vauxhall Workshop Repair Guides

Vauxhall Workshop Service and Repair Manuals

ABOUT US
Check diesel fuel injection pump setting (Y 17 DTL, without air conditioning, LHD) > < Check timing (Y 17 DTL, with air conditioning, LHD)

Corsa C

Adjust timing (Y 17 DT, with air conditioning, LHD)

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

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
•   Detach ground cable
3.   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)
Object Number: 2411064 Size: DEFAULT


4.   Detach front right wheel
5.   Raise vehicle
6.   Remove front right wheel
•   Remove 4 bolts
7.   Raise vehicle
8.   Detach ribbed V-belt cover
•   Remove 3 bolts (1)
•   Remove clip (arrow).
Object Number: 2410600 Size: DEFAULT


9.   Remove ribbed V-belt
•   Tension ribbed V-belt tensioner in direction of arrow
Note:   Mark direction of rotation
– With KM-913-A
Object Number: 2411073 Size: DEFAULT


10.   Attach KM-6169 (1)
•   Attach KM-6169 at left side of front axle unit (arrows, fig.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, Fig. III)
•   Tighten bolts
Object Number: 2409770 Size: DEFAULT


11.   Install support
•   An KM-6169
– Adjust bracket (2) for support
•   Screw on nut (1)
12.   Adjust supports
•   Transmission side
Note:   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)
Object Number: 2411093 Size: DEFAULT


13.   Lower vehicle
14.   Remove right engine damping block
•   Remove 4 bolts
Object Number: 2411070 Size: DEFAULT


15.   Detach alternator wiring harness
•   Disconnect wiring harness plug (1)
•   Unscrew nut (2)
•   Unclip wiring harness
Object Number: 2411191 Size: DEFAULT


16.   Remove wiring trough (1)
•   Unclip vacuum line (2)
•   Unclip wiring trough
– 2 clips (arrows)
•   Remove bolt (3)
Object Number: 2411071 Size: DEFAULT


17.   Detach right engine bracket (1)
•   Remove 3 bolts
Object Number: 2411072 Size: DEFAULT


18.   Remove upper toothed belt cover
•   Remove 8 bolts
Note:   Note dissimilar bolt lengths
Object Number: 2404431 Size: DEFAULT


19.   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


20.   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


21.   Correct timings
Note:   Twist camshaft gear and injection pump gear such that TDC fixing bolts can be screwed in.
22.   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
23.   Timing, Check
•   Turn crankshaft approx. 780° in direction of engine rotation
– At toothed belt drive gear bolt
•   Torsional vibration damper marking must be in line with pin on 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
24.   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 )
25.   Fasten upper part of toothed belt cover
•   Tighten bolts ( 9.8 Nm )
Note:   Note dissimilar bolt lengths
26.   Install right engine damping block
•   To side member
– Tighten bolts ( 40 Nm )
•   On engine bracket
– Tighten bolts ( 60 Nm + 30° + 15° )
27.   Attach wiring trough
•   Clip-in wiring trough
•   Clip in vacuum lines
•   Tighten bolt
28.   Attach alternator wiring harness
•   Attach wiring plug
•   Tighten nuts
29.   Raise vehicle
30.   Detach support
31.   Remove KM-6169
32.   Install ribbed V-belt
Note:   Pay attention to running direction and installation position
•   Release ribbed V-belt tensioner
33.   Attach ribbed V-belt cover
•   Screw in bolts
•   Install clip
34.   Lower vehicle
35.   Install right front wheel
•   Screw in bolts
36.   Lower vehicle
37.   Fasten right front wheel
•   Tighten bolts ( 110 Nm )
38.   Install air cleaner housing
•   Tighten bolt
•   Fasten air intake hose.
– Tighten clamp ( 5 Nm )
•   Connect wiring harness plug to hot film mass air flow meter
39.   Connect battery
40.   Calibrate steering angle sensor
•   Switch on ignition
Note:   Rotate the steering wheel one time from its right-hand to its left-hand stop.
41.   Program volatile memories
42.   Close bonnet

Check diesel fuel injection pump setting (Y 17 DTL, without air conditioning, LHD) > < Check timing (Y 17 DTL, with air conditioning, LHD)