Vauxhall Workshop Service and Repair Manuals

J609100 Coolant Pump, Remove and Install (Z 18 XE, with Air Conditioning, LHD)

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

  Remove

4.   Remove air cleaner housing (1) •   Disconnect 2 wiring harness plugs – Hot film mass air flow meter (4), tank vent valve (2) •   Unclip tank vent valve •   Detach intake hose •   Detach engine vent hose (3) •   Remove bolt (arrow)

5.   Remove upper part of toothed belt cover •   Unscrew 3 bolts (arrows) •   Unclip from rear toothed belt cover

6.   Raise vehicle 7.   Remove right-hand air duct •   Unscrew 3 bolts (arrows) 8.   Remove ribbed V-belt cover •   Unscrew 3 bolts (1) •   Remove clip (2) 9.   Lower vehicle

10.   Detach front right wheel •   Loosen 4 bolts 11.   Raise vehicle 12.   Remove right front wheel. •   Remove 4 bolts 13.   Raise vehicle 14.   Remove ribbed V-belt •   Tension ribbed V-belt tensioner in direction of arrow with KM-913-A (2) •   Use KM-6130 (1)

15.   Remove ribbed V-belt tensioner •   Tension ribbed V-belt tensioner. •   Remove KM-6130 (2) •   Release ribbed V-belt tensioner •   Remove bolt (1)

16.   Detach crankshaft ribbed V-belt pulley •   Prise front closure plug out of oil pan •   Use KM-911 •   Remove bolt •   Remove KM-911

17.   Release lower part of toothed belt cover •   Remove bolt (arrow) •   Unclip from rear toothed belt cover 18.   Lower vehicle

20.   Attach KM-6169 (1) •   Attach KM-6169 to left of front axle body (arrows, illus. I) – Guide pin must be seated in bore in front axle body •   Attach both right holders on the front axle body (arrows, Illus. II). – Guide pin must be seated in bore in front axle body (arrow, Fig. III) •   Tighten 8 bolts

21.   Install support •   An KM-6169 – Adjust bracket (2) for support •   Screw on nut (1) 22.   Adjust supports •   Transmission side – 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 without play (arrow) – Tighten nuts (1) 23.   Lower vehicle

24.   Remove right engine damping block •   Loosen engine bracket adapter – Unscrew 2 bolts (1) •   Loosen engine damping block – Unscrew 2 bolts (2) 25.   Remove upper part of toothed belt cover •   Unscrew 3 bolts (arrows) •   Unclip from rear toothed belt cover 26.   Disconnect camshaft sensor wiring harness plug •   Unclip from bracket 27.   Remove lower part of toothed belt cover •   Unclip from rear toothed belt cover •   Remove downwards

28.   Set 1st cylinder to TDC of combustion stroke •   Install crankshaft V-belt pulley bolt •   Set crankshaft to mark. – Turn crankshaft evenly – Marks on drive gear toothed belt and rear toothed belt cover must align (III). •   Fix camshaft sprockets in position. – Marks must be opposite one another and aligned with the top edge of the cylinder head (I) – Use KM-852 (II) 29.   Remove toothed belt •   Release toothed belt tension roller (IV) – Loosen bolt – Turn adjusting eccentric in direction of arrow (clockwise) until pointer (1) of the toothed belt tension roller is located just before left stop. •   Remove toothed belt.

30.   Raise vehicle 31.   Remove toothed belt drive pulley •   Use KM-911 •   Unscrew crankshaft ribbed V-belt pulley bolt •   Remove KM-911

32.   Release rear toothed belt cover •   Unscrew 2 bolts (arrows)

33.   Remove intake side toothed belt guide roller •   Remove bolt (1) 34.   Remove exhaust side toothed belt guide roller •   Remove bolt (2) 35.   Remove right engine bracket (3) •   Unscrew 3 bolts 36.   Remove toothed belt tension roller •   Remove bolt (4) 37.   Raise vehicle

38.   Drain coolant •   Place collecting basin underneath. •   Open drain bolt (arrow) 39.   Lower vehicle

40.   Remove coolant pump •   Unscrew 3 bolts (arrows)

  Install

48.   Install toothed belt tension roller •   Detent lever (1) of toothed belt tension roller must engage in guide web (2) of oil pump. •   Bolt in bolt Note:   Adjust toothed belt tension before tightening bolt.

49.   Install right engine bracket •   Renew bolts •   Insert bolts with locking compound (red) •   Tighten 3x bolts 65 Nm + 45° - 60°

52.   Fix camshaft sprockets in position. •   Marks must be opposite one another and aligned with the top edge of the cylinder head (I) •   Use KM-852 (II) – Turn the camshafts at hexagonal section 53.   Lock crankshaft •   Set crankshaft to mark. – Turn crankshaft evenly – Marks on drive gear toothed belt and rear toothed belt cover must align (III).

54.   Inspect components •   Ribbed V-belt, ribbed V-belt tensioner, ribbed V-belt pulleys, toothed belt drive 55.   Install toothed belt Note:   Pay attention to direction of travel and timing marks. •   Position toothed belt – Tensioned side must be taut. 56.   Tension toothed belt •   Tension toothed belt tension roller – Turn adjusting eccentric in direction of arrow (anticlockwise) until pointer of the toothed belt tension roller is located just before left stop •   Fasten toothed belt tension roller bolt (1) 57.   Remove KM-852

58.   Timing, Check •   Turn crankshaft in direction of engine rotation at the crankshaft ribbed V-belt pulley bolt (720°) •   Set crankshaft to mark. – Marks on drive gear toothed belt and rear toothed belt cover must align (III). •   Use KM-852 (II) – Marks must be opposite one another and aligned with the top edge of the cylinder head (I) 59.   Remove KM-852

60.   Adjust toothed belt tension •   Release toothed belt tension roller – Loosen bolt •   Turn adjustment eccentric in the direction of the arrow (clockwise) until pointer (1) of toothed belt tension roller is aligned with the notch mark NEW (2). •   Tighten toothed belt tension roller bolt 20 Nm 61.   Check toothed belt tension •   Turn crankshaft (720°) •   Pointer on the toothed belt tension roller and notch mark NEW must align