Vauxhall Workshop Service and Repair Manuals

J463051 Upper Toothed Belt Cover, 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. 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

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

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 journal of the support in the bore of the cylinder block without play (arrow)
• Tighten nuts (1)

11. Lower vehicle

12. 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)

13. Remove right engine damping block Remove 4 bolts

14. Detach alternator wiring harness Disconnect wiring harness plug Unscrew nut

15. Remove wiring trough (1)

• Unclip vacuum lines (2)
• Unclip wiring trough
• 2 clips (arrows)
• Remove bolt (3)

16. Loosen upper part of toothed belt cover Remove 8 bolts Note! Note dissimilar bolt lengths

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

18. 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.)

19. Fasten upper part of toothed belt cover

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

20. 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°.)

21. Attach wiring trough

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

22. Attach alternator wiring harness

• Connect wiring harness plug.
• Tighten nuts

23. 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

24. Raise vehicle

25. Detach support

26. Remove KM-6169

27. Install ribbed V-belt cover

• Screw in bolts
• Install clip

28. Lower vehicle

29. Install right front wheel

• Screw in bolts

30. Lower vehicle

31. Fasten right front wheel

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

32. Connect battery

33. Calibrate steering angle sensor

• Switch on ignition

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

34. Program volatile memories

35. Close bonnet