Vauxhall Workshop Service and Repair Manuals

1. Open bonnet

Important:   On vehicles as of 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. Drain coolant

• Place collecting basin underneath.
• Open drain bolt (arrow)

4. Remove engine cover

• Unscrew oil filler pipe cap
• Remove 2 bolts
• Screw on oil filler pipe cap

5. Remove air cleaner housing (1)

• Disconnect wiring harness plug
• Intake air temperature sensor (4), tank vent valve (2)
• Unclip tank vent valve
• Remove air intake pipe
• From throttle valve module
• Detach engine vent hose (5)
• Remove air intake hose
• Remove bolt (3)

6. Loosen right front wheel

7. Raise vehicle

8. Remove right front wheel

• Remove 4 bolts

9. Raise vehicle

10. Remove ribbed V-belt cover

• Remove 3 bolts (1)
• Remove clip (arrow).

11. Remove ribbed V-belt

• Tension ribbed V-belt tensioner in direction of arrow
• With KM-913-A (2) (SW 15)
• Insert KM-6130 (1)
• Note: Mark running direction

12. Remove ribbed V-belt tensioner

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

13. Detach crankshaft ribbed V-belt pulley

• Lever out front closure plug
• From oil pan
• Insert KM-911
• Remove bolt
• Remove KM-911

14. Loosen lower part of toothed belt cover

• Remove bolt (arrow)
• Unclip from rear toothed belt cover

15. Attach KM-6169-3

• Tighten bolts (95 Nm / 70 lbf. ft.)

16. 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

17. Install support

• To KM-6169
• Adjust bracket (2) for support
• Screw on nut (1)

18. 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)

19. Lower vehicle

20. Remove right engine damping block

• Loosen engine bracket adapter
• Remove 2 bolts (1)
• Loosen engine damping block
• Remove 2 bolts (2)

21. Remove upper part of toothed belt cover

• Remove 3 bolts (arrows)
• Unclip from rear toothed belt cover

22. Remove lower part of toothed belt cover

• Unclip from rear toothed belt cover

23. Disconnect wiring harness plug for camshaft sensor

24. Set 1st cylinder to TDC

• Install crankshaft V-belt pulley bolt
• Set crankshaft to mark.
• Turn crankshaft evenly
• Note: Marks on drive gear toothed belt and rear toothed belt cover must align (III)
• Lock camshafts
• Note: Marks must be opposite one another and aligned with the top edge of the cylinder head (I)
• Insert KM-852 (II)

25. 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.
• Note: Mark running direction
• Remove toothed belt.

26. Remove intake side toothed belt guide roller

• Remove bolt (1)

27. Remove exhaust side toothed belt guide roller

• Remove bolt (2)

28. Remove right engine bracket (3)

• Remove 3 bolts

29. Remove toothed belt tension roller

• Remove bolt (4)

30. Raise vehicle

31. Remove toothed belt drive gear

• Hold with KM-911
• Unscrew crankshaft ribbed V-belt pulley bolt
• Remove toothed belt drive pulley

32. Loosen rear toothed belt cover

• Remove 2 bolts (arrows)

33. Lower vehicle

35. Clean sealing surfaces

36. Install coolant pump

• Coat sealing surface with silicone grease
• Replace seal ring
• Note: Carefully lever off rear toothed belt cover. Mark on cylinder block must be aligned with mark on coolant pump (arrow)
• Tighten bolts (8 Nm / 6 lbf. ft.)

37. Raise vehicle.

38. Fasten rear of toothed belt cover

• Tighten bolts (6 Nm / 4.4 lbf. ft.)

39. Insert toothed belt drive gear in place

40. Lower vehicle

41. Install toothed belt tension roller

• Caution: Detent lever (1) of toothed belt tension roller must engage in guide web (2) of oil pump
• Bolt in bolt
• Note: Only tighten bolt after adjusting toothed belt tension

42. Install right engine bracket

• Tighten bolts (50 Nm / 37 lbf. ft.)

43. Install intake side toothed belt guide roller

• Tighten bolt (25 Nm / 18.5 lbf. ft.)
• Caution: Toothed belt guide roller with larger diameter is installed on intake side

44. Install exhaust side toothed belt guide roller

• Tighten bolt (25 Nm / 18.5 lbf. ft.)

45. Check TDC position for 1st cylinder

• Install crankshaft V-belt pulley bolt
• Set crankshaft to mark.
• Set crankshaft to mark.
• Note: Mark on drive gear toothed belt and rear toothed belt cover must align

46. Install toothed belt

• Note: Note running direction and timing marks
• Position toothed belt
• Note: Tensioned side must be taut (I)

47. 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)

48. Remove KM-852

49. Timing, Check

• Turn crankshaft (720°)
• At crankshaft ribbed V-belt pulley bolt
• Note: In direction of engine rotation
• Set crankshaft to mark.
• Note: Marks on drive gear toothed belt and rear toothed belt cover must align (III)
• Insert KM-852 (II)
• Note: Marks must be opposite one another and aligned with the top edge of the cylinder head (I)

50. Remove KM-852

51. Toothed Belt Tension, Adjust

• Release toothed belt tension roller
• Loosen bolt
• Turn adjustment eccentric in the direction of the arrow (clockwise) until pointer (1) is aligned with the notch mark at the toothed belt tension roller (2).
• Adjust used toothed belts to the marking USED
• Adjust new toothed belts to the marking NEW
• Tighten toothed belt tension roller bolt (20 Nm / 15 lbf. ft.)

52. Toothed Belt Tension, Check

• Turn crankshaft (720°)
• Note: Pointers on the toothed belt tension roller and notch mark must align
• Adjust used toothed belts to the marking USED
• Adjust new toothed belts to the marking NEW