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Vauxhall Workshop Service and Repair Manuals

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Oil Pan Lower Section, Remove and Install (Z 17 DTH, with AC, LHD) > < Oil Pump Drive Gear, Replace (Z 17 DTH, With AC, LHD)

Corsa C

Oil Pump, Remove and Install (Z 17 DTH, with AC, LHD)

  Remove

1.   Open bonnet
Important:   In vehicles as of model year 04 with ESP - every time the battery is disconnected, the steering angle sensor loses its basic setting and must be recalibrated
2.   Disconnect battery
•   Detach ground cable
3.   Remove oil filter element
•   Place collecting basin underneath.
•   Unscrew oil filter housing cover (1)
Object Number: 2411058 Size: DEFAULT


4.   Remove oil dipstick guide tube
•   Unscrew upper bolt (1)
Object Number: 2411104 Size: DEFAULT


5.   Detach front right wheel
6.   Raise vehicle
7.   Remove right front wheel
•   Unscrew 5 bolts
8.   Raise vehicle
9.   Remove ribbed V-belt cover
•   Unscrew 3 bolts (1)
•   Remove clip (arrow)
Object Number: 2410600 Size: DEFAULT


10.   Drain engine oil
•   Place collecting basin underneath.
•   Remove drain bolt
11.   Fit drain bolt
•   Replace seal ring
•   Tighten bolt 78.4 Nm
12.   Remove front exhaust pipe
Note:   When removing the centre muffler, a catalytic converter, an exhaust manifold or exhaust manifold with catalytic converter, the exhaust system piece remaining in the vehicle must be secured to prevent it sagging uncontrollably. The exhaust gas system piece with the flex pipe inside it can be fastened to the vehicle underbody with suitable materials such as e.g. wire.
•   Unscrew 3 nuts
13.   Attach exhaust system
•   Attach retaining rubber (5x)
•   Tether exhaust system laterally
Note:   Second person required
14.   Remove oil dipstick guide tube
•   Unscrew 2 bolts (arrows)
Object Number: 2411104 Size: DEFAULT


15.   Detach oil pan lower part
•   Unscrew 15 bolts
•   Use KM-J-37228
Object Number: 2411060 Size: DEFAULT


16.   Remove front reaction member
•   Unscrew 2 bolts
•   Unscrew nut
Object Number: 2411109 Size: DEFAULT


17.   Detach oil pan upper part
•   Disconnect dynamic oil level check wiring harness plug
•   Unscrew 14 bolts
Note:   Note dissimilar bolt lengths
•   Unscrew 4x bolt (1)
•   Unscrew 2 nuts
•   Use KM-J-37228
•   Undo intermediate shaft bearing support
– Unscrew 2 bolts
Object Number: 2411061 Size: DEFAULT


18.   Attach front reaction member
•   Tighten 2 bolts
19.   Attach KM-6394
•   Position KM-6394 (1) at the front on the front axle body
Note:   Both locating pins (arrows) must be seated in the holes in the front axle body
•   Push front bracket (2) in the direction of the arrow
•   Place rear bracket (4), right hand side, on front axle body
•   Attach rear bracket (3), left hand side
– Screw in 2x bolt
•   Tighten 6 bolts
Object Number: 2408346 Size: DEFAULT


Object Number: 2411021 Size: DEFAULT

20.   Install support
•   On KM-6394
– Adjust bracket (2) for support
•   Screw on nut (1)
21.   Adjust 3x support
•   Transmission side
Note:   Turn spindles until mounts (3) are positioned at guide journals free of play
•   Engine timing side
– Insert journal of the support in the bore of the cylinder block free of play (arrow)
– Tighten nuts (1)

22.   Loosen coolant pump ribbed V-belt pulley (1)
•   Undo 3 bolts
Object Number: 2406521 Size: DEFAULT


23.   Remove ribbed V-belt
•   Tension ribbed V-belt tensioner in direction of arrow
– Use KM-913-A
Note:   Mark running direction.
Object Number: 2411073 Size: DEFAULT


24.   Detach coolant pump ribbed V-belt pulley
•   Unscrew 3 bolts
25.   Detach starter wiring harness
•   Electrically disconnect starter
– Unscrew 2 nuts
– Remove bolt
•   Disconnect wiring harness plug of fuel pressure sensor
26.   Lower vehicle
27.   Remove air cleaner housing
Object Number: 2408126 Size: DEFAULT

28.   Remove wiring trough
•   Unclip vacuum line (4)
•   Unclip wiring trough (5)
– 2 clips
•   Remove bolt (3)
•   Disconnect 2 wiring harness plugs
– Camshaft sensor (2)
– Charge pressure sensor (1)
•   Unclip wiring harness
29.   Remove camshaft sensor
•   Remove bolt (arrow)

30.   Remove right engine damping block
•   Unscrew 4 bolts
Object Number: 2411070 Size: DEFAULT


31.   Detach right engine bracket (1)
•   Unscrew 3 bolts
Note:   Lower bolt cannot be removed
•   With right engine bracket adapter
Object Number: 2411072 Size: DEFAULT


32.   Remove upper toothed belt cover
Important:   Take care not to damage the increment counter for the camshaft sprocket when removing the upper toothed belt cover.
•   Unscrew 8 bolts
Note:   Note dissimilar bolt lengths
Object Number: 2404431 Size: DEFAULT


33.   Raise vehicle
34.   Remove torsional vibration damper (1)
•   Unscrew 4 bolts
Object Number: 2411100 Size: DEFAULT


35.   Detach lower part of toothed belt cover
•   Unscrew 3 bolts
Object Number: 2411099 Size: DEFAULT


36.   Remove right engine bracket
37.   Set 1st cylinder to TDC
•   Install torsional vibration damper
– Bolt in bolt
•   Turn crankshaft evenly until TDC fixing bolts can be screwed in
– Camshaft gear M6 (1)
– High pressure pump drive gear M8 (2)
Note:   The mark on the torsional vibration damper must align with the pin on the oil pump cover (arrows)
•   Remove torsional vibration damper
Object Number: 2404425 Size: DEFAULT


38.   Loosen toothed belt tension roller (1)
•   Loosen bolt of toothed belt tension roller (2)
•   Rotate toothed belt tension roller anticlockwise approx. 90°
•   Tighten bolt of toothed belt tension roller
39.   Remove toothed belt
Note:   Mark running direction.
Object Number: 2406524 Size: DEFAULT


40.   Detach oil pump drive gear (1)
•   Unscrew nut
Note:   Counterhold with socket wrench and loosen with wrench (2)
Object Number: 2411145 Size: DEFAULT


41.   Attach KM-662-C (2)
•   Screw in 2x bolt
42.   Remove toothed belt drive gear (1)
•   Remove bolt (3)
– Counterhold using KM-662-C
•   Remove toothed belt drive gear
– Use KM-161-B
•   Remove plate
Object Number: 2411146 Size: DEFAULT


43.   Remove oil pump (1)
•   Unscrew 9 bolts
Note:   Note different bolt lengths. Remove inner and outer rotor (2)
44.   Clean sealing surfaces
•   Cylinder block, oil pump cover
Object Number: 2393053 Size: DEFAULT


45.   Inspect components
46.   Remove oil pump seal ring (2)
Important:   Do not damage sealing surfaces
•   Lever out seal ring
47.   Remove front crankshaft front seal ring (1)
Important:   Do not damage sealing surfaces
•   Lever out seal ring
Object Number: 2411148 Size: DEFAULT


  Install

48.   Install oil pump seal ring
•   Drive in seal ring with KM-657 until flush
49.   Install oil pump
•   Insert inner and outer rotor
– Coat with engine oil
•   Clean threads
•   Replace gasket (1)
•   Apply adhesive sealing compound
•   Attach oil pump cover (2)
•   Tighten 9 bolts 9.8 Nm
Object Number: 2393052 Size: DEFAULT


50.   Install front crankshaft seal ring
•   Drive in seal ring with KM-656 until flush
Object Number: 2411149 Size: DEFAULT


51.   Install toothed belt drive gear
•   Install sheet metal panel
•   Put toothed belt drive gear on
Note:   Note woodruff key
•   Tighten bolt 198 Nm
52.   Remove KM-662-C
•   Unscrew 2 bolts
53.   Install oil pump gear
Note:   Pay attention to installation position
•   Tighten nuts
Note:   Counterhold with socket wrench
– 60 Nm
– Hold for 20 seconds
– Remove nut
– 60 Nm
54.   Turn crankshaft
•   Install torsional vibration damper
– Bolt in bolt
•   Set crankshaft to 1st cylinder TDC
Note:   Mark on torsional vibration damper must align with pin on oil pump cover
– Remove torsional vibration damper
55.   Lower vehicle
56.   Install toothed belt
Note:   TDC locking bolt must be installed in the camshaft sprocket and marking (6) and (7) must align.
•   Position toothed belt
– Toothed belt must be tensioned in the direction of the arrow from the toothed belt drive gear (5) via the oil pump drive gear (4), via the high pressure pump drive gear (2) to the camshaft sprocket (1)
– Note running direction
•   Loosen toothed belt tension roller (3)
•   Remove TDC locking bolt
•   Rotate crankshaft 60° against direction of engine rotation
•   Tighten toothed belt tension roller 38Nm
Object Number: 2412651 Size: DEFAULT


57.   Timing, Check
•   Turn crankshaft 720° in the direction of rotation of the engine
•   Mark on toothed belt drive gear (2) must align with cast lug (1) on oil pump cover
•   Screw in TDC fixing bolts (arrows)
•   Install torsional vibration damper
– Bolt in bolt
Note:   The mark on the torsional vibration damper (3) must align with the pin (4) on the oil pump cover. If the TDC fixing bolts cannot be screwed in, basic adjustment must be repeated
•   Unscrew TDC fixing bolts
•   Remove vibration damper
Object Number: 2404425 Size: DEFAULT


58.   Raise vehicle
59.   Attach right engine bracket
•   Insert lower bolt
– Into right engine bracket and right engine bracket adapter
•   Fit right engine bracket with adapter
60.   Attach lower part of toothed belt cover
•   Tighten 3 bolts 9.8 Nm
61.   Lower vehicle
62.   Install upper toothed belt cover
•   Tighten 8 bolts 9.8 Nm
Note:   Note dissimilar bolt lengths
•   Clip in vacuum hose
63.   Fasten right engine bracket
•   Screw in 3 bolts
•   Tighten 2 upper bolts 40 Nm
64.   Install camshaft sensor
•   Replace seal ring
•   Tighten bolt 9.8 Nm
65.   Attach wiring trough
•   Route wiring harness
•   Clip-in wiring trough
•   Clip in vacuum hose
•   Tighten bolt 6 Nm
•   Connect 2 wiring harness plugs
66.   Install right engine damping block
•   To side member
– Tighten 2 bolts 40 Nm
•   On engine bracket
– Tighten 2 bolts 60 Nm + 30° + 15°
67.   Raise vehicle
68.   Fasten right engine bracket
•   Tighten lower bolt 40 Nm
69.   Attach coolant pump ribbed V-belt pulley
•   Screw in 3 bolts
70.   Install torsional vibration damper
•   Tighten 4 bolts 19.6 Nm
71.   Install ribbed V-belt
Note:   Observe running direction and installation position
•   Release ribbed V-belt tensioner
72.   Fasten coolant pump ribbed V-belt pulley
•   Tighten 3 bolts 9.8 Nm
73.   Detach supports
74.   Detach KM-6394
75.   Clean sealing surfaces
•   Cylinder block, upper part of oil pan, lower part of oil pan
76.   Detach front reaction member
77.   Attach oil pan upper part
•   Apply silicone sealing compound
Important:   The application of silicone sealing compound and installation of the lower part of the oil pan, including torque test, must be completed within 10 minutes
•   Tighten 14 bolts 9.8 Nm
•   Tighten 2 nuts 9.8 Nm
•   Tighten 4 M10 bolts 40 Nm
•   Attach intermediate shaft bearing support
– Tighten 2 bolts 55 Nm
•   Connect dynamic oil level check wiring harness plug
78.   Attach front reaction member
•   Tighten 2x bolts 95 Nm
•   Tighten nut 60 Nm
79.   Attach oil pan lower section
•   Apply silicone sealing compound
•   Tighten 15 bolts 9.8 Nm
80.   Attach starter wiring harness
•   Electrically connect starter
– Tighten 2 nuts
– Tighten bolt
•   Connect fuel pressure sensor wiring harness plug
•   Route wiring harness
81.   Detach exhaust system
Note:   Second person required
•   Attach retaining rubber (5x)
82.   Fasten front exhaust pipe
•   Replace gasket
•   3 new nuts
83.   Install oil dipstick guide tube
•   Replace seal ring
•   Tighten 2 bolts 9.8 Nm
84.   Attach ribbed V-belt cover
•   Tighten 3 bolts
•   Install clip
85.   Lower vehicle
86.   Attach front right wheel
•   Screw in 5 bolts
87.   Lower vehicle
88.   Fasten right front wheel
•   Tighten 5 bolts 110 Nm
89.   Install air cleaner housing
•   Fasten clamp 5 Nm
90.   Install oil dipstick guide tube
•   Tighten upper bolt
91.   Install oil filter element
•   Tighten oil filter housing cover 25 Nm
•   Replace seal ring
92.   Top up engine oil
•   Start engine and allow to run until the oil check display lights up
•   Check and correct engine oil level
•   Observe specified engine oil quantity
93.   Connect battery
94.   Close bonnet
95.   Program volatile memory

Oil Pan Lower Section, Remove and Install (Z 17 DTH, with AC, LHD) > < Oil Pump Drive Gear, Replace (Z 17 DTH, With AC, LHD)