Vauxhall Workshop Service and Repair Manuals

J461900 Camshaft Housing, Replace (Y 17 DTL, without AC, LHD)

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

1. Open bonnet

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. Loosen air intake pipe.

• From turbocharger
• Release clamp

9. 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

10. Install support To KM-6169 Adjust bracket (2) for support Screw on nut (1)

11. Adjust supports

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

12. Lower vehicle

13. Drain coolant Place collecting basin underneath. Remove drain bolt

14. 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)

15. Detach air intake pipe Remove 3 bolts Remove vent hose (1) From cylinder head cover Detach air intake pipe from turbocharger Unclip wiring harness

16. Remove right engine damping block Remove 4 bolts

17. Detach alternator wiring harness

• Disconnect wiring harness plug (1)
• Unscrew nut (2)

18. Detach vacuum hoses for vacuum pump (3) Brake servo Exhaust gas recirculation solenoid valve

19. Remove wiring trough Unclip vacuum lines (2) Unclip wiring trough (1) 2 clips (arrows) Remove bolt (3)

20. Release upper toothed belt cover Remove 8 bolts Note! Note dissimilar bolt lengths

21. Detach right engine bracket (1) Remove 3 bolts Remove right engine bracket, right engine bracket adapter, upper part of toothed belt cover

22. Raise vehicle

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

24. Detach ribbed V-belt Tension ribbed V-belt tensioner in direction of arrow With KM-913-A Note! Mark running direction

25. Detach coolant pump ribbed V-belt pulley

• Remove bolts

26. Remove torsional vibration damper (1) Remove 4 bolts

27. Remove lower toothed belt cover Remove 3 bolts

28. 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)

29. Lower vehicle

30. 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)

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)

31. Remove toothed belt

• Note! Mark running direction

32. Detach camshaft pulley Unscrew TDC-fixing bolt (2) Remove bolt (1) Counterhold using KM-6156 and KM-956-1

32. Loosen rear toothed belt cover Remove 2 bolts 34. Detach engine control unit wiring harness plug 3 off Release 2 wiring harness plugs in direction of arrow

35. Remove engine control unit Remove wiring harness plug bracket Remove 2 bolts (1) Unscrew 2 bolts (2), 2 nuts (3)

36. Remove engine control unit bracket Unscrew 2 bolts (2), nut (1) Unclip wiring harness (arrows)

37. Remove rear right engine transport shackle

• Remove bolt

38. Release left rear engine transport shackle

39. Detach oil leak line

40. Detach injection lines

• From injector nozzles

41. Detach injection nozzle outer seals Remove 8 bolts

42. Detach oil dipstick guide tube bracket

• Unscrew 2 nuts, bolt

43. Remove camshaft housing cover Unscrew 7 bolts (1), 3 studs (2)

44. Remove camshaft housing cover

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

45. Detach inner oil leak line

• Remove 5 banjo bolts
• Note! Note sealing rings

46. 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 sealing 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

47. 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

48. Remove camshaft bearing caps 5 off Remove 15 nuts Note! Note identification on camshaft bearing caps. The camshafts must be uniformly released from the bearing seats. Loosen nuts (180° – 360°)

49. Remove camshafts Remove intake camshaft seal ring

50. Remove camshaft housing cover

• Loosen bolts (180°)
• Caution! Observe sequence (1 - 12)
• Remove 12 bolts
• Remove gasket.

51. Detach outer oil leak line Unscrew banjo bolt Remove seal rings Remove bolt

52. Attach outer oil leak line

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

53. Clean sealing surfaces

• Cylinder head, camshaft housing, camshaft housing cover, exhaust recirculation valve

54. Check for plane surface

• camshaft housing
• With straightedge

55. Install camshaft housing Replace gasket Tighten bolts (21.6 Nm / 15.9 lbf. ft.) Caution! Observe sequence (1 - 12)

56. 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

57. Attach camshaft bearing caps

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

58. Attach camshaft bearing caps Tighten nuts M8 (21.6 Nm/15.9 lbf. ft.), M10 (43.1 Nm/31.8 lbf. ft.) Caution! Observe sequence (1 - 15) Remove KM-955-2

59. Install intake camshaft seal ring (1) Coat seal lips with grease Slide onto camshaft Drive in until flush using KM-656 (2)

60. Attach rear toothed belt cover

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

61. Attach camshaft gear

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

62. Set cylinder 1 to TDC Mark on toothed belt drive gear (2) must align with casting lug at oil pump cover (1)

63. 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

65. Timing, Check

• Turn crankshaft approx. 780° in direction of engine rotation
• At toothed belt drive gear 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

66. Unscrew TDC-fixing bolts

67. Remove torsional vibration damper

• Remove 2 bolts

68. Rotate crankshaft Turn crankshaft until cam pairs (1) and (2) point upwards

69. 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

70. 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

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 71. Insert adjustment shim Coat new shim (7) with engine oil and insert in cup tappet with identification mark facing downwards. 72. Rotate 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

73. Attach lower part of toothed belt cover

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

74. 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 2 upper bolts
• Tighten 3 bolts (40 Nm / 29.5 lbf. ft.)

75. Fasten upper part of toothed belt cover

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

76. Attach coolant pump ribbed V-belt pulley

• Screw in bolts

77. Raise vehicle

78. Install torsional vibration damper

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

79. Install ribbed V-belt

• Note! Observe running direction and installation position

80. Release ribbed V-belt tensioner

81. Fasten coolant pump ribbed V-belt pulley

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

82. Lower vehicle

83. 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°.)

84. 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.)

85. Attach new inner oil leak line

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

86. 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

87. Install camshaft housing cover

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

88. Tighten camshaft housing cover

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

89. Install oil dipstick guide tube bracket

• Tighten nuts, bolt

90. Attach injection nozzle outer seals

• Replace seals
• Tighten bolts

91. Install injection lines

• Tighten union nuts (22.5 Nm/16.6 lbf. ft.)

92. Fasten rear left engine transport shackle

• Tighten bolts (20 Nm / 15 lbf. ft.)

93. Install right rear engine transport shackle

• Tighten bolt (20 Nm / 15 lbf. ft.)

94. Attach oil leak hose

• Fasten clamp

95. Attach wiring trough

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

96. Install alternator wiring harness

• Connect wiring harness plug.
• Tighten nuts

97. Attach vacuum pump vacuum lines

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

98. 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

99. Install engine control unit

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

100. Install air intake pipe

• Tighten bolts
• Tighten clamp (3.5 Nm / 2.6 lbf. ft.)
• Attach engine vent hose
• Fasten clamp
• Attach wiring harness

101. Connect wiring harness plug for engine control unit

• 3 off

102. Install air cleaner housing

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

103. Raise vehicle

104. Detach support

105. Detach KM-6169

106. Attach ribbed V-belt cover

• Tighten bolts
• Install clip

107. Lower vehicle

108. Mount right front wheel

• Screw in bolts

109. Lower vehicle

110. Fasten right front wheel

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

111. Check and correct engine oil level

• Observe specified engine oil quantity

112. Top up coolant

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

113. Connect battery

114. Calibrate steering angle sensor

• Switch on ignition

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

115. Program volatile memories

116. Close bonnet