The steps below are shortened from the Vauxhall TIS pages for the Speedster. The VX220 shares the same engines and most of the car, but check anything unusual against your own car. The TIS pictures and the full wording aren't reproduced, so use the workshop manual if you are doing the job. We haven't seen owners' accounts of this job, so there are no owner tips here.
Engine-out work. Clearances are on Turbo engine data and torques on Torque values.
A four post hoist must be used to raise the vehicle when removing the engine undertray and exhaust pipe undertray. The vehicle can be moved to a two post hoist for other operations if required.
Other jobs from the same factory chapter: Crankshaft and bearing clearances (Turbo); Balancer shaft unit and backlash (Turbo); Pistons, con-rods and piston rings (Turbo).
Crankshaft oil seal, flywheel side
Turbo (Z20LET) only.
Remove
- Remove engine with transmission - see “Engine with Transmission, Remove and Install (Z 20 LET)”
- Remove turbocharger heat shield from engine and transmission assembly (Remove 2x bolt)
- Remove transmission from engine assembly (Remove 11x bolt)
- Remove clutch plate with pressure plate from flywheel
- Install Flywheel Holder KM-652 to (Install Flywheel Holder KM-652 to engine block)
- Remove 6x bolt, then discard
- Remove flywheel from crankshaft (Remove 6x bolt, then discard)
- Remove Flywheel Holder KM-652 from engine block
- Remove seal ring from crankshaft (Prise out using suitable tool)
Install
- Install seal ring to crankshaft (Use Seal Ring Installer KM-635 with; Apply oil to seal lip)
- Install flywheel to crankshaft (Do not tighten (Apply locking compound))
- Immobilize flywheel (Install Flywheel Holder KM-652 to)
- Secure flywheel to crankshaft (Secure 6x bolt 65 Nm + 30° +)
- Install clutch plate with pressure plate to flywheel (Install 6x new bolt 15 Nm)
- Remove Flywheel Holder KM-652 from engine block
- Install transmission to engine (Install 7x bolt 60 Nm; Install 4x bolt 40 Nm)
- Install turbocharger heat shield to engine and transmission assembly (Install 2x bolt)
- Check oil level and top-up if required
Crankshaft oil seal, timing side
Turbo (Z20LET) only.
Remove
- Remove engine undertray (Raise vehicle; Remove 13x bolt, 13x washer)
- Lower vehicle
- Disconnect battery negative lead
- Release windscreen wash reservoir, then move to one side
- Remove nut, bolt
- Disconnect intercooler hose from throttle body (Release clip)
- Raise vehicle to suitable working height and support
- Remove rear road wheel from right side
- Use special socket located under front bonnet
- Remove 4x wheel bolt
- Remove liner from wheel arch (Remove 6x screw)
- Disconnect intercooler hose from intercooler (Release clip; Remove, then discard 4x cable tie)
- Remove upper cover of camshaft timing belt (Remove 2x bolt)
- Remove ribbed V-belt
- Using suitable spanner rotate tensioner clockwise, then (Using suitable spanner rotate tensioner clockwise, then Install suitable locking pin)
- Remove crankshaft pulley
- Apply match marks to crankshaft pulley and crankshaft
- Remove 4x bolt, using spanner to counter-hold centre nut on
- Remove ribbed V-belt tensioner (Remove 2x bolt)
- Remove lower cover of camshaft timing belt (Remove 2x bolt)
- Rotate crankshaft clockwise to top dead centre (TDC) on cylinder No. 1, until 2x timing mark are aligned
- Lock camshafts in position (Use Locking Tool KM-853)
- Release tension from camshaft timing belt
- Release bolt, then turn adjusting eccentric in direction of
- Remove camshaft timing belt from pulleys, move to one side
- Do not remove camshaft timing belt from vehicle
- Remove crankshaft sprocket from crankshaft (Counter-hold using KM-662-C)
- Remove retaining key from crankshaft (Prise out using suitable tool)
- Remove washer from crankshaft
- Remove, then discard crankshaft oil seal from crankshaft (Prise out using suitable tool)
Install
- Install new crankshaft oil seal to crankshaft (Use Assembly Sleeve KM-693)
- Install washer to crankshaft
- Install retaining key to crankshaft
- Install crankshaft sprocket to crankshaft (Counter-hold using KM-662-C)
- Install camshaft timing belt to pulleys (Ensure timing marks are aligned)
- Adjust tension of camshaft timing belt - see “Camshaft Timing Belt Tension, Check and Adjust (Z 20 LET)”
- Install lower cover of camshaft timing belt (Install 2x bolt 6 Nm)
- Install ribbed V-belt tensioner (Install 2x bolt 25 Nm)
- Install crankshaft pulley
- Align match marks on crankshaft pulley and crankshaft
- Counter-hold centre nut on crankshaft sprocket using (Counter-hold centre nut on crankshaft sprocket using spanner)
- Install ribbed V-belt
- Using suitable spanner rotate tensioner clockwise, then remove
- Install upper cover of camshaft timing belt (Install 2x bolt 6 Nm)
- Install intercooler hose to intercooler (Secure clip; Install 4x new cable tie)
- Install liner to wheel arch (Install 6x screw)
- Install rear road wheel (Install 4x bolt, security bolt; Do not tighten)
- Lower vehicle
- Secure rear road wheel (Tighten 4x bolt, security bolt 90)
- Connect intercooler hose to throttle body (Secure clip)
- Connect battery negative lead (Install nut, bolt; Secure windscreen wash reservoir)
- Program all volatile memories
- Raise vehicle
- Install engine undertray (Install 13x bolt, 13x washer)
- Lower vehicle
Crankshaft pulley
Turbo (Z20LET) only.
Remove
- Remove engine undertray (Raise vehicle; Remove 13x bolt, 13x washer)
- Remove ribbed V-belt
- Using suitable spanner rotate tensioner clockwise, then (Using suitable spanner rotate tensioner clockwise, then Install suitable locking pin)
- Remove crankshaft pulley Note: Note position of crankshaft pulley.
- Counter-hold centre bolt on crankshaft sprocket
Install
- Install new crankshaft pulley Note: Note position of crankshaft pulley.
- Counter-hold centre nut on crankshaft sprocket
- Install ribbed V-belt
- Use suitable spanner to rotate tensioner clockwise, then remove
- Install engine undertray (Install 13x bolt, 13x washer)
- Lower vehicle
Crankshaft sprocket (timing belt)
Turbo (Z20LET) only.
Remove
- Remove engine undertray (Raise vehicle; Remove 13x bolt, 13x washer)
- Lower vehicle
- Disconnect battery negative lead
- Release windscreen wash reservoir, then move to one side
- Release nut, bolt
- Disconnect intercooler hose from connecting pipe for throttle body (Release clip; Pull off)
- Raise vehicle to suitable working height
- Remove rear road wheel from right side
- Use special socket located under front bonnet
- Remove 4x wheel bolt
- Remove wheel arch liner, right rear (Remove 4x screw, 2x clip)
- Remove intercooler hose from intercooler (Release clip; Remove, then discard 4x cable tie)
- Remove upper front cover for timing belt (Remove 2x bolt; Pull off)
- Remove ribbed V-belt
- Using suitable spanner rotate tensioner clockwise, then (Using suitable spanner rotate tensioner clockwise, then Install suitable locking pin)
- Remove crankshaft pulley Note: Note position of crankshaft pulley.
- Counter-hold centre bolt on crankshaft sprocket
- Remove ribbed V-belt tensioner (Remove 2x bolt)
- Remove lower cover for timing belt (Remove 2x bolt)
- Rotate crankshaft in normal direction of rotation to Top Dead Centre (TDC) on cylinder no. 1, until timing marks are aligned
- Lock camshafts in position (Use Locking Tool KM-853)
- Release tension from timing belt
- Release bolt, then turn adjusting eccentric clockwise in
- Remove timing belt from pulleys (Position timing belt to one side)
- Remove crankshaft sprocket from crankshaft (Counter-hold using KM-662-C)
Install
- Install new crankshaft sprocket to crankshaft (Counter-hold using KM-662-C)
- Check timing marks are aligned
- Install timing belt to pulleys
- Pre-tension timing belt
- Turn eccentric of tensioner in direction of arrow
- Remove Locking Tool KM-853 from
- Rotate crankshaft two complete turns in normal direction of
- Install Locking Tool KM-853 to
- Tension timing belt
- Release tensioner bolt, then turn eccentric of tensioner in
- Secure tensioner (Secure bolt 20 Nm; Remove Locking Tool KM-853)
- Rotate crankshaft two complete turns in normal direction of rotation to (TDC) on cylinder no. 1, until timing marks are aligned. If pointer of tensioner does not align with corresponding notch mark, then repeat adjustment procedure
- Install lower cover of camshaft timing belt (Install 2x bolt 6 Nm)
- Install ribbed V-belt tensioner (Install 2x bolt 25 Nm)
- Install crankshaft pulley Note: Note position of crankshaft pulley.
- Counter-hold centre nut on crankshaft sprocket
- Install ribbed V-belt
- Use suitable spanner to rotate tensioner clockwise, then remove
- Install upper cover of camshaft timing belt (Push on; Install 2x bolt 6 Nm)
- Install intercooler hose to intercooler (Secure clip; Install 4x new cable tie)
- Install liner to wheel arch (Install 4x screw, 2x clip)
- Install rear road wheel to right side (Install 4x bolt, security bolt; Do not tighten)
- Lower vehicle
- Secure rear road wheel right side (Tighten 4x bolt, security bolt 90)
- Install intercooler hose to throttle body (Secure clip)
- Connect battery negative lead (Secure nut and bolt)
- Install windscreen wash reservoir (Push fit)
- Program all volatile memories
- Raise vehicle
- Install engine undertray (Install 13x bolt, 13x washer)
- Lower vehicle
Crankshaft pulse sensor
Turbo (Z20LET) only.
Remove
- Disconnect crankshaft pulse sensor from engine harness (Disconnect harness connector; Release 3x clip)
- Remove engine undertray (Raise vehicle; Remove 13x bolt, 13x washer)
- Remove ribbed V-belt
- Using suitable spanner rotate tensioner clockwise, then (Using suitable spanner rotate tensioner clockwise, then Install suitable locking pin)
- Remove hose from turbocharger and intercooler (Release 2x clip; Remove, then discard cable tie)
- Remove ribbed V-belt idler pulley from accessory bracket (Remove 3x bolt, washer)
- Remove accessory bracket from engine cylinder block (Remove 3x bolt)
- Remove crankshaft pulse sensor from engine cylinder block (Remove bolt)
Install
- Install crankshaft pulse sensor to engine cylinder block (Install bolt 8 Nm)
- Install accessory bracket to engine cylinder block (Install 4x bolt 35 Nm)
- Install ribbed V-belt idler pulley to accessory bracket (Install 3x bolt, washer 20 Nm)
- Install hose to turbocharger and intercooler (Install new cable tie; Secure 2x clip; Remove, then discard cable tie)
- Install ribbed V-belt
- Using suitable spanner rotate tensioner clockwise, then remove
- Install engine undertray (Install 13x bolt, 13x washer)
- Lower vehicle
- Connect crankshaft pulse sensor to engine harness (Connect harness connector; Secure 3x clip)