Vauxhall Workshop Service and Repair Manuals

J 452700 All Pistons with Con-rods, Remove and Install (Y 17 DT, with AC, LHD)

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

1. Open bonnet 2. Drain air conditioning Note! Drain air conditioning – see operation "Drain air conditioning" in group "D" 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. 3. Disconnect battery Detach ground cable 4. Remove oil filter insert Place collecting basin underneath. Unscrew oil filter housing cover (1)

5. Remove air cleaner housing (1) Disconnect 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)

6. Detach refrigerant line

• From compressor
• Remove bolt

7. Remove oil dipstick guide tube

• Unscrew upper bolt
• Unclip vacuum lines

8. Loosen right front wheel.

9. Raise vehicle

10. Drain coolant Place collecting basin underneath. Open coolant expansion tank cover Open drain bolt

11. Remove right front wheel.

• Remove 4 bolts

12. Raise vehicle

13. Close coolant drain bolt

14. Remove ribbed V-belt cover Remove 3 bolts (1) Remove clip (arrow).

15. Drain engine oil

• Place collecting basin underneath.
• Remove drain bolt

16. Install drain bolt

• Replace seal ring
• Tighten bolt (78.4 Nm / 57.9 lbf. ft.)

17. Loosen front exhaust pipe

Note:   When removing the centre muffler, a catalytic converter, an exhaust manifold, or an exhaust manifold with catalytic converter, secure that portion of the exhaust system remaining on the vehicle against uncontrolled suspension.

For this purpose, the exhaust system portion including the flexpipe may be fastened to the vehicle underbody using suitable means, e.g. wire.

Caution!

Angular dislocations of the flexpipe as small as 5 to 10 degrees offset from the intended installation position can already cause damage and subsequent complete failure of the flexpipe.

• Remove 2 nuts

18. Detach exhaust system

• Remove from damping rings
• Note! 2. mechanic
• Hang exhaust system aside and suspend in place

19. Remove oil dipstick guide tube

• Remove 2 lower bolts

20. Detach oil pan lower part Remove 15 bolts Detach with KM-J-37228

21. Detach oil pan upper part Remove 14 bolts Note! Note dissimilar bolt lengths Remove 3 bolts (1) Remove 2 nuts Note! Use wide spatulas Push oil dipstick guide tube upwards

22. Detach oil intake pipe Remove bolt (1) 23. Remove oil baffle plate Remove 5 bolts (arrows)

24. Detach turbocharger oil return hose (1) Remove 2 clamps

25. Remove turbocharger oil feed line Unscrew nut (1) Note! Counterhold at threaded port (2)

26. Release turbocharger bracket

• Remove bolt

27. Detach waste gate unit vacuum hose

28. Detach air intake pipe

• From turbocharger
• Release clamp

29. Detach centre charge air pipe from lower charge air pipe Remove lower bolt (1) Loosen clamp (2)

30. Remove ribbed V-belt Tension ribbed V-belt tensioner in direction of arrow With KM-913-A (15) Note! Mark running direction

31. 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

32. Install support To KM-6169 Adjust bracket (2) for support Screw on nut (1) 33. 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)

34. Lower vehicle

35. Remove compressor

• Remove wiring harness plug
• Remove 3 bolts
• Note! Note dissimilar bolt lengths

36. Detach oil dipstick guide tube bracket

• From camshaft housing cover
• Remove 2 nuts
• Unclip vacuum hoses

37. Remove oil dipstick guide tube

38. Remove compressor bracket

• Remove 3 bolts

39. Detach centre charge air pipe Remove upper bolt (1) Detach charge air hose from turbocharger Loosen clamp (2)

40. Remove wiring harness plug for engine management Detach 2 engine control unit wiring harness plugs Release in direction of arrow Disconnect combination plug (grey) Disconnect combination plug (black)

41. Remove engine control unit Remove wiring harness plug bracket Remove 2 bolts (1) Unscrew 2 bolts (2), 2 nuts (3)

42. Detach air intake pipe Remove 2 bolts Detach engine vent hose (1) From cylinder head cover Detach air intake pipe from turbocharger Unclip wiring harness

43. Unclip brake servo vacuum line 44. Detach exhaust manifold heat shield Remove 4 bolts

45. Remove exhaust gas recirculation pipe Remove 2 bolts (1) Remove gasket.

46. Remove turbocharger oil feed line Unscrew banjo bolt (1) Remove seal rings

47. Remove exhaust manifold Remove 7 bolts Remove 2 nuts (1) Remove gasket.

48. Remove right engine damping block Remove 4 bolts

49. Detach alternator wiring harness Disconnect wiring harness plug (1) Unscrew nut (2) Unclip wiring harness

50. Detach wiring trough (1) Unclip vacuum lines (2) Unclip wiring trough 2 clips (arrows) Remove bolt (3)

51. Detach right engine bracket (1) Remove 3 bolts

52. Release upper toothed belt cover Remove 8 bolts Note! Note dissimilar bolt lengths Remove adapter for right engine bracket

53. Detach coolant pump ribbed V-belt pulley

• Remove bolts

54. Remove torsional vibration damper (1) Remove 4 bolts

55. Remove lower toothed belt cover Remove 3 bolts

56. Set 1st cylinder to TDC Turn crankshaft evenly until TDC-fixing bolts can be inserted Camshaft gear (M6) (1) Injection pump gear (M8) (2) Note! The mark on toothed belt drive gear must align with lug on oil pump cover (arrows)

57. 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)

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)

58. Remove toothed belt

• Note! Mark running direction

59. Detach camshaft pulley Unscrew TDC-fixing bolt (2) Counterhold camshaft gear using KM-6156 and KM-956-1 Remove bolt (1)

60. Loosen toothed belt tension roller spring retainer

• Unscrew upper bolt

61. Release rear toothed belt cover

• Remove 2 upper bolts

62. Remove engine control unit bracket Unscrew 2 bolts (2), nut (1) Unclip wiring harness (arrows)

63. Remove wiring harness for engine management Disconnect wiring harness plug Coolant temperature sensor (arrow), oil pressure switch, diesel injection pump (3), sheathed glow plugs Unclip wiring harness Set wiring harness to one side

64. Disconnect wiring harness plug Exhaust gas recirculation solenoid valve (2), charge pressure sensor (1)

65. Remove upper charge air pipe (1) Remove charge air hose Release clamp Unscrew stud (2), 2 bolts (arrows) 66. Detach starter/alternator wiring harness bracket From exhaust recirculation valve Unscrew nut

67. Remove exhaust gas recirculation valve (1) Unscrew studs (3), 2 bolts (arrows) Detach vacuum hose (2) Remove gasket.

68. Detach injection line spacers (1) Remove 3 bolts 69. Remove injection lines With KM-6098 4 off

70. Detach vacuum hose

• From exhaust gas recirculation solenoid valve

71. Detach oil leak line

• Release clamp

72. Detach coolant hoses From thermostat Upper radiator hose (6), coolant pipe 2 off (1), coolant compensation tank (2), add-on heater (5), heater core (4) From cylinder head (3)

73. Detach waste gate unit vacuum hose bracket Remove bolt 74. Remove engine transport shackles 3 off Remove bolts 75. Detach injection nozzle outer seals Remove 8 bolts

76. Remove camshaft housing cover Unscrew 7 bolts (1), 3 stud bolts (2)

77. Detach inner oil leak line Unscrew 5 banjo bolts (1) Note! Note sealing rings

78. Remove injector nozzles Caution! Ensure that upon removal of injector nozzles heat protection sleeves remain in their position on the cylinder head. Otherwise, heat protection sleeves must be removed completely and installed again using new seal rings. This is the only way to ensure that no coolant can reach the combustion chamber, which would inevitably cause engine damage. Replace heat protection sleeves – see operation "Replace heat protection sleeves" in document "Check and measure cylinder head". Remove injection nozzle bracket Remove 2 nuts (1) Remove injector nozzles

79. Remove camshaft housing cover Loosen bolts, stud bolts (180°) Caution! Observe sequence Unscrew 2 stud bolts, 15 bolts Remove gasket.

80. Remove cup tappets With KM-845 Caution! Observe installation position and allocation 81. Remove cylinder head bolts Remove 10 bolts Note! Loosen bolts in order shown (180° – 360°)

82. Remove cylinder head

• Note! 2. mechanic
• Caution! Place cylinder head on wooden blocks, note sheathed glow plugs
• Remove cylinder head gasket

83. Raise vehicle

84. Remove con-rod bearing caps 2. and 3rd cylinder Remove 4 nuts (1) Remove con-rod bearing caps Note! Observe identification on con-rod bearing caps and con-rods. If not present, apply identification Push piston upwards

85. Turn crankshaft

• In direction of engine rotation by 180°

86. Remove con-rod bearing caps 1. and 4th cylinders Remove 4 nuts (1) Remove con-rod bearing caps Note! Observe identification on con-rod bearing caps and con-rods. If not present, apply identification Push piston upwards

87. Lower vehicle

88. Remove piston

• 4 off
• Remove combustion residues

89. Remove con-rod bearing shells

• From con-rod, con-rod bearing cap

90. Visually inspect components

• Crankshaft with con-rod and piston assemblies, engine timing components, cylinder head, cylinder block, exhaust manifold, turbocharger, valve train, ribbed V-belt drive

91. Install con-rod bearing shells

92. Adjust piston rings Arrange piston ring end gaps offset by 120° I Rectangular ring (first compression ring) II Tapered ring (second compression ring) III Double-bevelled ring (oil scraper ring)

93. Install piston 1. and 4th cylinders Coat with engine oil Caution! Mark (1) on piston head and mark (2) on con-rod point to engine timing side Compress piston rings with piston ring tensioner Coat with engine oil Insert piston

94. Raise vehicle

95. Attach con-rod bearing cap Replace nuts Caution! Observe identification of cylinder sequence on con-rod bearing caps and con-rods. Small bead (arrow) points towards engine timing side Tighten nuts (24.5 Nm / 18.1 lbf. ft. + 100° + 15°)

96. Turn crankshaft

• In direction of engine rotation by 180°

97. Lower vehicle

98. Install piston 2. and 3rd cylinder Coat with engine oil Caution! Mark (1) on piston head and mark (2) on con-rod point to engine timing side Compress piston rings with piston ring tensioner Coat with engine oil Insert piston

99. Raise vehicle

100. Attach con-rod bearing cap Replace nuts Caution! Observe identification of cylinder sequence on con-rod bearing caps and con-rods. Small bead (arrow) points towards engine timing side Tighten nuts (24.5 Nm / 18.1 lbf. ft. + 100° + 15°)

101. Lower vehicle

102. Clean sealing surfaces

• Cylinder head, cylinder block, camshaft housing, camshaft housing cover, exhaust manifold, turbocharger, exhaust gas recirculation valve, upper charge air pipe

103. Check for plane surface Cylinder head, cylinder block With straightedge, feeler gauge

104. Measure piston projection Insert MKM-571-B (1) in KM-301 (2) Note pretension Set dial to zero Place probe on cylinder block Measure piston projection on all four pistons Carry out measurement on two different locations (3 and 4) or (5 and 6) Determine high point by turning crankshaft

105. Turn crankshaft

• approx. 60° before TDC of cylinder-1

106. Replace cylinder head gasket Piston projection Thickness of cylinder head gasket Code 0.630 – 0.696 mm 1.45 mm no hole 0.697 – 0.763 mm 1.50 mm one hole 0.764 – 0.830 mm 1.55 mm two holes Caution! The largest determined piston projection is used for the selection of the cylinder head gasket with corresponding identification (arrows). Lay cylinder head gasket in place Note guide bushings

107. Position cylinder head

• Note! 2. mechanic

108. Fasten cylinder head Replace cylinder head bolts Screw in bolts by several threads Tighten cylinder head bolts (39.2 Nm + 60° + 13° + 60° + 13°) Note! Observe tightening sequence

109. Insert cup tappets

• Coat with engine oil
• Caution! Observe sequence and allocation

110. Install camshaft housing Replace gasket Tighten bolts M8 (21.6 Nm / 16 lbf. ft.) Tighten bolts M10 (43.1 Nm / 32 lbf. ft.) Caution! Observe sequence

111. Fasten rear toothed belt cover

• Tighten bolts (9.8 Nm / 7.2 lbf. ft.)

112. Attach camshaft gear

• Counterhold using KM-6156 and KM-956-1
• Tighten bolt (63.7 Nm / 47.0 lbf. ft.)
• Install TDC-fixing bolt

113. For toothed belt tension roller with leaf spring: fasten toothed belt tension roller spring retainer

• Tighten bolt 9.8 Nm

114. Set cylinder 1 to TDC Mark on toothed belt drive gear (2) must align with casting lug at oil pump cover (1)

115. Install toothed belt

Note:   Toothed belt must be taut from toothed belt drive gear via oil pump drive gear and injection pump drive gear

• Position toothed belt

• 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

116. For toothed belt tension roller with leaf spring: unscrew bolt (M10) from lower bore of toothed belt tensioner

117. Check timing Turn crankshaft approx. 780° in direction of engine rotation At toothed belt drive gear bolt The mark on toothed belt drive gear must align with lug on oil pump cover (arrows) Install TDC-fixing bolt Camshaft gear M6 (1) Injection pump drive gear M8 (2) Note! If the TDC fixing bolts cannot be inserted, the basic adjustment must be repeated

118. Unscrew TDC-fixing bolts

119. Turn crankshaft Turn crankshaft until cam pairs (1) and (2) point upwards

120. Check valve play

• Using feeler gauge
• Test values: Intake valves/Exhaust valves (0.35 – 0.45 mm)
• Note! Checking and adjustment of valve clearances is done on a cold engine – room temperature

121. Adjust valve play

• Turn cup tappet until tappet groove points outwards
• Press down cup tappets using KM-6090
• Note! Note different tool versions for intake and exhaust valves
• Mark – IN = Intake side
• Mark – EX = Exhaust side
• Caution! Ensure that valves do not interfere with piston head
• Remove adjustment shim

Example for determination of shim thickness

122. Insert shim Coat new shim with engine oil and insert in cup tappet with identification mark facing downwards 123. Turn crankshaft In direction of engine rotation by 180° Check and adjust valve pair (6) and (2) In direction of engine rotation by 180° Check and adjust valve pair (5) and (3) In direction of engine rotation by 180° Check and adjust valve pair (4) and (1) Note! Valve clearances must be checked again for all adjusted valves

124. Install lower toothed belt cover

• Tighten bolts (9.8 Nm / 7.2 lbf. ft.)

125. Install torsional vibration damper

• Tighten bolts (19.6 Nm / 14.5 lbf. ft.)

126. 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.)

127. Fasten upper toothed belt cover

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

128. Attach coolant pump ribbed V-belt pulley

• Tighten bolts (9.8 Nm / 7.2 lbf. ft)

129. 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°.)

130. Install injector nozzles

• Renew seal rings
• Renew copper sealing washers
• Insert injection nozzles in cylinder head.
• Install injector nozzle bracket (22.1 Nm/16.3 lbf. ft.)

131. Attach new inner oil leak line

• Renew seal rings
• Tighten banjo bolt (14.7 Nm/10.8 lbf. ft.)

132. Attach camshaft housing cover Replace gasket Apply adhesive sealant compound (white) Areas (1, 3) Caution! Oil return bore (2) must not be covered with adhesive sealing compound or by the camshaft housing cover gasket Tighten bolts, studs (9.8 Nm/7.2 lbf. ft.)

133. Attach injection nozzle outer seals

• Replace seals
• Tighten bolts

134. Install injection lines

• Caution! Injection lines must be installed without tension. Hand-tighten at injector nozzles and injection pump.
• With KM-6098
• Tighten union nuts (22.5 Nm/16.6 lbf. ft.)

135. Install injection line spacers

• Note! Note spacer positions

136. Install oil filter element (1) Replace seal rings (2) Replace oil filter housing cover (3) Install new oil filter element into cover Tighten oil filter housing cover (25 Nm/18.5 lbf. ft.)

137. Attach waste gate unit vacuum hose bracket

• Tighten bolt (24.5 Nm / 18.1 lbf. ft.)

138. Attach coolant hoses

• 7 off

139. Attach engine transport shackles

• 3 off
• Tighten bolts (20 Nm / 15 lbf. ft.)

140. Attach oil leak hose

• Fasten clamp

141. Connect wiring harness plug

• Exhaust gas recirculation solenoid valve, charge pressure sensork

142. Attach vacuum hose

• To exhaust gas recirculation solenoid valve

143. Install exhaust gas recirculation valve

• Replace gasket
• Tighten studs, bolts (24.5 Nm/18.1 lbf. ft.)
• Connect vacuum hose.

144. Attach upper charge air pipe

• Clean sealing surface
• Replace gasket
• Tighten stud bolt, bolt
• Upper charge air pipe bracket to camshaft housing
• Tighten bolt (24.5 Nm / 18.1 lbf. ft.)

145. Attach starter/alternator wiring harness bracket

• Tighten nuts

146. Install alternator wiring harness

• Tighten nuts
• Connect wiring harness plug.
• Attach wiring trough
• Clip-in wiring trough
• Tighten bolt

147. Attach wiring harness for engine management

• Route wiring harness
• Connect wiring harness plug.

148. Install engine control unit bracket

• Tighten bolts (9.8 Nm / 7.2 lbf. ft.)
• Tighten nut (9.8 Nm/7.2 lbf. ft.)
• Attach wiring harness

149. Install exhaust manifold

• Install exhaust manifold
• Replace gasket
• Screw in bolts
• Attach exhaust gas recirculation pipe
• Replace gasket
• Screw in bolts
• Tighten bolts, nuts (23.5 Nm/17.3 lbf. ft.)
• Tighten exhaust gas recirculation pipe (28.4 Nm/20.9 lbf. ft.)
• Exhaust gas recirculation pipe bracket to camshaft housing
• Tighten bolt (8.8 Nm / 6.5 lbf. ft.)

150. Attach turbocharger oil feed line

• Renew seal rings
• Insert oil feed line
• Tighten banjo bolt (9.8 Nm / 7.2 lbf. ft.)

151. Attach exhaust manifold heat shield

• Tighten bolts (11.7 Nm / 8.6 lbf. ft.)

152. Raise vehicle

153. Detach support

154. Detach KM-6169

155. Attach turbocharger oil feed line

• Renew seal rings
• Note! Counterhold at threaded port
• Tighten nut (9.8 Nm/7.2 lbf. ft.)

156. Install turbocharger oil return hose

157. Attach turbocharger bracket

• Tighten bolt (26.5 Nm / 19.6 lbf. ft.)

158. Connect waste gate unit vacuum hose

159. Clean sealing surfaces

• Cylinder block, upper part of oil pan, lower part of oil pan

160. Install oil baffle plate

• Tighten bolts (18.6 Nm / 13.7 lbf. ft.)

161. Install oil intake pipe

• Replace seal ring
• Tighten bolt (18.6 Nm / 13.7 lbf. ft.)

162. Attach oil pan upper part

• Apply sealing compound (grey)
• Caution! The application of silicone sealing compound (grey) and installation of lower part of oil pan including torque test must be performed within 10 minutes!
• Tighten bolts, nuts (9.8 Nm/7.2 lbf. ft.)
• Tighten bolts (M10) (40 Nm / 29.5 lbf. ft.)
• Replace oil dipstick guide tube sealing ring

163. Attach oil pan lower part

• Apply sealing compound (grey)
• Tighten bolts (9.8 Nm / 7.2 lbf. ft.)

164. Attach exhaust system

• Note! 2. mechanic
• Install damping rings

165. Attach front exhaust pipe

• Replace gasket, nuts
• Tighten nuts (65 Nm / 48 lbf. ft.)

166. Lower vehicle

167. Install compressor bracket

• Tighten bolts (43 Nm / 31.7 lbf. ft.)

168. Install oil dipstick guide tube

169. Install compressor

• Tighten bolts (22 Nm / 16.2 lbf. ft)
• Connect wiring harness plug.

170. Attach oil dipstick guide tube bracket

• Tighten nuts
• Clip in vacuum lines

171. Attach refrigerant line

• Renew seal rings
• Tighten bolt (20 Nm / 15 lbf. ft.)

172. Attach charge air hose

• Tighten clamp (3.5 Nm / 2.6 lbf. ft.)

173. Attach centre charge air pipe

• Insert in lower charge air pipe
• Tighten upper bolt
• Fasten turbocharger charge air hose (3.5 Nm / 2.5 lbf. ft.)

174. Install air intake pipe

• Tighten bolts
• Attach engine vent hose
• Tighten clamp (3.5 Nm / 2.6 lbf. ft.)
• Attach wiring harness

175. Install engine control unit

• Tighten bolts, nuts (5.9 Nm/4.4 lbf. ft.)
• Install wiring harness plug bracket
• Tighten bolts
• Connect wiring harness plug.
• Attach wiring harness

176. Raise vehicle

177. Fasten oil dipstick guide tube

• Tighten lower bolts (9.8 Nm / 7.2 lbf. ft.)

178. Install ribbed V-belt

• Note! Observe running direction and installation position
• Release ribbed V-belt tensioner

179. Install ribbed V-belt cover

• Tighten bolts
• Install clip

180. Fasten centre charge air pipe

• Tighten lower bolt
• Fasten clamp (3.5 Nm / 2.6 lbf. ft.)

181. Lower vehicle

182. Mount right front wheel

• Screw in bolts

183. Lower vehicle

184. Fasten right front wheel

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

185. Fasten oil dipstick guide tube

• Tighten upper bolt
• Clip in vacuum hoses

186. 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

187. Top up engine oil

• Start engine and allow to run until oil pressure telltale extinguishes.
• Check engine oil level, if necessary correct.
• Observe specified engine oil quantity

188. Top up coolant

• Note! Top up and bleed cooling system – see operation "Top up and bleed cooling system"
• Observe specified coolant quantity

189. Connect battery

190. Calibrate steering angle sensor

• Switch on ignition

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

191. Program volatile memories

192. Charge air conditioning

• Note! Charge air conditioning – see operation "Evacuate and charge air conditioning" in group "D".

193. Close bonnet