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Vauxhall Workshop Service and Repair Manuals

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High-Pressure Pump, Remove and Install > < Replace accelerator pedal module

Astra H

High-Pressure Pump Drive Gear, Remove and Install

  Remove

1.   Open bonnet
2.   Disconnect battery
•   Detach earth connection from earth terminal
3.   Remove engine cover (2)
•   Detach oil filler port closure cap (1)
•   Pull off engine cover
Note:   Rubber retainers (3) must remain on engine cover
•   Attach oil filler port closure cap
Object Number: 2412632 Size: DEFAULT


4.   Remove air cleaner housing (5) with air intake hose
•   Disconnect wiring harness plug (2) from hot film mass air flow meter
•   Detach air intake hose from air intake pipe
– Release clamp (1)
•   Detach air cleaner housing from wheel housing
– Unscrew bolt (4)
•   Detach water drain hose (3) from air cleaner housing
– Release clamp
Object Number: 3446547 Size: DEFAULT


5.   Remove ribbed V-belt
•   Mark direction of rotation
•   Apply tension to ribbed V-belt tensioner via bolt (1) in the direction of the arrow
•   Fix ribbed V-belt tensioner to bore (2)
•   Remove ribbed-V-belt
Object Number: 3447354 Size: DEFAULT


6.   Detach wiring trough (4) from front toothed belt cover (top)
•   Unscrew bolt (2)
•   Detach wiring harness (3)
– Disconnect camshaft sensor wiring harness plug
– Release 2x clip
•   Detach vacuum line (1)
– Release 2x clip
•   Unclip wiring trough in direction of arrow
– Undo clip
Object Number: 3447352 Size: DEFAULT


7.   Detach front toothed belt cover (top) (4)
•   Detach vacuum line (3)
– Unclip 3x clip
•   Unscrew 8x bolts
Note:   Note different bolt lengths
•   Remove camshaft sensor bracket (1)
– Unscrew bolt (2)
Object Number: 3447353 Size: DEFAULT


8.   Raise vehicle by its full height
9.   Detach the lower engine cover and right engine splash guard
10.   Insert KM-6173 (3)
•   Align support bearing (1)
•   Raise support bearing until journal (2) sits flush in mount (4)
•   Fasten KM-6173
– Screw in 2x bolts
Object Number: 2412781 Size: DEFAULT


11.   Attach KM-6001-A (1)
Note:   Attaching KM-6001-A guarantees perfect alignment of the drive unit with the front axle body
•   Slacken 4x bolts (arrows) in adjusting rails
•   Insert KM-6001-A
– Insert journals (2) and (5) in guide holes in front axle body
•   Tighten 4x bolts in adjusting rails
•   Adjust support bearings, front (4) and rear (3)
– Raise support bearings up to the stop on the guide journals
Note:   The guide journals must be seated free from play in the support bearings
Object Number: 2414110 Size: DEFAULT


12.   Detach torsional vibration damper (1)
•   Unscrew 4x bolts
Note:   Counterhold at bolt (2)
Object Number: 2412637 Size: DEFAULT


13.   Lower vehicle by its full height
14.   Remove engine damping block support
•   Detach from engine damping block bracket
– Unscrew 3x bolts (2)
•   Detach from cylinder block
– Unscrew 3x bolts (3)
•   Remove engine damping block adapter (1)
Object Number: 2412638 Size: DEFAULT


15.   Remove coolant pump drive gear (1)
•   Unscrew 3 bolts
Object Number: 2412639 Size: DEFAULT


16.   Remove front toothed belt cover (lower) (1)
•   Unscrew 3x bolts (2)
Object Number: 2412640 Size: DEFAULT


17.   Move crankshaft in direction of engine rotation to "Cylinder no.1 combustion stroke TDC"
Note:   Marking on toothed belt drive gear must align with projection on oil pump cover (arrows)
•   Fix with TDC fixing bolt (M6) (1) camshaft drive gear
•   Fix with TDC fixing bolt (M8) (2) high pressure pump gear
Object Number: 2404425 Size: DEFAULT


18.   Remove toothed belt
•   Mark direction of rotation
•   Slacken the toothed belt tension roller
– Loosen bolt (1)
•   Apply preliminary tension to toothed belt tension roller with hexagon (2) in direction of arrow
•   Fix toothed belt tension roller in pre-tensioned position
– Tighten bolt
Object Number: 2412642 Size: DEFAULT


19.   Remove high-pressure pump gear
•   Unscrew nut
Note:   using KM-6356

(1)

counterhold
•   Remove high pressure pump gear with KM-6355 (2)
Note:   Counterhold with KM-6356
Object Number: 2412646 Size: DEFAULT


  Install

20.   Fit high pressure pump wheel
Note:   Counterhold with KM-6356
•   Tighten nut 68,6 Nm
21.   Install toothed belt
Note:   TDC fixing bolts must be installed in the high pressure drive gear and camshaft drive gear and markings (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) and high pressure pump drive gear (2) to the camshaft sprocket (1)
– Observe direction of rotation
•   Slacken the toothed belt tension roller (3)
•   Remove 2x TDC fixing bolt
•   Turn crankshaft 60° against the direction of engine rotation
•   Tighten toothed belt tension roller 38.2 Nm
Object Number: 2412651 Size: DEFAULT


22.   Timing, Check
•   Turn crankshaft 6 revolutions in direction of engine rotation to the adjustment position
•   The following factors must be present at the adjustment position
Note:   If one of these factors is not present, the timing must be adjusted
1. TDC fixing bolt M6 (1) must be able to be inserted in the camshaft drive gear
2. TDC fixing bolt M8 (2) must be able to be inserted in the high pressure pump drive gear
3. Marking (4) on the toothed belt drive gear must align with the marking (3) on the oil pump housing cover

•   Remove 2x TDC fixing bolt
Object Number: 8125296 Size: DEFAULT


23.   Install front toothed belt cover (lower)
•   Tighten 3x bolt 9.8 Nm
24.   Install coolant pump drive gear
•   Tighten 3x bolt 12.3 Nm
25.   Install engine damping block bracket
•   Insert engine damping block adapter
•   Attach engine damping block support to cylinder block
– Tighten 3x bolt 50 Nm
•   Engine damping block support to engine damping block bracket
– Tighten 3x bolt 55 Nm
26.   Raise vehicle by its full height
Important:   Journal (1) of toothed belt drive gear must engage in the bore (2) of the torsional vibration damper
27.   Install torsional vibration damper
•   Tighten 4x bolt 19.6 Nm
Note:   Counterhold against bolt, toothed belt drive gear
Object Number: 2412652 Size: DEFAULT


28.   Remove engine mount KM-6173
29.   Remove engine mount KM-6001-A
30.   Install lower engine cover and right engine splash guard
31.   Lower vehicle by its full height
32.   Install front toothed belt cover (top)
•   Tighten 8x bolt 9.8 Nm
Note:   Note different bolt lengths
•   Install camshaft sensor bracket
– Tighten bolt 9.8 Nm
•   Attach vacuum line to toothed belt cover
– Clip in 3x clips
33.   Attach wiring trough to front toothed belt cover (top)
•   Attach wiring trough
– Attach clip
•   Tighten bolt 9.8 Nm
•   Attach wiring harness
– Clip in 2x clips
– Connect camshaft sensor wiring harness plug
•   Attach vacuum line
– Clip in 2x clips
34.   Insert ribbed V-belt
Note:   Note running direction of ribbed V-belt
•   Position ribbed V-belt
– I. Ribbed V-belt without air conditioning
– II. Ribbed V-belt with air conditioning
•   Apply tension to ribbed V-belt tensioner via bolt (1) in the direction of the arrow
•   Take out fixing
•   Release ribbed V-belt tensioner
Object Number: 2415977 Size: DEFAULT


35.   Install air cleaner housing with air intake hose
•   Attach water drain hose to air cleaner housing
– Fasten clamp
•   Tighten bolt 15 Nm
•   Attach air intake hose to air intake pipe
– Fasten clamp 3.5 Nm
•   Connect wiring harness plug to air mass flow meter
36.   Top up coolant or ensure correct quantity is present.
37.   Install engine cover
•   Detach oil filler port closure cap
•   Refit engine cover
•   Attach oil filler port closure cap
38.   Connect battery
•   Attach earth connection to earth terminal
39.   Program volatile memories
40.   Close bonnet

High-Pressure Pump, Remove and Install > < Replace accelerator pedal module