Repair Engine Using an Engine Short Block Opel Vectra C

(Z 32 Se, with Air Conditioning, with Auxiliary Heating, Lhd)

1. 1. Remove engine

Note. see operation "J340100 Engine, Remove and Install"

2. 2. Detach transmission from engine

Note. See operation "J340100007 Manual Transmission, Detach and Attach from/to Engine" or "J340100007 Automatic Transmission, Detach and Attach from/to Engine"

3. 3. Detach Adapter Plate KM-883-2
4. 4. Drain engine oil • Place collecting basin underneath. • Unscrew oil drain bolt
5. 5. Detach 3x coolant hose

6. 6. Detach engine damping block bracket (2) • Unscrew 4x bolt
7. 7. Detach ribbed V-belt • Tension ribbed V-belt tensioner (1) in direction of arrow • Use KM-913-A

Important. Mark running direction

8. 8. Detach ribbed V-belt tensioner (1) • Unscrew 2x bolt (2)

9. 9. Detach alternator • Detach alternator wiring harness – Unscrew 2x nut (1) • Unscrew 2x bolt

10. 10. Detach starter • Remove wiring harness for starter – Unscrew 2x nut (1) • Unscrew 2x bolt
11. 11. Detach starter/alternator wiring harness • Disconnect 3x wiring harness plug – Oil pressure switch (2), combination plug (3), engine control unit (4) • Detach 2x bracket – Unscrew 2x bolt (arrows)
12. 12. Remove wiring harness for engine management • Disconnect 12x wiring harness plug • Compressor (4), camshaft sensor (3), knock sensor for cylinders 2-4-6 (2), throttle valve module (6), tank vent valve (5), knock sensor for cylinders 1-3-5 (7), DIS ignition module for cylinders 1-3-5 (arrow), injection valves (10), switchover valve solenoid valve (8), coolant temperature sensor (11), DIS ignition module for cylinders 2-4-6 (arrow), engine control unit (9) • Detach 2x ground cable – Unscrew 2x bolt • Separate cable tie • Detach wiring trough – Unscrew 2x bolt

13. 13. Detach intake plenum • Detach 2x engine vent hose • Detach coolant hose (1) • Unscrew 6x bolt (arrows)

14. 14. Detach coolant bridge (1) • Unscrew 2x banjo bolt (2)

15. 15. Detach intake flange (1) • Unscrew 12x bolt

16. 16. Detach engine vent housing • Unscrew 4x bolt (1)

17. 17. Detach engine control unit (2) • Unscrew 4x bolt
18. 18. Detach engine control unit bracket (1) • Unscrew 2x bolt

19. 19. Detach oil filter housing • Detach cover of oil filter housing (4) • Remove oil filter element • Remove bolt
20. 20. Detach oil lines heat exchanger (1) • Release clamp (2) • Unscrew 2x banjo bolt (5) • Unscrew 2x union nut (3)

21. 21. Detach coolant connection • Unscrew 2x bolt
22. 22. Screw in oil drain bolt • Replace seal ring – Tightening torque 10 Nm
23. 23. Detach compressor (1) • Unscrew 3x bolt (2)
24. 24. Detach compressor support (3) • Unscrew 4x bolt (4)

25. 25. Remove oil dipstick guide tube • Remove bolt
26. 26. Detach 2x knock sensor • Unscrew 2x bolt • Unclip cable
27. 27. Detach crankshaft pulse pick-up • Remove bolt
28. 28. Detach coolant pump drive gear • Unscrew 3x bolt
29. 29. Detach front toothed belt cover (1) • Unscrew 5x bolt (2)
30. 30. Remove torsional vibration damper • Unscrew 6x bolt

31. 31. Remove toothed belt • Move crankshaft slowly and uniformly in direction of engine rotation until approx. 60° in front of 1st cylinder TDC of combustion stroke • Release tension roller (1) – Remove nut • Detach lower guide roller (2) – Remove bolt

Note. Reusing the toothed belt is only permitted if all the marks are visible.

32. 32. Detach ignition module for cylinders 2-4-6 • Unscrew 2x bolt • Use KM-6009
33. 33. Detach ignition module for cylinders 1-3-5 • Unscrew 2x bolt • Use KM-6009
34. 34. Detach cylinder head cover 2-4-6 • Unscrew oil filler port • Unscrew 8x bolt
35. 35. Detach cylinder head cover 1-3-5 • Unscrew 8x bolt
36. 36. Remove camshaft sensor • Remove bolt
37. 37. Detach 4x camshaft sprocket (1) • Unscrew 4x bolt (2)

Important. Counterhold camshaft at hexagonal section with open-ended wrench

38. 38. Detach base plate (3) • Unscrew 3x bolt (4)
39. 39. Detach rear toothed belt cover (1) • Unscrew 5x bolt (2) • Unscrew stud bolt (5)
40. 40. Detach coolant pipe (2)
41. 41. Remove thermostat (1) • Unscrew 2x bolt
42. 42. Detach coolant pump (3) • Unscrew 3x bolt (4)

43. 43. Remove exhaust camshaft for cylinders 2-4-6 (2) • Unscrew 8x bolt

Note. Release bearing cap uniformly in sequence shown

44. 44. Remove exhaust camshaft for cylinders 1-3-5 (1) • Unscrew 8x bolt

Note. Release bearing cap uniformly in sequence shown

45. 45. Remove cylinder head 1-3-5 • Unscrew 8x bolt – Use KM-2355 and MKM-916

Note. Release cylinder head bolts first 1/4, then 1/2 turn in sequence shown

46. 46. Remove cylinder head 2-4-6 • Unscrew 8x bolt – Use KM-2355 and MKM-916

Note. Release cylinder head bolts first 1/4, then 1/2 turn in sequence shown

47. 47. Remove heat exchanger cover (1) • Unscrew 8x bolt (2)

Note. Detach heat exchanger cover from cylinder block using suitable tool. Do not damage sealing surfaces. Carefully remove cover together with heat exchanger.

48. 48. Remove oil pressure switch

49. 49. Detach toothed belt drive gear (1) • Remove bolt (2) – Use KM-662-C

50. 50. Remove clutch

Note. See operation "K 2051 00-004 Thrust Plate and Clutch Disc, Remove and Install (with SAC)" in group "K"

51. 51. Remove flywheel • Use KM-652 • Unscrew 8x bolt
52. 52. Detach oil pan • Unscrew 16x bolt • Use KM-J-37228

Note. Detach oil pan carefully from cylinder block. Do not damage sealing surfaces.

53. 53. Detach oil intake pipe (4) • Unscrew 4x bolt (3)
54. 54. Remove oil baffle plate (1) • Unscrew 4x bolt (2)

55. 55. Detach oil pump (1) • Unscrew 7x bolt (2)
56. 56. Remove oil pump seal ring (3)

57. 57. Clean sealing surfaces. • 2x cylinder head, 2x cylinder head cover, oil filter housing, oil pan, coolant pump, 2x exhaust manifold, heat exchanger cover
58. 58. Inspect components

Note. If a cylinder head is to be checked and overhauled: Detach all external components from cylinder head

59. 59. Detach cylinder block • Attach KM-2358 • Suspend from workshop crane • Detach from KM-412 • Detach KM-412-13
60. 60. Attach cylinder block • Attach KM-2358 • Lift engine • Attach KM-412-13 – Tighten 6x bolt • Attach to KM-412 – Tighten 8x bolt • Detach KM-2358
61. 61. Drive in 6x centring sleeve • in engine block – 4x cylinder head – 2x transmission side • Use KM-472

Important. Do not cover oil ducts with sealant

62. 62. Position oil pump gasket

Note. Before installing oil pump, only coat gasket thinly and evenly on pump side in shaded area with surface sealant (green) (recommended value approx. 0.2 mm).

63. 63. Install oil pump • Tighten 7x bolt – Use screw locking compound (red) – Tightening torque 12 Nm • Tighten lower alternator fastening bolt – Tightening torque 40 Nm • Retighten 7x bolt – Tightening torque 20 Nm

Important. Note tightening sequence.

Note. Use nut

64. 64. Install oil pump seal ring (1) • Use KM-693-A (2)

Note. Lightly coat sealing lip of seal ring with silicon grease (white)

65. 65. Attach oil baffle plate • Tighten 4x bolt – Tightening torque 8 Nm
66. 66. Attach oil intake pipe • Replace seal ring • Tighten 4x bolt – Tightening torque 8 Nm
67. 67. Apply sealant • Oil pan, oil pump joints, cylinder block joints • Apply a bead approx. 3 mm thick of adhesive compound (black)

68. 68. Install oil pan • Screw in bolts – Use screw locking compound (red) – Unscrew 2x threaded pin • At cylinder block – Tightening torque 15 Nm • At oil pump – Tightening torque 15 Nm

Note. Screw in 2x threaded pins (M8) to guide the oil pan

Important. Complete assembly work within 10 minutes. Align oil pan on transmission side to cylinder block using a straightedge

Note. Tighten bolts in spiral pattern from inside outwards

69. 69. Install flywheel • Replace 8x bolt • Tighten 8x bolt – Tightening torque 65 Nm + 30° + 15° • Use KM-652
70. 70. Clean 6x thread • In flywheel
71. 71. Install clutch

Note. Clutch disc, remove and install - see operation "Clutch Disc, Remove and Install" in group "K"

72. 72. Detach KM-6263 , KM-6289
73. 73. Attach toothed belt drive gear • Replace bolt • Use KM-662-C
74. 74. Fasten toothed belt drive gear • Tighten bolt – Tightening torque 250 Nm + 45° + 15° • Detach KM-662-C

Note. 2nd mechanic is required

75. 75. Attach oil pressure switch • Replace seal ring • Tightening torque 40 Nm

76. 76. Attach heat exchanger cover • Apply sealant (light grey) (dimension I = 2 mm) • Replace 8x bolts • Tighten 8x bolt – Tightening torque 20 Nm

Important. Complete assembly operations within 10 minutes

Note. Use locking compound (red)

77. 77. Check for plane surface • From cylinder head

Note. Use straight edge and feeler gauge

78. 78. Attach cylinder head 2-4-6 • Replace cylinder head gasket • Replace 8x bolt • Tighten 8x bolt – Tightening torque 25 Nm + 90° + 90° + 90° + 15°

Important. "OBEN/TOP" mark should face the engine timing side. Move crankshaft to approx. 60° before TDC

Important. Note tightening sequence.

79. 79. Attach cylinder head 1-3-5 • Replace cylinder head gasket • Replace 8x bolt • Tighten 8x bolt – Tightening torque 25 Nm + 90° + 90° + 90° + 15°

Important. "OBEN/TOP" mark should face flywheel side. Move crankshaft to approx. 60° before TDC

Important. Note tightening sequence.

80. 80. Attach exhaust camshaft 1-3-5 • Coat sliding surfaces with engine oil • Insert camshaft, camshaft bearing cap • Tighten camshaft bearing caps – Tighten camshaft bearing caps in spiral pattern in stages from inside outwards – Tightening torque 8 Nm

Note. Apply sealant (black) to sealing surfaces of guide bearing (arrows).

Important. Note mark and allocation

81. 81. Attach exhaust camshaft 2-4-6 • Coat sliding surfaces with engine oil • Insert camshaft, camshaft bearing cap • Tighten camshaft bearing caps – Tighten camshaft bearing caps in spiral pattern in stages from inside outwards – Tightening torque 8 Nm

Note. Apply sealant (black) to sealing surfaces of guide bearing (arrows).

Important. Note mark and allocation

82. 82. Remove intake camshaft seal ring for cylinders 2-4-6

Note. Prise out seal ring from camshaft bearing cap using suitable tool. Do not damage sealing surfaces.

83. 83. Remove seal ring of intake camshaft for cylinders 1-3-5

Note. Prise out seal ring from camshaft bearing cap using suitable tool. Do not damage sealing surfaces.

84. 84. Install exhaust camshaft seal ring for cylinders 2-4-6 • Press seal ring into camshaft bearing cap – Use KM-422 – Use camshaft sprocket bolt

Note. Coat sealing lip of seal ring with silicon grease (white)

85. 85. Install intake crankshaft seal ring for cylinders 2-4-6 • Press seal ring into camshaft bearing cap – Use KM-422 – Use camshaft sprocket bolt

Note. Coat sealing lip of seal ring with silicon grease (white)

86. 86. Install intake crankshaft seal ring for cylinders 1-3-5 • Press seal ring into camshaft bearing cap – Use KM-422 – Use camshaft sprocket bolt

Note. Coat sealing lip of seal ring with silicon grease (white)

87. 87. Install exhaust camshaft seal ring for cylinders 1-3-5 • Press seal ring into camshaft bearing cap – Use KM-422 – Use camshaft sprocket bolt

Note. Coat sealing lip of seal ring with silicon grease (white)

88. 88. Attach coolant pump • Replace seal ring • Tighten 3x bolt – Tightening torque 25 Nm
89. 89. Install thermostat housing • Replace seal ring • Tighten 2x bolt – Tightening torque 20 Nm

Note. Use screw locking compound (red)

90. 90. Install coolant pipe • Replace 2x seal ring

Note. Lightly coat seal rings with silicone grease (white)

Note. Insert coolant pipe together with engine transport shackle

91. 91. Attach rear toothed belt cover • Tighten 5x bolt – Tightening torque 8 Nm • Tighten stud bolts – Tightening torque 10 Nm

Note. Use screw locking compound (red)

92. 92. Attach base plate • Tighten 3x bolt – Tightening torque 40 Nm
93. 93. Attach 2x camshaft sprocket for cylinders 1-3-5 • Replace 2x bolt • Screw in 2x bolt

Important. Marks must face forwards, crankshaft at 60° before ign. TDC of cylinder 1. Guide pin (arrow) of exhaust camshaft (1) must engage in mark "1" of camshaft sprocket guide slot. Guide pin (arrow) of intake camshaft (2) must engage in mark "2" of camshaft sprocket guide slot.

94. 94. Attach 2x camshaft sprocket for cylinders 2-4-6 • Replace 2x bolt • Screw in 2x bolt

Important. Marks must face forwards, crankshaft at 60° in front of 1st cylinder TDC in combustion stroke. Guide pin (arrow) of intake camshaft (3) must engage in mark "3" of camshaft sprocket guide slot. Guide pin (arrow) of exhaust camshaft (4) must engage in mark "4" of camshaft sprocket guide slot

95. 95. Secure 4x camshaft sprocket • Tighten 4x bolt – Tightening torque 50 Nm + 60° + 15°

Note. 2nd mechanic is required

Important. Counterhold camshaft at hexagonal section with open-ended wrench

96. 96. Attach camshaft sensor • Tighten bolt – Tightening torque 8 Nm
97. 97. Adjust camshafts • Adjust marks on camshaft sprockets (2) to corresponding notches (1) on rear toothed belt cover. • Insert KM-800-2 (green) (3) between camshaft pulleys "3" and "4" – Note "TOP" mark • Insert KM-800-1 (red) (4) between camshaft pulleys "1" and "2" – Note "TOP" mark

Important. Ensure that crankshaft is located at approx. 60° before 1st cylinder TDC of combustion stroke

98. 98. Adjust crankshaft • Attach KM-800-10 (1) • Move crankshaft slowly and uniformly in direction of engine rotation until approx. 10° in front of 1st cylinder TDC of combustion stroke – KM-800-10 must stand vertical

99. 99. Lay toothed belt in place (1) • Secure toothed belt – Use KM-800-30 (6)

Important. Note sequence, running direction and marks (2). Start with cylinder group 2-4-6 (3), upper guide roller (4), cylinder group 1-3-5, (8) toothed belt tension roller (7), toothed belt drive gear (5)

100. 100. Attach lower toothed belt guide roller (1) • Tighten bolt – Tightening torque 40 Nm

Note. Note spacer washer

Important. Guide roller must be installed free of tension. Double mark on toothed belt (3) must coincide with toothed belt drive gear mark (2) and oil pump groove (4). Otherwise, check toothed belt position

101. 101. Tension toothed belt • Remove KM-800-30 • Turn crankshaft to 1st Cylinder TDC – KM-800-10 must bear against coolant pump flange • Secure KM-800-10 • Adjust toothed belt tension roller • Detach KM-800-10 , KM-800-2 , KM-800-1

Important. Overtension toothed belt tension roller anticlockwise, allow to slide back and fix mark (1) 10 mm above mark (2)

102. 102. Set 1st cylinder to TDC of combustion stroke • Turn crankshaft slowly and uniformly approx. 660° in direction of engine rotation • Attach KM-800-10 • Turn crankshaft to 1st Cylinder TDC – KM-800-10 must bear against coolant pump flange – Secure KM-800-10
103. 103. Toothed Belt Tension, Adjust • Tighten nuts – Tightening torque 20 Nm • Detach KM-800-10

Note. Mark (1) must be positioned 3-4 mm above mark (2). If necessary, correct adjustment. When using an old toothed belt, the marks must coincide.

104. 104. Toothed Belt Tension, Check • Turn crankshaft slowly and uniformly approx. 660° in direction of engine rotation • Attach KM-800-10 (2) • Turn crankshaft to 1st Cylinder TDC – KM-800-10 must bear against coolant pump flange (1) – Secure KM-800-10 – Check toothed belt tension roller mark

105. 105. Check timings of cylinders 2-4-6 • Use KM-800-2 (green) (2) KM-800-20 (3)

Note. Marks on camshaft pulleys must align with the notches on rear toothed belt cover

Important. If the timings are not correct, the toothed belt must be repositioned

106. 106. Check timings of cylinders 1-3-5 • Use KM-800-1 (red) (1) KM-800-20 (3)

Note. Marks on camshaft pulleys must align with the notches on rear toothed belt cover

Important. If the timings are not correct, the toothed belt must be repositioned

107. 107. Detach KM-800-10 , KM-800-1 , KM-800-2 , KM-800-20

108. 108. Attach cylinder head cover 2-4-6 • Replace gasket • Apply sealant (arrows) • Tighten 8x bolt – Tightening torque 8 Nm
109. 109. Attach cylinder head cover 1-3-5 • Replace gasket • Apply sealant (arrows) • Tighten 8x bolt – Tightening torque 8 Nm

110. 110. Attach ignition module for cylinders 1-3-5 • Tighten 2x bolt – Tightening torque 8 Nm
111. 111. Attach ignition module for cylinders 2-4-6 • Tighten 2x bolt – Tightening torque 8 Nm
112. 112. Attach front toothed belt cover • Tighten 5x bolt – Tightening torque 8 Nm
113. 113. Install torsional vibration damper • Tighten 6x bolt – Tightening torque 20 Nm
114. 114. Clean 3x thread • On coolant pump
115. 115. Attach coolant pump drive gear • Replace 3x bolt – Tighten 3x bolt – Tightening torque 8 Nm + 30° + 30°

Note. Use screw locking compound (red)

116. 116. Attach crankshaft pulse pick-up • Replace seal ring • Tighten bolt – Tightening torque 8 Nm
117. 117. Attach knock sensor for cylinders 1-3-5 • Tighten bolt – Tightening torque 20 Nm

Note. Recommended tightening torque must be observed!

118. 118. Attach knock sensor for cylinders 2-4-6 • Tighten bolt – Tightening torque 20 Nm

Note. Recommended tightening torque must be observed!

119. 119. Install oil dipstick guide tube • Replace 2x seal ring • Tighten bolt – Tightening torque 25 Nm

Note. Note shackles of coolant pipe and engine transport shackle

120. 120. Attach compressor support • Tighten 4x bolt – Tightening torque 35 Nm
121. 121. Attach compressor • Tighten 3x bolt – Tightening torque 20 Nm
122. 122. Attach coolant connection • Replace seal ring • Tighten 2x bolt – Tightening torque 20 Nm
123. 123. Attach oil lines heat exchanger • Replace 4x seal ring • Tighten 2x banjo bolt – Tightening torque 30 Nm • Tighten 2x nut – Tightening torque 30 Nm • Attach clamp
124. 124. Install oil filter housing • Replace gasket • Tighten bolt – Tightening torque 45 Nm • Insert oil filter element • Replace seal ring • Tighten cover – Tightening torque 25 Nm
125. 125. Attach engine control unit bracket • Tighten 2x bolt – Tightening torque 20 Nm
126. 126. Install engine control unit • Tighten 4x bolt – Tightening torque 8 Nm
127. 127. Attach engine vent housing • Tighten 4x bolt – Tightening torque 8 Nm

Note. Apply an approx. 2 mm thick bead of silicone compound (grey) into groove of engine vent housing and install immediately while wet

128. 128. Clean 12x thread for intake flange
129. 129. Install intake flange • Replace 12x bolt • Tighten 12x bolt – Tightening torque 20 Nm

Important. If gaskets are damaged, replace intake flange

Note. Use screw locking compound (red)

Note. Note tightening sequence.

130. 130. Attach coolant bridge • Replace 4x seal ring • Tighten 2x banjo bolt – Tightening torque 30 Nm
131. 131. Attach intake plenum • Attach coolant hose. – To throttle valve module • Tighten 6x bolt – Tightening torque 7,5 Nm • Attach engine vent hose – Close clamp
132. 132. Attach wiring harness for engine management • Attach wiring trough – Tighten 2x bolt – Tightening torque 8 Nm • Attach 2x ground cable – Tighten 2x bolt • Connect 12x wiring harness plug • Compressor, camshaft sensor, knock sensor for cylinders 2-4-6, throttle valve module, tank vent valve, knock sensor for cylinders 1-3-5, DIS ignition module for cylinders 1-3-5, injection valves, switchover valve solenoid valve, coolant temperature sensor, DIS ignition module for cylinders 2-4-6, engine control unit • Attach cable ties
133. 133. Attach starter/alternator wiring harness • Attach 2x bracket – Tighten 2x bolt – Tightening torque 8 Nm • Connect 3x wiring harness plug – Oil pressure switch, combination plug, engine control unit
134. 134. Attach starter • Tighten 2x bolt – Tightening torque 40 Nm • Attach wiring harness for starter – Tighten 2x nut
135. 135. Attach alternator • Tighten 2x bolt – Tightening torque 35 Nm • Install alternator wiring harness – Tighten 2x nut
136. 136. Attach ribbed V-belt tensioner • Tighten 2x bolt – Tightening torque 35 Nm
137. 137. Install ribbed V-belt.

Important. Note running direction

138. 138. Attach engine damping block bracket • Tighten 4x bolt – Tightening torque 55 Nm
139. 139. Attach 3x coolant hose
140. 140. Top up engine oil. • Observe specified engine oil filling quantity

Note. After fitting the engine, check the engine oil level and correct if necessary.

141. 141. Attach Adapter Plate KM-883-2
142. 142. Attach transmission

Note. See operation "J340100007 Manual Transmission, Detach and Attach from/to Engine" or "J340100007 Automatic Transmission, Detach and Attach from/to Engine"

143. 143. Install engine with transmission

Note. see operation "J340100 Engine, Remove and Install"