vauxhall Workshop Repair Guides

Vauxhall Workshop Service and Repair Manuals

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J 459015 Valve Stem Seals, Replace (Y 17 DT, with AC, LHD) > < Camshaft Housing, Replace (Z 17 DTH, without AC, LHD)

Corsa C

Valve Clearance, Check and Adjust (Y 17 DTL)

Condition:

Timing checked – see operation "Timing, Check".

1. Open bonnet

Important:   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.

2. Disconnect battery

  • Remove ground strap
 Object Number: 2411064 Size: DEFAULT

3. Remove air cleaner housing (1)

  • Remove 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)

4. Remove wiring harness plug for engine management

  • 3 off
    • Release 2 wiring harness plugs in direction of arrow
 Object Number: 2411078 Size: DEFAULT

5. Remove engine control unit

  • Remove wiring harness plug bracket
    • Remove 2 bolts (1)
  • Unscrew 2 bolts (2), 2 nuts (3)
 Object Number: 2411079 Size: DEFAULT

6. Remove engine control unit bracket

  • Unscrew 2 bolts (2), nut (1)
  • Unclip wiring harness (arrows)

7. Remove right rear engine transport shackle

  • Remove bolt

8. Loosen left rear engine transport shackle

9. Remove injection lines

  • From injector nozzles
 Object Number: 2411080 Size: DEFAULT

10. Remove outer injector nozzle seals

  • Remove 8 bolts

11. Remove oil dipstick guide tube bracket

  • Unscrew 2 nuts, bolt
 Object Number: 2411157 Size: DEFAULT

12. Detach alternator wiring harness

  • Disconnect wiring harness plug
  • Unscrew nut

13. Remove wiring trough (1)

  • Unclip vacuum lines (2)
  • Unclip wiring trough
    • 2 clips (arrows)
  • Remove bolt
 Object Number: 2411071 Size: DEFAULT

14. Remove camshaft housing cover

  • Unscrew 7 bolts (1), 3 studs (2)

15. Remove camshaft housing cover

  • Note! 2. mechanic
  • Carefully push injection lines to rear
  • Remove engine vent hose
    • Release clamp
 Object Number: 2411156 Size: DEFAULT

16. Detach inner oil leak line

  • Remove 5 banjo bolts
  • Note! Note sealing rings

17. Remove injector nozzles

  • Remove injection nozzle bracket (1)
    • Remove 2 nuts
  • Remove injector nozzles
 Object Number: 2416066 Size: DEFAULT

18. Turn crankshaft

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

19. Check valve clearance

  • Using feeler gauge
    • Test values: Intake valve/Exhaust valve (0.35 – 0.45 mm)
  • Note! The valve clearances are checked on a cold engine – room temperature

20. Adjust valve clearance

  • 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
 Object Number: 2415968 Size: DEFAULT

Example for determination of shim thickness

1.

Thickness of installed shim

 

3.15 mm

2.

Measurement between cam and cup tappets

+

0.45 mm

 

 

=

3.60 mm

3.

Nominal valve play

-

0.40 mm

4.

Thickness of new shim

=

3.20 mm

21. Insert adjustment shim

  • Coat new shim (7) with engine oil and insert in cup tappet with identification mark facing downwards.

22. 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
 Object Number: 2415969 Size: DEFAULT

23. 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.)

24. Attach inner oil leak line

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

25. Install 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

26. Install camshaft housing cover

  • Note! 2. mechanic
  • Carefully push injection line to rear

27. Tighten camshaft housing cover

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

28. Attach engine vent hose

  • Fasten clamp
 Object Number: 2416086 Size: DEFAULT

29. Install oil dipstick guide tube bracket

  • Tighten nuts, bolt

30. Install outer injector nozzle seals

  • Replace seals
  • Tighten bolts

31. Install injection lines

  • Tighten union nuts (22.5 Nm/16.6 lbf. ft.)

32. Fasten left rear engine transport shackle

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

33. Install right rear engine transport shackle

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

34. Attach wiring trough

  • Clip-in wiring trough
  • Clip in vacuum lines
  • Tighten bolt

35. Attach alternator wiring harness

  • Connect wiring harness plug.
  • Tighten nuts

36. Install engine control unit bracket

  • Tighten bolts (24.5 Nm/18.1 lbf. ft.)
  • Tighten nut (9.8 Nm/7.2 lbf. ft.)
  • Attach wiring harness

37. Install engine control unit

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

38. Attach engine control unit wiring harness plug

  • 3 off

39. 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

40. Connect battery

41. Calibrate steering angle sensor

  • Switch on ignition

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

42. Program volatile memories

43. Close bonnet

J 459015 Valve Stem Seals, Replace (Y 17 DT, with AC, LHD) > < Camshaft Housing, Replace (Z 17 DTH, without AC, LHD)