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Thread: Vectra C 2.0 dti timing chain replacement

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    Vehicle : Vectra C

    Trim : ls

    Engine : 2.0 dti

    Year : 2003

    Default Vectra C 2.0 dti timing chain replacement

    Hi All

    I have a vectra c 2.0 dti which recently broke the crankshaft so I have had to purchase a second hand engine

    The problem I have is the the scrap yard cut the cam shaft chain to release the injector pump which has made this into a big job, the crank to injector pump chain is still in place.

    Has the timing chain got a removable link or is it one complete piece?

    Regards

    Chris

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    Vehicle : vectra

    Trim : vxr

    Engine : 2.8 v6 turbo

    Year : 2007

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    one piece me thinks

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    Vehicle : Vectra C

    Trim : ls

    Engine : 2.0 dti

    Year : 2003

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    It looks like this is not going to be an easy job.

    Do you know where I could get some info on this before I start into the dismantling.

    Regards

    Chris

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    Quote Originally Posted by chris2004 View Post
    It looks like this is not going to be an easy job.

    Do you know where I could get some info on this before I start into the dismantling.

    Regards



    Chris
    Pretty much the same procedure for your dti

    Fuel Injection Pump, Remove and Install


    Remove
    1. Remove inlet manifold upper section
    For X 20 DTL, Y 20 DTL, Y 20 DTH up to MY 2003
    For Y 20 DTH as of MY 2003, Y 22 DTR
    2. Remove intake manifold lower part
    3. Remove air cleaner housing with hot film mass air flow meter and air intake hose
    X 20 DTL and Y 20 DTH
    Y 20 DTH up to MY 2003
    Y 20 DTH as of MY 2003 and Y 22 DTR
    4. Lock engine on no. 1 cylinder "Ignition TDC"
    5. Detach fuel lines from fuel injection pump
    Important: To avoid bending the pins and thus replacing the injection pump, protective caps KM-6154 must be fitted on the injection pump immediately after removing the wiring harness plug and removed again just before attaching the wiring harness plugs
    6. For Y 20 DTH from MY 2003, Y 22 DTR engine: Detach wiring harness plugs (2) and attach KM-6154 (1) to injection pump

    7. Remove Simplex chain tensioner (3)
    Note installation position.
    Important: Use sheet metal plate or suitable heat shielding to avoid damaging the guide rails
    8. Heat fastening bolts (1) intensively with hot air blower and remove
    9. Remove guide rail for simplex timing chain upwards
    Note installation position.
    10. Clean thread for the fastening bolts (1) in cylinder head
    11. Remove duplex chain tensioner (2)
    Note installation position.

    12. Remove test gauge KM-932 from cylinder head and injection pump locking pin KM-927 from retaining bore
    13. Remove camshaft sprocket from camshaft
    Note: To simplify installation, suspend simplex timing chain at suitable point
    Counterhold with open-ended wrench on the hex nut of the camshaft
    14. Remove fastening bolts (1) and simplex injection pump gear
    Note: For Y 20 DTH from MY 2003 and Y 22 DTR: 5 fastening bolts
    15. Remove simplex timing chain upwards from cylinder head

    16. Remove fastening bolts (1) from injection pump with MKM-604-D
    17. Detach fuel injection pump bracket (2) from cylinder block and fuel injection pump. Remove fuel injection pump towards rear out of cylinder block and remove upwards out of engine compartment

    Install
    Important: The spacer disc (1) on the fuel injection pump flange (3) must not be removed, as this disc compensates for manufacturing tolerances and therefore corresponds to a precisely defined axial dimension
    18. Replace gasket (2)
    19. Insert injection pump in cylinder block
    Ensure that the duplex sprocket sits straight on the injection pump flange without tilting

    20. Injection pump to cylinder block
    Tightening torque 25 Nm / 18.5 lbf. ft.
    21. Injection pump bracket to injection pump
    Tightening torque 20 Nm / 15 lbf. ft.
    22. Fuel injection pump bracket to cylinder block
    Tightening torque 20 Nm / 15 lbf. ft.
    23. Guide simplex timing chain through timing case, and insert simplex injection pump gear in simplex timing chain
    Arrow (2) must align with recess in injection pump flange and retaining bore (3) in injection pump
    24. Loosely hand-tighten new fastening bolts (1) with bolt strength 10.9 of the simplex injection pump gear
    Note: For Y 20 DTH from MY 2003 and Y 22 DTR: 5 fastening bolts
    25. Insert injection pump locking pin KM-927 (4) in retaining bore of fuel injection pump
    26. Insert camshaft sprocket in simplex timing chain and fasten hand-tightened to camshaft with new fastening bolt
    Ensure that the camshaft sprocket is not askew on the camshaft
    Camshaft sprocket must lie flat on the camshaft

    Important: A distinction must be made between versions with and without release bolts (1). In versions with release bolts, the chain tensioner must be untightened using the release bolt after installation
    27. Insert duplex chain tensioner (4) in timing case
    The closed side of chain tensioner must point to tension rail. Install duplex chain tensioner closure bolt (2) with new seal ring (3)
    Tightening torque 60 Nm / 44 lbf. ft.
    28. Press in the release pin with a hammer shaft until a click is heard
    29. It must be possible to push in release bolt up to stop with thumb and for it to slide back to its original position automatically
    The release bolt can no longer be pushed in once the oil pressure has built up

    30. Remove injection pump locking pin KM-927
    31. Tighten fastening bolts (1) for simplex injection pump gear
    Note: For Y 20 DTH from MY 2003 and Y 22 DTR: 5 fastening bolts
    Tightening torque 28 Nm / 20.6 lbf. ft.
    32. Re-insert injection pump locking pin KM-927 into injection pump retaining bore

    33. Position test gauge KM-932 (3) on cylinder head
    Pin (2) must engage in hole (1) of camshaft

    34. Insert and install simplex timing chain guide rail (1)
    Note: Check installation position
    Use new fastening bolts (2)
    Tightening torque 8 Nm / 6 lbf. ft.

    35. Insert carrier (1) of adjuster KM-933 (4) vertically into camshaft sprocket. Mount adjuster KM-933 on cylinder head
    36. Use toggle (2) to exert slight pressure on the carrier in the direction of arrow (counter to direction of engine rotation) and fix in place with locking bolt (3)
    37. Injection pump locking pin KM-927 must be able to be installed and removed under suction. If this is not possible, decrease the pressure on the carrier disc slightly using the locking screw.
    38. Fasten camshaft sprocket to camshaft
    Tightening torque 90 Nm / 66 lbf. ft. + 60° + 30°

    Important: A distinction must be made between versions with and without release bolts (1). In versions with release bolts, the chain tensioner must be untightened using the release bolt after installation
    39. Insert simplex chain tensioner (4) in cylinder head
    The closed side of the chain tensioner must point to tension rail. Install simplex chain tensioner closure bolt (2) with new seal ring (3)
    Tightening torque 60 Nm / 44 lbf. ft.
    40. Press in the release pin with a hammer shaft until a click is heard
    41. It must be possible to push in release bolt up to stop with thumb and for it to slide back to its original position automatically
    The release bolt can no longer be pushed in once the oil pressure has built up

    42. Remove all locking and adjusting tools
    43. At fastening bolt of torsional vibration damper, turn crankshaft two turns (approx. 720°) in direction of engine rotation to just before "1st cylinder TDC"
    The mark (3) on the torsional vibration damper is located just before the lug (2) on the timing case
    44. In this position, the cams (1) of the 1st cylinder are just before TDC (both cams point upwards)

    45. Insert crankshaft locking pin KM-929 (1) in aperture for crankshaft pulse pick-up, and simultaneously slowly turn crankshaft further in engine rotational direction at fastening bolt of torsional vibration damper until crankshaft lock pin engages to stop in cylinder block or crank web
    46. Insert fuel injection pump locking pin KM-927 (2) into injection pump retaining bore and test gauge KM-932 (3) into cylinder head
    Note: If a tool cannot be inserted, then the adjustment procedure must be completely repeated

    47. Remove all locking tools
    48. Clean sealing surfaces on timing case cover and timing case
    Cover aperture in timing case with lint-free cloth
    49. Apply an approx. 2 mm (Dimension I) thick bead of silicone sealing compound to timing case cover.
    Note: The silicone sealing compound must be applied and the timing case must be installed (including torque checking) within 10 minutes

    50. Attach timing case cover to timing case with new fastening bolts
    Use 2 threaded pins (M6) to fasten
    Tightening torque 6 Nm / 4.5 lbf. ft.
    51. Fit fuel lines on injection pump with new seal rings
    Tightening torque 25 Nm / 18.5 lbf. ft.
    52. Attach crankshaft pulse pick-up to cylinder block with new O-ring
    Tightening torque 8 Nm / 6 lbf. ft.
    53. Install ribbed V-belt tensioner
    54. Install vacuum pump
    55. Install cylinder head cover
    56. Install air cleaner housing with hot film mass air flow meter and air intake hose
    X 20 DTL and Y 20 DTH
    Y 20 DTH up to MY 2003
    Y 20 DTH as of MY 2003 and Y 22 DTR
    57. For Y 20 DTH as of MY 2003, Y 22 DTR: Detach KM-6154 from injection pump and attach wiring harness plug
    2 items
    58. Install intake manifold lower part
    59. Install inlet manifold upper section
    For X 20 DTL, Y 20 DTL, Y 20 DTH up to MY 2003
    For Y 20 DTH as of MY 2003, Y 22 DTR
    60. Bleed fuel system

    http://vauxhall.workshop-manuals.com...ex.php?id=3358

  5. #5
    Regular Member Teapot's Avatar
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    Vehicle : Signum

    Trim : Design+

    Engine : 1.9 CDTI 150

    Year : 2007

    Mileage : 101000

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    Quote Originally Posted by chris2004 View Post
    Hi All

    I have a vectra c 2.0 dti which recently broke the crankshaft so I have had to purchase a second hand engine

    The problem I have is the the scrap yard cut the cam shaft chain to release the injector pump which has made this into a big job, the crank to injector pump chain is still in place.

    Has the timing chain got a removable link or is it one complete piece?

    Regards

    Chris
    I assume you are trying to fit your injection pump to the replacement engine because the new one won't work with your car (immobiliser etc)? To do this you don't need to remove the lower timing chain - only the upper one. I did one a couple of weeks ago. I assume you know about and have the required kit to set the timing?

    An even quicker option if you know the pump is ok on the replacement engine is to detach the ecu from the top of your old pump and fit it to the replacement engine/pump. You need a steady hand to remove and refit the pump speed sensor which is attached inside the pump by 2x T10 screws and connected internally to the ecu by a delicate ribbon cable - easy for me but not everybody!
    2006 Signum Design+ 1.9 CDTI and 2007 Signum Elite 2.8 V6 Turbo
    1.9 CDTI Diagnostics and tuning, remote remapping for distant members
    PM for more info.
    Remaps for Insignia 2.0 CDTI up to early 2012 *New* Remaps for 2.8 V6 Turbo

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    Vehicle : Vectra C

    Trim : ls

    Engine : 2.0 dti

    Year : 2003

    Default

    I have the replacement engine to fit but the breakers had already removed the injector pump and in the process they have used a grinder and cut right through the timing chain that goes to the cam.

    The info provided is great, do you have the same kind of detailed information for the chain replacement this would help me very much.

    Regards

    Chris

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    Quote Originally Posted by chris2004 View Post
    I have the replacement engine to fit but the breakers had already removed the injector pump and in the process they have used a grinder and cut right through the timing chain that goes to the cam.

    The info provided is great, do you have the same kind of detailed information for the chain replacement this would help me very much.

    Regards

    Chris
    Be careful you will have to cherry pick the data you need from this as its a total strip down.

    It should give you an idea how its setup.

    I recommend that this job is for experienced mechanics as its a bit more involved than a timing belt replacement.



    47. Remove camshaft sprocket
    Remove 1 bolt
    Note: Counterhold camshaft at hexagonal section. Attach Simplex timing chain at a suitable place.

    48. Loosen cylinder head
    Important: Loosen cylinder head bolts in illustrated sequence by first 1/4, then 1/2 turn
    4 fastening bolts (M8) (arrows)
    Note: Observe different bolt lengths
    10 fastening bolts (M12)

    Important: Place cylinder head on wooden blocks. Do not damage injectors, glow plugs or valves.
    49. Remove cylinder head.
    Note: 2nd mechanic is required.
    50. Remove cylinder head gasket
    51. Remove Duplex chain tensioner (3)
    Note: Note installation position.
    Remove bolt (1), seal ring (2), chain tensioner (3)

    52. Remove Simplex injection pump gear
    4 fastening bolts (1)
    Lower Simplex timing chain downwards
    Remove Simplex injection pump gear at side
    Remove Simplex timing chain upwards

    53. Release injection pump
    Remove 4 fastening bolts (1)
    Use MKM-604-30
    54. Remove engine block coolant drain connection
    Place collecting basin underneath
    55. Remove injection pump
    Remove cylinder block bolt
    From bracket (2)

    56. Remove coolant pump
    Place collecting basin underneath
    Ribbed V-belt pulley (1)
    3 fastening bolts
    Coolant pump (2)
    3 fastening bolts

    57. Rotate engine 180°
    58. Remove oil pan
    17 fastening bolts
    Remove gasket.
    59. Detach balancer shaft unit cover (1)
    4 fastening bolts
    60. Use KM-978 and KM-979
    Set engine to no.1 cylinder Ignition TDC
    Insert KM-979 (3)
    Note: At side in balancer shaft unit
    Insert KM-978 (2)
    Note: Push back chain tensioner by hand. Insert KM-978 into bores
    61. Detach sprocket (4)
    1 fastening bolt (5)

    62. Detach balancer shaft unit
    Important: Release bolts from outside inwards
    7 fastening bolts (1), (2)
    Note: Guide rail (4) and chain tensioner (3) must be transferred when replacing the balancer shaft unit

    63. Rotate engine 90°
    64. Remove crankshaft ribbed V-belt pulley bolt
    65. Remove timing case
    13 fastening bolts
    Note: Observe different bolt lengths
    66. Detach slide rail (5)
    1 fastening bolt
    67. Detach guide rail for Duplex timing chain (3)
    3 fastening bolts
    68. Remove Duplex chain drive
    Timing chain (2), crankshaft pulley (4), injection pump gear (1)
    69. Remove timing case gasket (6)

    Important: Edge seal ring out of timing case with suitable tool – ensure that the sealing surfaces are not damaged
    70. Remove crankshaft front seal ring, timing case seal ring
    71. Remove cylinder block
    Use KM-2358
    Suspend engine on workshop crane.
    Detach from KM-412-16 and KM-412-8-1
    6 fastening bolts
    Install
    72. Attach cylinder block
    Use KM-2358
    Raise engine.
    Attach KM-412-16 and KM-412-8-1 to engine
    6 fastening bolts
    Detach KM-2358
    73. Clean sealing surfaces
    Timing case, cylinder block, cylinder head, oil pan
    74. Inspect components
    75. Clean thread.
    2x simplex chain adjuster safety rails
    6x clutch pressure plates
    Important: A spacer washer (1) may be installed on the injection pump flange (2) to adjust the axial dimension. This spacer washer is allocated to the corresponding fuel injection pump and must always be left on the fuel injection pump flange. When installing a new fuel injection pump, this is supplied with the axial dimension adjusted, i.e. with or without spacer washer (1)
    76. Insert injection pump.
    Replace seal ring
    4 fastening bolts (3)
    77. Secure injection pump
    4 fastening bolts (3)
    Use MKM-604-30
    Tightening torque 25 Nm / 18.5 lbf. ft.
    Attach injection pump bracket
    Tightening torque 20 Nm / 15 lbf. ft.

    78. Attach engine block coolant drain connection
    Replace seal ring
    79. Rotate engine 180°
    80. Use KM-929
    Attach crankshaft ribbed V-belt pulley bolt
    Important: Pull balancer shaft unit chain upwards
    Turn crankshaft to no.1 cylinder Ignition TDC
    Remove crankshaft ribbed V-belt pulley bolt
    81. Rotate engine 90°
    82. Insert timing case gasket (1)
    Important: Note guide sleeves. Injection pump flange recess (2) must align with injection pump retaining bore (3)
    Replace gasket

    Important: Ensure that recess is positioned in injection pump flange and that injection pump retaining bore (1) is centrally positioned in oblong hole (2) on duplex injection pump gear – tension side (I) must be taut.
    83. Insert Duplex chain drive
    Note: Check state of crankshaft pulley spring washer, replace if necessary. Place crankshaft pulley (6) with Duplex timing chain (5) and Duplex fuel injection pump gear (3) on crankshaft or fuel injection pump flange
    84. Attach guide rail for Duplex timing chain (4)
    3 fastening bolts
    Tightening torque 8 Nm / 6 lbf. ft.
    85. Attach 2x tension rail (7)
    1 fastening bolts
    Tightening torque 20 Nm / 15 lbf. ft.

    86. Attach timing case.
    13 fastening bolts
    Note: Observe different bolt lengths. Tighten bolts uniformly
    Tightening torque 20 Nm / 15 lbf. ft.
    87. Install crankshaft front seal ring, timing case seal ring
    Use KM-935-1 (1)
    Note: Position seal ring straight in timing case
    Use KM-935-2 (2)
    Note: Press in seal ring until it lies flush in timing case. Use crankshaft ribbed V-belt pulley bolt

    88. Rotate engine 90°
    89. Attach balancer shaft unit
    Note: Guide rail (4) and chain tensioner (3) must be transferred when replacing the balancer shaft unit. Tighten bolts from inside outwards
    7 new fastening bolts
    2 fastening bolts (2)
    Tightening torque 20 Nm / 15 lbf. ft. + 60°
    5 fastening bolts (1)
    Tightening torque 20 Nm / 15 lbf. ft. + 30°

    90. Attach sprocket
    1 new fastening bolt
    Tightening torque 90 Nm / 66 lbf. ft. + 30°
    91. Remove KM-978 and KM-979
    92. Attach balancer shaft unit cover
    4 fastening bolts
    Tightening torque 8 Nm / 6 lbf. ft.
    93. Apply adhesive sealant
    Note: Apply a bead of adhesive sealing compound to joints (arrows) of timing case and rear crankshaft bearing cap

    94. Install oil pan
    Important: Hand-tighten all bolts
    Replace gasket
    To cylinder block, timing case
    17 fastening bolts
    Tightening torque 20 Nm / 15 lbf. ft.
    95. Rotate engine 90°
    Important: Clean thread in crankshaft before attaching flywheel
    96. Install flywheel
    Use KM-652
    10 new fastening bolts
    Tightening torque 45 Nm / 33 lbf. ft. + 30° + 15°
    97. Install clutch
    98. Rotate engine 180°
    99. Fasten crankshaft ribbed V-belt pulley
    Screw in new bolts
    100. Fasten ribbed V-belt pulley crankshaft
    Note: 2nd mechanic is required.
    Tighten bolt 150 Nm + 45° + 15°
    Up to MY 2003 and engine number 17K44148: Counterhold using KM-977-1 together with KM-956-1
    From MY 2003 and engine number 17K44149: Counterhold using KM-6619 together with KM-956-1
    101. Install coolant pump
    Note: Replace gasket
    Coolant pump
    3 fastening bolts
    Tightening torque 20 Nm / 15 lbf. ft.
    Ribbed V-belt pulley
    3 fastening bolts
    Tightening torque 20 Nm / 15 lbf. ft.
    Important: Arrow (2) on simplex injection pump sprocket must align with recess in injection pump flange and lock bore (3) in injection pump.
    102. Install Simplex injection pump gear
    Note: Insert Simplex timing chain with Simplex fuel injection pump gear and hand-tighten Simplex fuel injection pump gear with fastening bolts (1). Ensure bolt strength 10.9 of the fastening bolts
    Use KM-927 (4)
    103. Tighten Simplex injection pump gear
    Remove KM-927
    4 fastening bolts (1)
    Tightening torque 28 Nm / 20.6 lbf. ft.

    104. Install Duplex chain tensioner
    Note: Note installation position. Closed side of chain tensioner (3) must point to tension rail
    Replace gasket (2)
    1 bolt (1)
    Tightening torque 60 Nm / 44 lbf. ft.

    105. Check for plane surface
    Note: Check sealing surfaces in length and width for deformation and check for warping along the diagonals
    Cylinder head
    Important: Resurfacing of the cylinder head is not permitted.
    With straightedge, feeler gauge
    Measure cylinder head height
    Sealing surface to sealing surface: Dimension (I) = 140 mm

    106. Measure piston projection
    Insert MKM-571-B (1) into KM-301 (2)
    Note pretension
    Set dial to zero
    Place probe on cylinder block
    Measure piston projection at all four pistons
    Note: Measure the projection at two different points (3) and (4) or (5) and (6) for each piston. To do this, place measuring bridge with the dial gauge above the cleaned piston head on the cylinder block. Determine the highest point by turning the crankshaft.

    Important: The largest determined piston projection is used for the selection of the cylinder head gasket with corresponding identification. The identification (notch) is located in position (1). Do not insert cylinder head gasket with sealing compound.
    107. Replace cylinder head gasket
    Piston projection 0.51 – 0.60 mm
    Gasket with 1 notch
    Thickness of gasket 1.3 mm
    Piston projection 0.61 – 0.70 mm
    Gasket with 2 notches
    Thickness of gasket 1.4 mm
    Attach cylinder head gasket
    Note guide bushings

    108. Use KM-932 (3)
    Note: Place KM-932 on cylinder head. Pin (2) must engage in camshaft bore (1).

    Important: Approx. 60° before no.1 cylinder Ignition TDC
    109. Turn crankshaft
    110. Position cylinder head
    Note: 2nd mechanic is required. Note Simplex timing chain
    111. Attach cylinder head
    Note: Replace cylinder head bolts
    10 new cylinder head bolts
    Tightening torque 25 Nm / 18.5 lbf. ft. + 65° + 65° + 65° + 65° + 15°
    Use KM-470-B
    Note: Note tightening sequence.
    4 new fastening bolts (arrows)
    Tightening torque 20 Nm / 15 lbf. ft. + 30° + 5°

    112. Set engine to no.1 cylinder Ignition TDC
    Note: Turn crankshaft uniformly evenly in direction of engine rotation. Mark on torsional vibration damper (3) must be positioned just before lug (2) on timing case. Both cylinder 1 (1) cams must point upwards

    113. Use KM-929 (1)
    Note: Insert KM-929 into bore for crankshaft pulse pick-up. Turn crankshaft uniformly in direction of engine rotation. KM-929 must latch in to the stop. Marks on crankshaft ribbed V-belt pulley and lug on timing case must align (2).

    114. Use KM-927 (3)
    Note: Arrow (1) on Simplex injection pump gear must align with the recess in injection pump flange and injection pump retaining bore (2). Insert KM-927 into injection pump retaining bore.

    115. Insert camshaft sprocket
    Position Simplex timing chain
    Important: Ensure that the camshaft sprocket is not askew on the camshaft – camshaft sprocket must lie plane on the camshaft.
    1 new fastening bolt
    116. Install guide rail for Simplex timing chain (1)
    Important: Note installation position of guide rail
    2 new fastening bolts (2)
    Tightening torque 8 Nm / 6 lbf. ft.

    117. Attach KM-933 (4)
    Insert carrier (1)
    Note: Position upright in camshaft pulley
    2 fastening bolts
    Important: It must be possible to remove and install KM-927 under suction. If this is not possible, the pressure on the adapter plate must be slightly reduced using the adjustment screw (3).
    118. Adjust KM-933 (4)
    Note: Use handle (2) to exert slight pressure on the carrier in the direction of arrow (counter engine rotational direction) and fix in place with holder bolt (3).

    119. Secure camshaft sprocket
    Tighten fastening bolt
    Tightening torque 90 Nm / 66 lbf. ft. + 60° + 30°
    120. Install Simplex chain tensioner (3)
    Note: Note installation position.
    Replace gasket (2)
    1 bolt (1)
    Tightening torque 60 Nm / 44 lbf. ft.

    121. Remove KM-927 , KM-932 , KM-933 and KM-929
    Remove KM-933
    2 fastening bolts
    Remove carrier
    122. Turn crankshaft
    Note: Turn crankshaft slowly and uniformly two turns (720°) in direction of engine rotation until just before no. 1 cylinder Ignition TDC. Mark on crankshaft ribbed V-belt pulley (3) must be positioned just before lug (2) on timing case. Both cylinder 1 (1) cams must point upwards

    123. Use KM-929 (1)
    Note: Insert KM-929 into bore for crankshaft pulse pick-up. Turn crankshaft uniformly in direction of engine rotation. KM-929 must latch in to the stop. Marks on crankshaft ribbed V-belt pulley and lug on timing case must align (2).

    124. Use KM-927 (3)
    Note: Arrow (1) on Simplex injection pump gear must align with the recess in injection pump flange and injection pump retaining bore (2). Insert KM-927 into injection pump retaining bore.

    125. Use KM-932 (3)
    Note: Place KM-932 on cylinder head. Pin (2) must engage in camshaft bore (1).

    126. Remove KM-932 , KM-927 and KM-929
    127. Install crankshaft pulse pick-up
    Replace seal ring
    1 fastening bolt
    Tightening torque 8 Nm / 6 lbf. ft.
    128. Attach cylinder head cover
    Replace gasket
    Note: Gasket (2) must be inserted in gap (1) between cylinder head cover and sleeve. Apply sealing compound to sealing surfaces (arrows)
    8 fastening bolts
    Tightening torque 8 Nm / 6 lbf. ft.

    129. Install vacuum pump
    Replace gasket
    4 fastening bolts
    Tightening torque 8 Nm / 6 lbf. ft.
    130. Attach vacuum line
    To vacuum unit switchover valves
    Clip on 2 brackets
    131. Install 2 fuel lines
    Replace 4 gaskets
    2 banjo bolts
    Tightening torque 25 Nm / 18.5 lbf. ft.
    Connect leak oil hose
    132. Install oil dipstick guide tube
    1 fastening bolt
    Tightening torque 8 Nm / 6 lbf. ft.
    133. Attach thermostat housing
    Replace gasket
    4 fastening bolts
    Tightening torque 8 Nm / 6 lbf. ft.
    Attach coolant hose.
    Fasten clamp
    134. Install 4 injection lines
    8 union nuts
    Note: Note installation position.
    135. Attach 2 injection line spacer washers
    Note: Note fitting positions
    2 fastening bolts
    136. Tighten 4 injection lines
    Use KM-6098
    8 union nuts
    Tightening torque 30 Nm / 22 lbf. ft.
    137. Attach intake pipe
    Replace gasket
    Position upper engine cover bracket
    4 fastening bolts
    Note: For engines with throttle valve vacuum unit: Connect vacuum hose
    Tightening torque 8 Nm / 6 lbf. ft.
    138. Attach cylinder block coolant flange
    Replace seal ring
    2 fastening bolts
    Tightening torque 20 Nm / 15 lbf. ft.
    Fasten clamp
    139. Attach upper bracket for alternator (coolant flange)
    Replace gasket
    Tighten 3 bolts
    Tightening torque 20 Nm / 15 lbf. ft.
    140. Install starter
    1 fastening bolt
    Tightening torque 45 Nm / 33 lbf. ft.
    141. Attach turbocharger oil return line
    1 union nut
    Tightening torque 20 Nm / 15 lbf. ft.
    142. Attach exhaust manifold support
    2 fastening bolts
    Tightening torque 25 Nm / 18.5 lbf. ft.
    143. Attach turbocharger oil feed line
    Tighten union nut
    Tightening torque 20 Nm / 15 lbf. ft.
    144. Attach 2 exhaust manifold heat shields
    2 fastening bolts
    145. Install turbocharger heat shield
    3 fastening bolts
    146. Attach 3 heat shields
    5 fastening bolts
    Tightening torque 8 Nm / 6 lbf. ft.
    Important: The application of silicone sealing compound, installation of timing case cover and tightening to torque must be performed within 10 minutes!
    147. Install timing case cover
    Note: Apply an approx. 2 mm (Dimension I) thick bead of silicone sealing compound to timing case cover
    6 fastening bolts
    Tightening torque 6 Nm / 4.5 lbf. ft.

    148. Install right engine bracket
    3 fastening bolts
    Tightening torque 55 Nm / 41 lbf. ft.
    149. Install compressor main bracket
    2 fastening bolts
    Tightening torque 35 Nm / 26 lbf. ft.
    Attach KM-6313-10
    150. Install compressor
    3 fastening bolts
    Tightening torque 20 Nm / 15 lbf. ft.
    151. Install alternator
    Position coolant hose bracket
    2 fastening bolts and 2 fastening nuts
    Tightening torque 35 Nm / 26 lbf. ft.
    152. Install ribbed V-belt tensioner
    2 fastening bolts
    Tightening torque (M8) 20 Nm / 15 lbf. ft.
    Tightening torque (M10) 42 Nm / 31 lbf. ft.
    153. Attach ribbed V-belt
    Note: Note running direction
    Tension ribbed V-belt tensioner at hex lug (1) anti-clockwise (arrow)

    154. Attach wiring harness bracket for engine management
    2 fastening bolts
    155. Install wiring harness for engine management
    Remove KM-6154
    Connect wiring harness plug.
    Oil pressure switch, intake pipe pressure sensor, crankshaft pulse pickup, EGR valve, engine control unit, coolant temperature sensor, dynamic oil level control sensor, oil temperature sensor, compressor
    Connect wiring harness plug for sheathed glow plugs
    Attach 2 turbocharge control vacuum hoses
    Vacuum reservoir, solenoid valve
    Starter
    2 fastening nuts
    Alternator
    2 fastening nuts
    156. Attach wiring trough
    2 fastening bolts
    157. Attach upper charge air pipe
    1 clamp
    Tightening torque 3.5 Nm / 2.6 lbf ft
    2 fastening bolts
    Tightening torque 3 Nm / 2 lbf. ft.
    158. Top up engine oil.
    Observe specified engine oil quantity
    Note: After installing the engine, the engine oil level must be checked and corrected if necessary
    http://vauxhall.workshop-manuals.com...ex.php?id=2626
    Last edited by C-Owner; 24th March 2013 at 00:15.

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    Vehicle InfoStats

    Vehicle : Vectra C

    Trim : ls

    Engine : 2.0 dti

    Year : 2003

    Default

    Hi C-Owner


    Thanks for all the advice, I will have a go today and see how I get on .


    Many Thanks

    Chris

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