vauxhall Workshop Repair Guides

Vauxhall Workshop Service and Repair Manuals

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

Corsa C

Check diesel fuel injection pump setting (Y 17 DTL, without 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)
•   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)
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.   Remove ribbed V-belt cover
•   Remove 3 bolts (1)
•   Remove clip (arrow).
Object Number: 2410600 Size: DEFAULT


9.   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


10.   Install support
•   An KM-6169
•   Adjust bracket (2) for support
•   Screw on nut (1)
11.   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


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


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


15.   Remove vacuum pump vacuum lines
•   Brake servo
•   Exhaust gas recirculation solenoid valve
16.   Remove wiring trough
•   Unclip vacuum lines (2)
•   Unclip wiring trough (1)
– 2 clips (arrows)
•   Remove bolt (3)
Object Number: 2411071 Size: DEFAULT


17.   Loosen upper part of toothed belt cover
•   Remove 8 bolts
Note:   Note dissimilar bolt lengths
Object Number: 2404431 Size: DEFAULT


18.   Detach right engine bracket
•   Remove 3 bolts
•   Remove right engine bracket, right engine bracket adapter, upper part of toothed belt cover
Object Number: 2411072 Size: DEFAULT


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


20.   Remove wiring harness plug for engine control unit
•   3 off
– Release 2 wiring harness plugs in direction of arrow
•   Unclip wiring harness
Object Number: 2411078 Size: DEFAULT


21.   Remove air intake pipe
•   Remove 3 bolts
•   Remove vent hose (1)
– From cylinder head cover
•   Release 2 clamps
•   Unclip wiring harness (arrow)
Object Number: 2411065 Size: DEFAULT


22.   Remove charge air hose
•   From turbocharger, centre charge air pipe
– Release 2 clamps
23.   Remove engine control unit
•   Unclip wiring harness for engine management
•   Remove wiring harness plug bracket
– Remove 2 bolts (1)
•   Unscrew 2 bolts (2), 2 nuts (3)
Object Number: 2411079 Size: DEFAULT


24.   Remove engine control unit bracket
•   Unscrew 2 bolts (2), nut (1)
•   Unclip wiring harness (arrows)
Object Number: 2411080 Size: DEFAULT


25.   Detach starter/alternator wiring harness bracket
•   From exhaust recirculation valve
•   Remove 2 nuts
26.   Remove centre charge air pipe (1)
•   Unscrew studs (2), 2 bolts (arrows)
Object Number: 2411081 Size: DEFAULT


27.   Remove exhaust recirculation valve (1)
•   Remove exhaust recirculation pipe
– Remove 2 bolts
•   Unscrew studs (3), 2 bolts (arrows)
•   Detach vacuum hose (2)
•   Remove gaskets
Object Number: 2411082 Size: DEFAULT


28.   Remove oil filter insert
•   Place collecting basin underneath.
•   Unscrew oil filter housing cover (1)
Object Number: 2411058 Size: DEFAULT


29.   Detach oil filter housing cover return hose
•   From oil filter housing
•   Release clamp
30.   Detach injection line spacers (1)
Note:   Mark spacer positions
•   Remove 3 bolts
31.   Remove injection lines
•   4 off
•   With KM-6098
Object Number: 2411139 Size: DEFAULT


32.   Attach KM-798
•   Turn crankshaft in direction of engine rotation to 45° before no.1 cylinder TDC
– At toothed belt drive gear bolt
•   Remove central bleeder screw
•   Install KM-798 under pre-tension
•   Determine BDC position of injection pump plunger by turning crankshaft back and forth
Note:   Dial gauge needle must not move
•   Set dial gauge to "0".
Object Number: 2411155 Size: DEFAULT


33.   Check start of feed
•   Turn crankshaft to 1st Cylinder TDC
Note:   Mark on oil pump cover must align with mark on torsional vibration damper.
Important:   If test value is not achieved, diesel injection pump setting must be corrected - see operation "Adjusting diesel fuel injection pump".
•   Read test value
– Test value: 0.28 – 0.38 mm
34.   Remove KM-798
•   Remove dial gauge
•   Tighten central bleeder screw ( 23.5 Nm )
– Replace seal ring
35.   Install injection lines
•   Caution! Injection lines must be installed without tension. Hand-tighten at injector nozzles and injection pump.
•   Tighten union nuts ( 22.5 Nm )
36.   Install injection line spacers
Note:   Pay attention to spacer positions
•   3 off
37.   Attach oil filter housing return hose
•   To oil filter housing
38.   Install oil filter insert
•   Renew 3 seal rings
•   Tighten oil filter housing cover ( 23.5 Nm )
39.   Install exhaust recirculation valve
•   Clean sealing surfaces.
•   Insert exhaust recirculation valve
– Tighten studs, 2 bolts ( 24.5 Nm )
– Replace gasket
– Connect vacuum hose.
•   Attach exhaust gas recirculation pipe
– Tighten 2 bolts ( 28.4 Nm )
– Replace gasket
40.   Install centre charge air pipe
•   Clean sealing surface
•   Tighten studs, 2 bolts
•   Replace gasket
41.   Attach starter/alternator wiring harness bracket
•   Tighten 2 nuts
42.   Install engine control unit bracket
•   Tighten 2 bolts, nut
•   Attach wiring harness
43.   Install engine control unit
•   Install engine control unit
– Tighten 2 bolts, 2 nuts ( 5.9 Nm .)
•   Install wiring harness plug bracket
– Tighten 2 bolts
44.   Install air intake pipe
•   Tighten 3 bolts
•   Fasten clamp ( 5 Nm )
•   Attach engine vent hose
– Fasten clamps
•   Attach wiring harness
45.   Attach charge air hose.
•   Fasten clamps ( 5 Nm )
46.   Connect wiring harness plug for engine control unit
•   Route wiring harness
•   Connect wiring harness plug.
– 3 off
•   Attach wiring harness
47.   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 )
48.   Fasten upper part of toothed belt cover
•   Tighten bolts ( 9.8 Nm )
Note:   Note dissimilar bolt lengths
49.   Install right engine damping block
•   To side member
– Tighten bolts ( 40 Nm )
•   On engine bracket
– Tighten bolts ( 60 Nm + 30° + 15° )
50.   Attach wiring trough
•   Clip-in wiring trough
•   Clip in vacuum lines
•   Tighten bolt
51.   Attach alternator wiring harness
•   Connect wiring harness plug.
•   Tighten nuts
52.   Attach vacuum pump vacuum lines
•   Route lines and clip in
•   Tighten union nut ( 18 Nm )
53.   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
54.   Raise vehicle
55.   Detach support
56.   Remove KM-6169
57.   Install ribbed V-belt cover
•   Screw in bolts
•   Install clip
58.   Lower vehicle
59.   Install right front wheel
•   Screw in bolts
60.   Lower vehicle
61.   Fasten right front wheel
•   Tighten bolts ( 110 Nm )
62.   Check and correct engine oil level
•   Observe specified engine oil quantity
•   Start engine and allow to run until oil pressure telltale extinguishes.
•   Check engine oil level, if necessary correct.
63.   Connect battery
•   Connect ground cable.
64.   Calibrate steering angle sensor
•   Switch on ignition
Note:   Rotate the steering wheel one time from its right-hand to its left-hand stop.
65.   Program volatile memories
66.   Close bonnet

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