Vauxhall Workshop Service and Repair Manuals

J450100 Engine, 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 "Air Conditioning, Drain " 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 steering intermediate shaft (1) Remove lower clamp pin (2) Unscrew nut (3) Steering in straight ahead position Engage steering lock Remove steering intermediate shaft Caution! Do not change steering wheel position

5. Loosen front wheels

• Loosen 8 bolts

6. Release upper front panelling Remove 3 bolts (1)

7. Raise vehicle

8. Release lower front panelling Disconnect wiring harness plug Remove 3 clips (2) Remove 4 bolts (1) Remove 2 nuts (3)

9. Detach front panelling

• Note! 2. mechanic
• Remove and close the hose – high-pressure – Headlamp washer system
• With KM-807

10. Remove front wheels

11. Remove horn

• Disconnect wiring harness plug
• Remove bolt

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

13. Drain coolant Place collecting basin underneath. Open drain bolt

14. Lower vehicle

15. 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)

16. Remove coolant compensation tank

• Unclip coolant hoses
• Detach coolant compensation tank and lay aside.

17. Detach heater fluid hoses From heater core (1) 2 off From auxiliary heater coolant line (2) 2 off

18. Remove wiring harness for engine management Disconnect wiring harness plug Engine control unit, 2 combination plugs Unclip wiring harness and lay aside

19. Detach engine wiring harness Detach ground cable from battery. Detach battery positive cable Remove positive terminal (1) Disconnect combination plug (2) Remove rubber seal (3) Unclip wiring harness 1 bracket (arrow) Remove cable harness and lay aside

20. Remove wiring harness for AC Detach wiring harness plug for ABS control unit (1) Release in direction of arrow Detach ground cable Unscrew nut (3) Remove relay box cover (2) Remove 2 fuses (5) Disconnect wiring harness plug (4) Release right relay frame and remove Unclip wiring harness and lay aside

21. Detach pressure line for central release (2) Remove cover of brake fluid reservoir Top up brake fluid reservoir to "MAX" marking Attach MKM-558-10 Disengage retaining clip (1) with a screwdriver Suspend pressure line for central release Note! Escaping brake fluid Clamp retaining clip

22. Detach brake servo vacuum line

• Detach vacuum line
• From brake servo
• Withdraw vacuum line
• From bulkhead with grommet

23. Detach fuel feed line (1) Detach using KM-796 Unclip fuel line Close with KM-6015

24. Detach return fuel line (2)

• From injection pump

25. Remove AC line Remove bolt (1)

26. Raise vehicle

27. Close coolant drain bolt

28. Loosen axle shafts Remove protective caps (1) Remove split pin (2) Attach KM-468-B (4) Unscrew nut (3) Hold with KM-468-B Remove washer

29. Detach tie rods From steering knuckle Remove 2 nuts Press off tie rods Using KM-507-C

30. Remove swing arm From spring strut support tube Remove 2 nuts Note! Counterhold using open-end spanner

31. Remove guide joints From steering knuckle Remove 2 nuts (1) Remove bolts Expand steering knuckle With KM-915

32. Press out axle shafts

• From wheel hub

33. Raise vehicle

34. Detach exhaust system

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.

• Detach rear muffler
• Detach front exhaust pipe
• Remove 2 nuts

35. Remove exhaust system

• Detach exhaust system
• 2 damping rings
• Note! 2nd mechanic

36. Detach shift linkage Loosen bolt (1)

37. 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

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

39. 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)

40. Lower vehicle

41. Remove right engine damping block Remove 4 bolts

42. Loosen left engine damping block Loosen left engine bracket adapter Remove 2 bolts

43. Raise vehicle

44. Insert hydraulic jack

• With KM-904

45. Attach KM-6168 (2) Apply KM-6168 On KM-904 (1) Note! Observe different centring bolt thread sizes Lower body positioning pins (3) Position KM-6168 Without play under front axle body Note! Observe centring points in front axle body

46. Remove front axle body

• Remove 4 bolts
• Caution! Removal of the front axle body with an impulse or impact screwdriver is not permissible

47. Lower drive unit

• Note! 2. mechanic
• Caution! Carefully lower engine with transmission downwards out of engine compartment – do not damage attaching parts

48. Move out drive unit

49. Check thread of clamping nuts 4 off Caution! Before installing front axle body, the threads of the clamping nuts must be checked for free movement, replace clamping nuts if necessary

50. Replace AC seal rings

51. Insert drive unit

52. Raise drive unit

• Note! 2. mechanic
• Caution! Carefully guide engine with front axle body and transmission upwards into the engine compartment. Note rear centring tips. Do not damage attaching parts
• Steering shaft, upper radiator bracket

53. Fasten front axle body.

• Renew bolts
• Tighten bolts (90 Nm / 70 lbf. ft. + 45° + 15°.)
• Caution! Installation of the front axle body with an impulse or impact screwdriver is not permissible

54. Remove hydraulic jack

• Lower hydraulic jack

55. Lower vehicle

56. Fasten left engine damping block

• Tighten bolts (80 Nm / 59 lbf. ft. + 45° + 15°)

57. 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°.)

58. Raise vehicle

59. Detach support

60. Detach KM-6169

61. Install shift linkage.

62. Position exhaust system

• Note! 2nd mechanic

63. Attach exhaust system

• Replace gasket
• Replace nuts
• Tighten nuts (65 Nm / 48 lbf. ft.)
• Install damping rings
• Attach rear muffler

64. Lower vehicle

65. Install axle shafts

• Insert guide joint

66. Attach guide joints

• Replace nuts
• Tighten bolts (60 Nm / 44.5 lbf. ft.)

67. Attach pendulum

• Replace nuts
• Tighten nuts (65 Nm / 48 lbf. ft.)
• Note! Counterhold using open-end spanner

68. Attach tie rods

• Replace nuts
• Tighten nuts (60 Nm / 44 lbf. ft.)

69. Attach axle shafts

• Replace nuts
• Install discs
• Attach KM-468-B
• Tighten nuts (120 Nm / 89 lbf. ft.)
• Hold with KM-468-B
• Loosen nuts
• Tighten nuts (20 Nm / 15 lbf. ft. + 90°)
• Hold with KM-468-B
• Install retaining split pins
• Note! If necessary, turn nut back until one split pin hole aligns with the next castellated nut groove
• Install protective caps

70. Install ribbed V-belt cover

• Screw in bolts
• Install clip

71. Install horn

• Tighten bolts
• Connect wiring harness plug.

72. Position front panelling

• Note! 2. mechanic
• Install high-pressure headlamp washer hose

73. Fasten lower front panelling

• Install clips
• Tighten bolts
• Tighten nuts
• Connect wiring harness plug.

74. Attach front wheels

• Screw in bolts

75. Lower vehicle

76. Fasten upper front panelling

• Tighten bolts

77. Fasten front wheels

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

78. Attach AC line

• Tighten bolt (20 Nm / 15 lbf. ft.)
• Note! Check sealing ring installation positions

79. Install brake servo vacuum line

• Route vacuum line
• through bulkhead with grommet
• Insert in brake servo
• Close water deflector service flap

80. Attach return fuel line

81. Attach fuel feed line

82. Attach pressure line for central release

• Note! Pressure line must engage audibly
• Detach MKM-558-10
• Bleed hydraulic clutch actuation – see operation "Hydraulic Clutch Actuation, Bleed " in group "K".
• Screw on cover of brake fluid reservoir

83. Attach wiring harness for AC

• Attach wiring harness
• Install right relay frame
• Connect combination plug
• Insert fuse
• Install relay frame cover
• Connect ground cable.
• Attach wiring harness plug for ABS control unit

84. Attach engine wiring harness

• Route wiring harness
• Connect wiring harness plug.
• Install positive terminal
• Attach positive cable
• Connect ground cable.
• Fasten cable harness
• Install rubber seal

85. Attach wiring harness for engine management

• Route wiring harness
• Connect wiring harness plug.
• 4 off
• Attach wiring harness

86. Connect heater fluid hoses

87. Install coolant compensation tank

88. 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

89. Install steering intermediate shaft Note! Wheels in straight ahead position Release steering lock Push on steering intermediate shaft Note! Bore hole for clamp bolt must be on the flat milled side of the steering pivot Insert clamp pin Replace nut (2) Adjust length compensator Fasten with KM-6181 (1) Tighten nut (22 Nm/16 lbf. ft.) Remove KM-6181

90. Lock transmission shift linkage Unclip manual shift lever cover Arrest shift lever and shift lever housing Use KM-527-A (1) Engage locking pin in adjustment bore in shift cover by turning shift rod to the left (direction of 3rd gear) (arrow)

91. Raise vehicle

92. Fasten clamp

• Tighten bolt (12 Nm / 9 lbf. ft + 90°+ 90° to 90°+ 90° + 45°)

93. Lower vehicle

94. Check transmission shift linkage Remove Adjusting Pin KM-527-A Note! Locking pin (1) in adjustment bore releases automatically when first shifting towards "R" Engage all gears Clip in manual shift lever cover

95. Connect battery

96. Calibrate steering angle sensor

• Switch on ignition

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

97. Top up coolant

• Note! Top up and bleed cooling system – see operation "Cooling System, Top up and Bleed".
• Observe specified coolant quantity

98. Charge air conditioning

• Note! Charge air conditioning – see operation "Air Conditioning, Evacuate and Charge" in group "D"

99. Program volatile memories

100. Close bonnet