vauxhall Workshop Repair Guides

Vauxhall Workshop Service and Repair Manuals

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Front Crankshaft Seal Ring, Replace (Z 17 DTH, with AC, LHD) > < Check crankshaft alignment (Y 17 DT, Y 17 DTL)

Corsa C

Removing and installing crankshaft (Y 17 DTL)

1.   Remove engine
Note:   See operation "J 4501 00 Remove and install engine".
2.   Detach manual transmission from engine
Note:   See operation "J 4501 00 007 Remove and install manual transmission from/to engine".
3.   Drain engine oil
•   Place collecting basin underneath.
•   Remove bolt
4.   Remove ribbed V-belt
•   Tension ribbed V-belt tensioner in direction of arrow
Note:   Mark direction of rotation
Object Number: 2411073 Size: DEFAULT


5.   Remove oil dipstick guide tube
•   Remove bolt
6.   Detach upper toothed belt cover
•   Remove 8 bolts
Note:   Note dissimilar bolt lengths
Object Number: 2404431 Size: DEFAULT


7.   Set no.1 cylinder to TDC
•   Rotate crankshaft evenly until torsional vibration damper mark (2) is flush with pin (3) on oil pump cover. Pair of no.1 cylinder exhaust cams (1) must be on top.
•   Screw in the TDC fixing bolts (arrows)
– Camshaft pulley (M6)
– Drive gear injection pumps (M8)
Object Number: 2405628 Size: DEFAULT


8.   Remove torsional vibration damper (1)
•   Remove 4 bolts
9.   Detach coolant pump ribbed V-belt pulley
•   Remove bolts
Object Number: 2411100 Size: DEFAULT


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


11.   Detach right engine bracket
•   Remove bolt
12.   For toothed belt tension roller with leaf spring:
•   loosen toothed belt tensioner
– Screw in bolt (M10) in lower bore (3) of toothed belt tensioner
– Loosen bolt (2)
– Remove tension spring (1)
Object Number: 7360927 Size: DEFAULT


13.   For toothed belt tension roller with spiral spring:
•   Loosen toothed belt tension roller (1)
– Rotate toothed belt tension roller anticlockwise approx. 90°
– Tighten bolt (2)
Object Number: 2406524 Size: DEFAULT


14.   Remove oil pump drive gear (1)
•   Unscrew nut (2)
Note:   Counterhold using socket wrench and unscrew nut using spanner (2).
Object Number: 2411145 Size: DEFAULT


15.   Remove toothed belt drive gear bolt (3)
•   Counterhold toothed belt drive gear (1) using KM-662-C (2)
Note:   2nd mechanic
Object Number: 2411146 Size: DEFAULT


16.   Remove toothed belt drive gear (1)
•   Using KM-161-B (2)
•   Remove plate
17.   Remove clutch
Note:   Remove clutch - see operation "Remove and install thrust plate and clutch disc (without SAC)" in group "K".
Object Number: 2405633 Size: DEFAULT


18.   Detach flywheel
•   Remove 8 bolts
•   Remove KM-652
19.   Turn engine
•   180°
Object Number: 2411158 Size: DEFAULT


20.   Detach oil pan lower part
•   Remove 15 bolts
•   Remove using KM-J-37228
Object Number: 2411060 Size: DEFAULT


21.   Detach oil pan upper part
Note:   Bolts (1) have been unscrewed.
•   Remove 14 bolts
Note:   Note dissimilar bolt lengths
•   Remove 2 nuts
Note:   Use wide spatula.
Object Number: 2411061 Size: DEFAULT


22.   Remove oil intake pipe
•   Remove bolt (1)
Object Number: 2411062 Size: DEFAULT


23.   Remove oil baffle plate
•   Remove 5 bolts (arrows)
24.   Remove con-rod bearing caps
•   4 off
– Unscrew 8 nuts
•   Remove con-rod bearing shells
Note:   Pay attention to identifier on con-rod bearing cover and con-rod (1). If not present, mark with identifier.
25.   Remove con-rod bearing shells
•   Mark con-rod bearing shells
Note:   Follow order.
Object Number: 2416034 Size: DEFAULT


26.   Remove oil pump cover (1)
•   Remove 9 bolts
Note:   Note dissimilar bolt lengths
•   Remove inner and outer rotors
Object Number: 2411147 Size: DEFAULT


27.   Remove rear crankshaft cover sealing ring (1)
•   Unscrew 5 bolts (2)
Important:   Note guide bushings when removing.
•   Carefully prise off rear crankshaft sealing ring cover
Object Number: 2405634 Size: DEFAULT


28.   Remove crankshaft
•   Remove crankshaft bearing cover
Note:   Undo crankshaft bearing cover fastening screws in depicted order (1 - 10).
– 5 off
– Remove 10 bolts
Note:   Place crankshaft onto wooden blocks.
Object Number: 2405635 Size: DEFAULT


29.   Remove crankshaft bearing shells
•   Mark crankshaft bearing shells
Note:   Note markings on crankshaft bearing shells.
30.   Remove thrust rings
Object Number: 2393068 Size: DEFAULT


31.   Remove crankshaft pulse pick-up (1)
•   Remove 3 bolts
Object Number: 2416087 Size: DEFAULT


32.   Clean components
•   Oil pan lower section, oil pan upper section, cylinder block
33.   Inspect components
34.   Install crankshaft pulse pick-up
•   Renew bolts
•   Tighten bolts ( 10.8 Nm )
35.   Insert con-rod bearing shells
•   In con-rod, con-rod bearing cap
– Coat with engine oil
Important:   Pay attention to identification and allocation
36.   Insert crankshaft bearing shells
•   In cylinder block and crankshaft bearing cover
– Coat with engine oil
37.   Replace thrust rings
•   Coat with engine oil
•   Oil grooves face outward
Object Number: 2393068 Size: DEFAULT


38.   Insert crankshaft
•   Coat crankshaft journals with engine oil
Note:   Note installation position.
39.   Fit crankshaft bearing cover
Important:   Note installation position. Arrows point to engine control side.
•   Renew bolts
•   Tighten bolts ( 88.2 Nm )
Note:   Note tightening order (1 - 10).
Object Number: 2416042 Size: DEFAULT


40.   Attach con-rod bearing cap
Important:   Note cylinder order markings on con-rod bearing cover and con-rod (11). Narrow bead faces engine control side.
•   Replace nuts
•   Tighten nuts ( 24.5 Nm + 100° + 15° )
41.   Remove rear crankshaft sealing ring
Important:   Do not damage sealing surface.
•   Lever out seal ring
42.   Fit rear crankshaft sealing ring cover (1)
Note:   Ensure correct seating of guide bushings.
•   Apply adhesive sealing compound (black) (2)
Note:   Use screw locking compound (red)
•   Tighten bolts ( 9.8 Nm )
Note:   Fit screws within 10 minutes.
Object Number: 2416085 Size: DEFAULT


43.   Fit rear crankshaft sealing ring
•   Coat sealing lip with grease
•   Attach KM-658-2 to crankshaft journal
•   Slide sealing ring onto KM-658-2
•   Drive in until flush using KM-658-1 (1)
Object Number: 2414894 Size: DEFAULT


44.   Remove oil pump cover sealing rings
•   Front crankshaft sealing ring (1), oil pump sealing ring (2)
Important:   Do not damage sealing surface.
– Prise out sealing rings
Object Number: 2411148 Size: DEFAULT


45.   Attach oil pump
•   Insert inner and outer rotor
– Coat with engine oil
•   Replace gasket (1)
•   Apply adhesive sealing compound (black)
•   Attach oil pump cover (2)
– Note different bolt lengths
– Tighten bolts ( 9.8 Nm )
Object Number: 2393052 Size: DEFAULT


46.   Install oil pump cover sealing rings
•   Coat sealing lips with silicon grease (white)
•   Install oil pump seal ring
– Drive in until flush using KM-657
•   Install front crankshaft sealing ring (1)
– Drive in until flush using KM-656 (2)
Object Number: 2411149 Size: DEFAULT


47.   Install oil baffle plate
•   Tighten bolts ( 18.6 Nm )
48.   Install oil intake pipe
•   Replace gasket
•   Tighten bolt ( 18.6 Nm )
49.   Clean thread.
•   Oil pan upper section
– 14 off
•   Oil pan lower section
– 15 off
50.   Attach oil pan upper section
•   Apply silicon sealing compound (grey)
•   Tighten bolts, nuts ( 9.8 Nm )
51.   Attach oil pan lower section
•   Apply silicon sealing compound (grey)
•   Tighten bolts ( 9.8 Nm )
52.   Screw in oil drain screw
•   Replace seal ring
53.   Clean thread.
•   In crankshaft
54.   Attach flywheel
•   Renew bolts
•   Attach KM-652
•   Tighten bolts ( 29,4 Nm + 45° + 15° )
Note:   Use screw locking compound (red)
55.   Install clutch
Note:   Remove clutch - see operation "Remove and install thrust plate and clutch disc (without SAC)" in group "K".
56.   Turn engine
•   180°
57.   Install toothed belt drive gear
•   Install sheet metal panel
•   Insert toothed belt drive gear in place
– Note woodruff key
•   Bolt in bolt
58.   Tighten toothed belt drive gear
•   Counterhold using KM-662-C
Note:   2nd mechanic
•   Tighten bolt ( 196 Nm )
•   Remove KM-662-C
59.   Install oil pump drive gear
Note:   Pay attention to installation position
•   Tighten nut ( 44.1 Nm )
60.   Install toothed belt
•   Set no.1 cylinder to TDC
– Mark on toothed belt drive gear must align with lug on oil pump cover (arrows)
Object Number: 2404425 Size: DEFAULT


61.   Install toothed belt
•   Position toothed belt
Note:   Toothed belt must be taut from toothed belt drive gear via oil pump drive gear and injection pump drive gear
•   For toothed belt tension roller with leaf spring:
– Attach leaf spring
•   Unscrew TDC-fixing bolt
•   Rotate crankshaft 60° against direction of engine rotation
•   Tighten bolt of toothed belt tension roller
– For toothed belt tension roller with spiral spring 49 Nm
– For toothed belt tension roller with leaf spring 38.2 Nm
•   For toothed belt tension roller with leaf spring: unscrew bolt (M10) from lower bore of toothed belt tensioner
62.   Timing, Check
•   Turn crankshaft approx. 780° in direction of engine rotation
– At fastening bolt
•   Mark on toothed belt drive gear must align with casting lug at oil pump cover
•   Install TDC-fixing bolt
Note:   If the TDC fixing bolts cannot be screwed in, basic adjustment must be repeated
•   Unscrew TDC-fixing bolts
63.   Attach right engine bracket
•   Remove bolt
•   Insert engine bracket
•   Screw in bolt with bushing
64.   Attach lower part of toothed belt cover
•   Tighten bolts ( 9.8 Nm )
65.   Attach upper toothed belt cover
•   Tighten bolts ( 9.8 Nm )
Note:   Note dissimilar bolt lengths
66.   Attach coolant pump ribbed V-belt pulley
•   Tighten bolts ( 9.8 Nm )
67.   Install torsional vibration damper
•   Tighten bolts ( 19.6 Nm )
68.   Install oil dipstick guide tube
•   Replace seal ring
•   Tighten bolt ( 9.8 Nm )
69.   Install ribbed V-belt
•   Tension ribbed V-belt tensioner in direction of arrow
Note:   Observe running direction
Object Number: 2415977 Size: DEFAULT


70.   Attach transmission
Note:   See operation "J 4501 00 007 Remove and install manual transmission from/to engine".
71.   Install engine
Note:   See operation "Remove and install engine".
72.   Pour in engine oil
•   Start engine and allow to run until oil pressure telltale extinguishes.
•   Check engine oil level, if necessary correct.
•   Use prescribed quantity of oil
Related Literature Units
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Front Crankshaft Seal Ring, Replace (Z 17 DTH, with AC, LHD) > < Check crankshaft alignment (Y 17 DT, Y 17 DTL)