – Rail pressure sensor – Pressure regulator – 4x sheathed glow plug • Unclip 5x bracket • Detach cable duct – Unscrew 2x bolt
34. 34. Detach coolant pipe (2) from intake manifold • Detach coolant hose from coolant pipe – Release clamp • Unscrew 3x bolt
35. 35. Detach oil leak line (1) • Release 4x locking clamps (arrows) • Detach oil leak line

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)

36. 36. Detach 4x high pressure line (1), pressure reservoir to injector • Release 8x union nuts

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

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

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

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

38. 38. Detach pressure reservoir (1) • Detach return line (2) – Release clamp • Unscrew 2x bolt (3)

39. 39. 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

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

40. 40. Detach toothed belt cover bracket (1) • Remove bolt

41. 41. Remove 4x injectors (2) • Unscrew 4x nut (1) • Remove 4x injector with bracket • Remove 4x seal rings

Note. If the injectors cannot be removed manually, use EN-46786 in conjunction with KM-328-B .

Note. After removal, close the openings of the injectors with protective caps 1)

42. 42. Remove coolant pipe (1) • Unscrew 4x bolt • Remove gasket.

43. 43. Remove 4x sheathed glow plugs with EN-48390 • Disconnect 4x wiring harness plug, sheathed glow plug (arrows)

44. 44. 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

45. 45. 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)

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

47. 47. 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

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

Note. Remove with throttle valve module and EGR valve

49. 49. Detach crankshaft pulse pickup (1) • Disconnect wiring harness plug (3). • Unscrew bolts (2) with EN-47631

50. 50. Attach engine transport shackle. • Tighten bolt
51. 51. Suspend engine on workshop crane.
52. 52. Detach engine from KM-412-A • Unscrew 8x bolt • Lower engine
53. 53. Detach KM-412-36-1 and KM-412-36-2 from the engine block. • Unscrew 7x bolt
54. 54. Unhook engine from workshop crane
55. 55. Detach engine transport shackle, • Remove bolt

Install

56. 56. Attach engine transport shackle. • Tighten bolt
57. 57. Suspend engine on workshop crane.
58. 58. Attach KM-412-36-1 and KM-412-36-2 to the engine block. • Tighten 7x bolt
59. 59. Attach engine to KM-412-A • Tighten 8x bolt
60. 60. Unhook engine from workshop crane
61. 61. Detach engine transport shackle, • Remove bolt
62. 62. Install charge air pipe bracket • Tighten bolt
63. 63. Install crankshaft pulse pickup • Coat sealing ring with special grease (white) • Tighten bolt 9 Nm
64. 64. Install intake manifold • Replace gasket • Tighten 9x new nuts 25 Nm
65. 65. 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

66. 66. Fit high pressure pump • Tighten 3x nuts 25 Nm
67. 67. Attach high pressure pump wheel • Screw in nut
68. 68. 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

69. 69. Attach 4x sheathed glow plugs • Tighten 4x sheathed glow plugs with EN-48390 , 8 Nm • Connect 4x wiring harness plugs for glow plugs
70. 70. Fit coolant pipe. • Replace gasket • Tighten 4x bolt
71. 71. Clean 4x injector shaft

Note. 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.

72. 72. Attach 4x injectors • Replace 4x seal ring • Insert 4x injector with bracket • Tighten 4x nut 25 Nm

Note. Note cylinder sequence 4, 3, 2, 1.

73. 73. Attach toothed belt cover bracket • Tighten bolt
74. 74. 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

75. 75. Attach pressure reservoir • Attach return line – Fasten clamp • Tighten 2x bolt 25 Nm

Important. When tightening the lock nut to the connection, counterhold fuel high pressure pump with open-ended wrench.

76. 76. Attach new high pressure line, high pressure pump to pressure reservoir • Tighten 2x union nut – (M12) 25 Nm – (M14) 23 Nm

Important. When tightening the union nut, counterhold at injector with open-ended wrench.

77. 77. Attach 4x new high pressure line, pressure reservoir to injector • Tighten 8x union nut – (M12) 25 Nm – (M14) 23 Nm
78. 78. Attach oil leak line • Clip 4x leakage oil line into injector

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

79. 79. Attach coolant pipe to intake manifold • Attach coolant pipe to coolant hose – Fasten clamp • Tighten 3x bolt 9 Nm
80. 80. Attach wiring harness for engine management • Connect wiring harness plug – Actuator drive for twist valve – Boost pressure sensor – EGR valve – Coolant temperature sensor – Rail pressure sensor – Pressure regulator – 4x sheathed glow plug • Clip in 5x brackets • Attach cable duct – Tighten 2x bolt
81. 81. Attach compressor wiring harness bracket • Tighten bolt
82. 82. Clip vacuum line into cable duct • Clip in 3x clips • Attach 2x vacuum hoses
83. 83. 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.

84. 84. Install EN-46789 (1) in camshaft housing • Unscrew exhaust camshaft closure bolt • Screw in EN-46789
85. 85. Check camshaft settong on cylinder 1 to ignition TDC • Reference drift EN-46789 must be engaged in exhaust camshaft

86. 86. 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

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

Important. Tensioned side (1) must be taut

88. 88. Block crankshaft. • Attach positioning disk EN-46788 – Screw in bolt – Screw in nut
89. 89. Tension toothed belt • Screw in bolt (6) • Tension toothed belt tension roller • Tighten bolt, toothed belt tension roller (3) 25 Nm • Detach positioning disk EN-46788 – Remove bolt – Unscrew nut

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).

90. 90. Turn crankshaft 720° in direction of engine rotation, disengage EN-46789 (1) • Rotate crankshaft 720° in direction of engine rotation until reference drift EN-46789 audibly engages in exhaust camshaft

91. 91. 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

92. 92. Remove EN-46789 from camshaft housing • Screw in closure bolt
93. 93. Attach engine venting pipe • Attach engine vent hose from engine vent pipe – Fasten clamp • Tighten 2x bolts 9 Nm
94. 94. Install engine damping block adapter • Tighten 3x bolts (M10) 50 Nm • Tighten 2x bolts (M8) 25 Nm

Note. Note dissimilar bolt lengths

95. 95. Install toothed belt cover • Tighten 5x bolts (M6) 9 Nm • Tighten 2x bolts (M8) 25 Nm
96. 96. Attach ribbed V-belt upper guide roller • Tighten bolt 50 Nm
97. 97. Install torsional vibration damper • Tighten 4x bolt 25 Nm

Note. Note installation position.

Note. Counterhold at toothed belt drive gear bolt

98. 98. Attach compressor retaining bracket to engine block • Tighten 4x bolt 50 Nm

Note. Note guide bushings

99. 99. Attach compressor to compressor support • Tighten 3x bolt 22 Nm • Connect wiring harness plug
100. 100. Clean sealing surface
101. 101. Attach vacuum pump • Replace gasket • Tighten 4x new bolts 5 Nm + 50° • Attach vacuum hose
102. 102. Install engine oil filler port • Replace gasket • Tighten 3x bolt

Note. Re-cut thread before re-using and insert bolt (red) with locking compound. The maximum installation time including the torque check is 10 minutes.

103. 103. Attach intake connector to throttle valve module • Replace gasket • Tighten 2x bolt

Note. Coat with special grease (white)

104. 104. Attach EGR cooler • Tighten 2x bolt 25 Nm
105. 105. Attach exhaust gas recirculation metal pipe to EGR valve • Insert new gasket • Tighten 2x bolt • Tighten clamp
106. 106. Attach 3x coolant hose • Attach coolant hose to top coolant pipe – Fasten clamp • Attach coolant hose to lower coolant pipe – Fasten clamp • Attach coolant hose to exhaust gas recirculation cooler – Fasten clamp
107. 107. Clean sealing surface
108. 108. Clean 2x thread
109. 109. Install thermostat housing • Insert new gasket • Tighten 2x bolt • Attach 4x coolant hoses – Secure 4x clamp

Note. Coat gasket with special grease (white)

110. 110. Connect wiring harness plug for coolant temperature sensor
111. 111. Install oil separator/vacuum reservoir bracket • Tighten 3x bolt – Tighten 2x nut • Secure 2x clamp • Connect engine breather hose – Fast closure • Clip in wiring harness bracket

Note. If fitted

112. 112. Attach vacuum line • Connect 4x vacuum hose • Tighten 3x bolt 9 Nm

Note. Note marking

113. 113. Attach engine vent hose • Secure 2x clamp • Clip into bracket
114. 114. Install heat shield
115. 115. Clean 6x thread
116. 116. For vehicles with automatic transmission: attach drive disk • Attach EN-46792 • Tighten 6x new bolts 160 Nm
117. 117. For vehicles with manual transmission: Install flywheel • Attach EN-46792 – Tighten bolt • Tighten 6x new bolts 160 Nm • Detach EN-46792 – Remove bolt
118. 118. For vehicles with manual transmission: Fit 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

119. 119. For vehicles with manual transmission: Install clutch
120. 120. Attach transmission to engine • On vehicles with manual transmission • On vehicles with automatic transmission

1

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