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Vauxhall Workshop Service and Repair Manuals

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J462060 Seal Ring - Camshaft, Replace (Y 17 DTL, without AC, LHD) > < All Roller Cam Followers, Replace

Corsa C

J314570 Both Camshafts, Remove and Install (Y 17 DTL, without AC, LHD)

Note:   KM-6394 must be used from model year 04 instead of KM-6169-1 .

1. Open bonnet

 Object Number: 2410600 Size: DEFAULT

Caution!

On vehicles from model year 04 with ESP - the steering angle sensor loses its basic adjustment each time the battery is disconnected. It must be recalibrated.

2. Disconnect battery

  • Detach ground cable

3. Detach front right wheel

4. Raise vehicle

5. Remove front right wheel

  • Remove 4 bolts

6. Raise vehicle

7. Remove ribbed V-belt cover

  • Remove 3 bolts (1)
  • Remove clip (arrow).

8. Attach KM-6169 (1)

  • Place left of KM-6169 onto front axle body (arrows, illus. I)
    • Note! Guide pin must be seated in bore in front axle body
  • Attach both right holders on the front axle body (arrows, Illus. II).
    • Note! Guide pin must be seated in bore in front axle body (arrow, Illus. III)
  • Tighten bolts
 Object Number: 2409770 Size: DEFAULT

9. Install support

  • To KM-6169
    • Adjust bracket (2) for support
  • Screw on nut (1)
 Object Number: 2411093 Size: DEFAULT

10. Adjust supports

  • Transmission side
    • Note! Turn spindles until the mounts (3) are positioned at the guide journals free of play
  • Engine timing side
    • Insert support pin in cylinder block bore without play (arrows)
    • Tighten nuts (1)

11. Lower vehicle

12. Drain coolant

  • Place collecting basin underneath.
  • Open drain bolt
 Object Number: 2411059 Size: DEFAULT

13. Remove air cleaner housing (1)

  • Remove wiring harness plug for hot film mass air flow meter (3)
    • Release in direction of arrow
  • Remove air intake hose (4)
    • Loosen clamp (5)
  • Remove bolt (2)
 Object Number: 2411064 Size: DEFAULT

14. Remove right engine damping block

  • Remove 4 bolts
 Object Number: 2411070 Size: DEFAULT

15. Detach alternator wiring harness

  • Disconnect wiring harness plug (1)
  • Unscrew nut (2)
 Object Number: 2411119 Size: DEFAULT

16. Detach vacuum hoses for vacuum pump (3)

  • Brake servo
  • Exhaust gas recirculation solenoid valve

17. Remove wiring trough

  • Unclip vacuum lines (2)
  • Unclip wiring trough (1)
    • 2 clips (arrows)
  • Remove bolt (3)
 Object Number: 2411071 Size: DEFAULT

18. Release upper toothed belt cover

  • Remove 8 bolts
  • Note! Note dissimilar bolt lengths
 Object Number: 2404431 Size: DEFAULT

19. Detach right engine bracket (1)

  • Remove 3 bolts
  • Remove right engine bracket, right engine bracket adapter, upper part of toothed belt cover
 Object Number: 2411072 Size: DEFAULT

20. Raise vehicle

 Object Number: 2411103 Size: DEFAULT

21. Loosen coolant pump ribbed V-belt pulley (1)

  • Loosen bolts

22. Detach ribbed V-belt

  • Tension ribbed V-belt tensioner in direction of arrow
  • With KM-913-A
  • Note! Mark running direction
 Object Number: 2411073 Size: DEFAULT

23. Detach coolant pump ribbed V-belt pulley

  • Remove bolts
 Object Number: 2411100 Size: DEFAULT

24. Remove torsional vibration damper (1)

  • Remove 4 bolts

25. Remove lower toothed belt cover

  • Remove 3 bolts
 Object Number: 2411099 Size: DEFAULT

24. Set 1st cylinder to TDC

  • Turn crankshaft evenly until TDC-fixing bolts can be inserted
    • Camshaft gear (M6) (1)
    • Injection pump gear (M8) (2)
  • Note! The mark on toothed belt drive gear must align with lug on oil pump cover (arrows)
 Object Number: 2404425 Size: DEFAULT

27. Lower vehicle

28. For toothed belt tension roller with leaf spring:

  • loosen toothed belt tensioner
    • Screw in bolt (M10) in lower bore (3) of toothed belt tensioner
    • Loosen bolt (2)
    • Remove tension spring (1)
 Object Number: 7360927 Size: DEFAULT

For toothed belt tension roller with spiral spring:

  • Loosen toothed belt tension roller (1)
    • Rotate toothed belt tension roller anticlockwise approx. 90°
    • Tighten bolt (2)
 Object Number: 2406524 Size: DEFAULT

29. Remove toothed belt

  • Note! Mark running direction

30. Detach camshaft pulley

  • Unscrew TDC-fixing bolt (2)
  • Remove bolt (1)
    • Counterhold using KM-6165 and KM-956-1
 Object Number: 2411076 Size: DEFAULT

31. Remove air intake pipe

  • Remove 3 bolts
  • Remove vent hose (1)
    • From cylinder head cover
  • Release clamp
  • Unclip wiring harness
 Object Number: 2411065 Size: DEFAULT

32. Detach engine control unit wiring harness plug

  • 3 off
    • Release 2 wiring harness plugs in direction of arrow
 Object Number: 2411078 Size: DEFAULT

33. Remove engine control unit

  • Remove wiring harness plug bracket
    • Remove 2 bolts (1)
  • Unscrew 2 bolts (2), 2 nuts (3)
 Object Number: 2411079 Size: DEFAULT

34. Remove engine control unit bracket

  • Unscrew 2 bolts (2), nut (1)
  • Unclip wiring harness (arrows)
 Object Number: 2411080 Size: DEFAULT

35. Remove right rear engine transport shackle

  • Remove bolt

36. Release rear left engine transport shackle

37. Detach injection lines

  • From injector nozzles
  • With KM-6098

38. Detach injection nozzle outer seals

  • Remove 8 bolts
 Object Number: 2411157 Size: DEFAULT

39. Detach oil dipstick guide tube bracket

  • Unscrew 2 nuts, bolt

40. Remove camshaft housing cover

  • Unscrew 7 bolts (1), 3 studs (2)
 Object Number: 2411156 Size: DEFAULT

41. Remove camshaft housing cover

  • Note! 2. mechanic
  • Carefully push injection lines to rear

42. Detach inner oil leak line

  • Unscrew 5 banjo bolts (1)
  • Note! Note sealing rings
 Object Number: 2411086 Size: DEFAULT

43. Remove injector nozzles

Caution!

Ensure that upon removal of injector nozzles heat protection sleeves remain in their position on the cylinder head.

Otherwise, heat protection sleeves must be removed completely and installed again using new seal rings. This is the only way to ensure that no coolant can reach the combustion chamber, which would inevitably cause engine damage. Replace heat protection sleeves – see operation "Replace heat protection sleeves" in document "Check and measure cylinder head".

  • Remove injection nozzle bracket (1)
    • Remove 2 nuts
  • Remove injector nozzles
 Object Number: 2411150 Size: DEFAULT

44. Lock exhaust camshaft equaliser gear

  • Insert KM-955-2 (1)
    • Note! Insert in exhaust camshaft gear and exhaust camshaft equaliser gear up to camshaft bearing cap stop. Exhaust camshaft gear and exhaust camshaft equaliser gear must be locked in place with rotation impossible
 Object Number: 2411160 Size: DEFAULT

45. Remove camshaft bearing caps

  • 5 off
  • Remove 10 nuts
  • Note! Note identification on camshaft bearing caps. The camshafts must be uniformly released from the bearing seats. Loosen nuts (180° – 360°)
 Object Number: 2411186 Size: DEFAULT

46. Remove camshafts

  • Remove intake camshaft seal ring

47. Clean sealing surfaces

  • Camshaft housing, camshafts, intake camshaft bearing cap seal ring

48. Inspect components

When replacing exhaust camshaft:

49. Lock exhaust camshaft equaliser gear

  • Pretension exhaust camshaft compensating gear in anti-clockwise direction using KM-6092 (1)
  • Insert KM-955-2 (2)
  • Note! Insert pin until flush, camshaft bearing cap could be damaged upon installation. Exhaust camshaft gear and exhaust camshaft equaliser gear must be locked in place with rotation impossible
 Object Number: 2411169 Size: DEFAULT

50. Insert camshafts

  • Caution! Mark on exhaust camshaft gear (1) must be positioned between both intake camshaft gear marks (2). The marks must be in one plane with the top edge of the camshaft housing
 Object Number: 2416017 Size: DEFAULT

51. Attach camshaft bearing caps

  • Note! Apply surface sealant (green) to sealing surfaces of 1st camshaft bearing cap (3)
  • 5 off
  • Screw in nuts

52. Tighten camshaft bearing caps

  • Tighten nuts M8 (21.6 Nm / 16 lbf. ft.)
    • Caution! Observe sequence (1 - 15)
  • Remove KM-955-2
 Object Number: 2416018 Size: DEFAULT

53. Install intake camshaft seal ring (1)

  • Coat seal lips with grease
  • Slide onto camshaft
  • Drive in until flush using KM-656 (2)
 Object Number: 2411137 Size: DEFAULT

54. Attach camshaft pulley

  • Lock with KM-6156 and KM-956-1
  • Tighten bolt (63.7 Nm / 47.0 lbf. ft.)
  • Install TDC-fixing bolt

55. Install toothed belt

Note:   Toothed belt must be taut from toothed belt drive gear via oil pump drive gear and injection pump drive gear

  • Position toothed belt
  • For toothed belt tension roller with leaf spring:
    • Attach leaf spring
  • Unscrew TDC-fixing bolt
  • Rotate crankshaft 60° against direction of engine rotation
  • Tighten bolt of toothed belt tension roller
    • For toothed belt tension roller with spiral spring 49 Nm
    • For toothed belt tension roller with leaf spring 38.2 Nm
  • For toothed belt tension roller with leaf spring: unscrew bolt (M10) from lower bore of toothed belt tensioner

56. Check timing

  • Turn crankshaft approx. 780° in direction of engine rotation
    • At fastening bolt
  • Mark on toothed belt drive gear (2) must align with casting lug at oil pump cover (1)
  • Screw in TDC-fixing bolts (arrows)
  • Install torsional vibration damper
    • Install 2 bolts
  • Note! Mark on torsional vibration damper (3) must align with pin (4) on oil pump cover If the TDC fixing bolts cannot be inserted, the basic adjustment must be repeated
  • Unscrew TDC-fixing bolts
 Object Number: 2411124 Size: DEFAULT

57. Remove torsional vibration damper

58. Rotate crankshaft

  • Turn crankshaft until cam pairs (1) and (2) point upwards

59. Check valve clearance

  • Using feeler gauge
    • Test values: Intake valves/Exhaust valves (0.35 – 0.45 mm)
  • Note! The valve clearances are checked on a cold engine – room temperature

60. Adjust valve clearance

  • Turn cup tappet until tappet groove points outwards
  • Press down cup tappets using KM-6090
  • Note! Note different tool versions for intake and exhaust valves
    • Mark – IN = Intake side
    • Mark – EX = Exhaust side
  • Caution! Ensure that valves do not interfere with piston head
  • Remove adjustment shim
 Object Number: 2415968 Size: DEFAULT

Example for determination of shim thickness

1.

Thickness of installed shim

 

3.15 mm

2.

Measurement between cam and cup tappets

+

0.45 mm

 

 

=

3.60 mm

3.

Nominal valve play

-

0.40 mm

4.

Thickness of new shim

=

3.20 mm

61. Insert adjustment shim

  • Coat new shim (7) with engine oil and insert in cup tappet with identification mark facing downwards.

62. Turn crankshaft

  • In direction of engine rotation by 180°
    • Check and adjust valve pair (6) and (2)
  • In direction of engine rotation by 180°
    • Check and adjust valve pair (5) and (3)
  • In direction of engine rotation by 180°
    • Check and adjust valve pair (4) and (1)
  • Note! Valve clearances must be checked again for all adjusted valves
 Object Number: 2415969 Size: DEFAULT

63. Install injector nozzles

  • Renew seal rings
  • Renew copper sealing washers
  • Insert injection nozzles in cylinder head.
  • Install injector nozzle bracket (22.1 Nm/16.3 lbf. ft.)

64. Attach inner oil leak line

  • Renew seal rings
  • Tighten banjo bolt (14.7 Nm/10.8 lbf. ft.)

65. Attach lower part of toothed belt cover

  • Tighten bolts (9.8 Nm / 7.2 lbf. ft.)

66. Attach right engine bracket

  • Insert lower bolt
    • Into right engine bracket and right engine bracket adapter
  • Insert right engine bracket, right engine bracket adapter, upper part of toothed belt cover
  • Install upper bolts
  • Tighten bolts (40 Nm / 29.5 lbf. ft.)

67. Fasten upper part of toothed belt cover

  • Tighten bolts (9.8 Nm / 7.2 lbf. ft.)
  • Note! Note dissimilar bolt lengths

68. Attach coolant pump ribbed V-belt pulley

  • Screw in bolts

69. Raise vehicle

70. Install torsional vibration damper

  • Tighten bolts (19.6 Nm / 14.5 lbf. ft.)

71. Install ribbed V-belt

  • Note! Observe running direction and installation position

72. Release ribbed V-belt tensioner

73. Fasten coolant pump ribbed V-belt pulley

  • Tighten bolts (9.8 Nm / 7.2 lbf. ft.)

74. Lower vehicle

75. Install right engine damping block

  • To side member
    • Tighten bolts (40 Nm / 29.5 lbf. ft.)
  • On engine bracket
    • Tighten bolts (60 Nm/44 lbf. ft + 30° + 15°.)

76. Attach camshaft housing cover

  • Replace gasket
  • Apply adhesive sealant compound (white)
    • Areas (1) and (3)
  • Caution! Oil return bore (2) must not be covered with adhesive sealing compound or by the camshaft housing cover gasket

77. Install camshaft housing cover

  • Note! 2. mechanic
  • Carefully push injection lines to rear

78. Tighten camshaft housing

  • Tighten bolts, studs (9.8 Nm/7.2 lbf. ft.)
 Object Number: 2416086 Size: DEFAULT

79. Install oil dipstick guide tube bracket

  • Tighten nuts, bolt

80. Attach injection nozzle outer seals

  • Replace seals
  • Note! Note identification
  • Tighten bolts

81. Install injection lines

  • With KM-6098
  • Tighten union nuts (22.5 Nm/16.6 lbf. ft.)

82. Fasten rear left engine transport shackle

  • Tighten bolts (20 Nm / 15 lbf. ft.)

83. Install right rear engine transport shackle

  • Tighten bolt (20 Nm / 15 lbf. ft.)

84. Install engine control unit bracket

  • Tighten bolts (24.5 Nm/18.1 lbf. ft.)
  • Tighten nut (9.8 Nm/7.2 lbf. ft.)
  • Attach wiring harness

85. Install engine control unit

  • Tighten bolts, nuts (5.9 Nm/4.4 lbf. ft.)
  • Install wiring harness plug bracket
    • Tighten bolts
  • Connect wiring harness plug.

86. Connect wiring harness plug for engine control unit

  • 3 off

87. Attach wiring trough

  • Clip-in wiring trough
  • Clip in vacuum lines
  • Tighten bolt

88. Install alternator wiring harness

  • Connect wiring harness plug.
  • Tighten nuts

89. Attach vacuum pump vacuum lines

  • Route lines and clip in
  • Tighten union nut (18 Nm/13.3 lbf. ft.)

90. Install air intake pipe

  • Tighten bolts
  • Fasten clamp
  • Attach engine vent hose
    • Fasten clamp
  • Attach wiring harness

91. Install air cleaner housing

  • Tighten bolt
  • Fasten air intake hose.
    • Fasten clamp (3.5 Nm / 2.6 lbf. ft.)
  • Connect wiring harness plug to hot film mass air flow meter

92. Raise vehicle.

93. Detach support

94. Detach KM-6169

95. Install ribbed V-belt cover

  • Tighten bolts
  • Install clip

96. Lower vehicle

97. Install right front wheel

  • Screw in bolts

98. Lower vehicle

99. Fasten right front wheel

  • Tighten bolts (110 Nm / 81 lbf. ft.)

100. Top up coolant

  • Note! Top up and bleed cooling system – see operation "Top up and bleed cooling system"
  • Observe specified coolant quantity

101. Connect battery

102. Calibrate steering angle sensor

  • Switch on ignition

Note:   Rotate the steering wheel one time from its right-hand to its left-hand stop.

103. Program volatile memories

104. Close bonnet
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J462060 Seal Ring - Camshaft, Replace (Y 17 DTL, without AC, LHD) > < All Roller Cam Followers, Replace