Vauxhall Workshop Service and Repair Manuals

J456600 Oil Pump, Remove and Install (Y 17 DTL, without AC, LHD)

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

1. Open bonnet

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.

2. Disconnect battery

• Detach ground cable

3. Remove oil filter element

• Place collecting basin underneath.
• Unscrew oil filter housing cover (1)

4. Remove oil dipstick guide tube Remove upper bolt (1)

5. Loosen front right wheel

6. Raise vehicle

7. Remove front right wheel

• Remove 4 bolts

8. Raise vehicle

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

10. Drain engine oil

• Place collecting basin underneath.
• Remove drain bolt

11. Install drain bolt

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

12. 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 Release clamp Remove from rubber dampers Detach front exhaust pipe Remove 2 nuts

13. Remove exhaust system

• Remove exhaust system
• Remove from 2 damping rings
• Note! 2. mechanic

14. Remove oil dipstick guide tube

• Remove 2 bolts (arrows)

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

16. Detach upper part of oil pan Remove 14 bolts Note! Note dissimilar bolt lengths Remove 3 bolts (1) Remove 2 nuts Note! Use wide spatulas

17. Remove oil dipstick guide tube

18. 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

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

20. 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)

21. Lower vehicle

22. 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) Remove bolt (2)

23. Remove right engine damping block Remove 4 bolts

24. Detach alternator wiring harness

• Disconnect wiring harness plug
• Unscrew nut

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

26. Loosen upper part of toothed belt cover Remove 8 bolts Note! Note dissimilar bolt lengths

27. Detach right engine bracket (1) Remove 3 bolts Remove right engine bracket, right engine bracket adapter, upper part of toothed belt cover

28. Raise vehicle

29. Loosen coolant pump ribbed V-belt pulley (1) Loosen bolts

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

31. Detach coolant pump ribbed V-belt pulley

• Remove bolts

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

33. Detach lower part of toothed belt cover Remove 3 bolts

34. 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)

35. Lower vehicle

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)

37. Remove toothed belt

• Note! Mark running direction

38. Remove oil pump drive gear (1) Unscrew nut Note! Counterhold using socket spanner (2)

39. Raise vehicle

40. Turn crankshaft Turn crankshaft to approx. 60° before TDC on power stroke of 1st cylinder At fastening bolt

41. Attach KM-662-C (2)

• Install 2 bolts

42. Detach toothed belt drive pulley (1)

• Remove bolt (3)
• Counterhold using KM-662-C
• Remove toothed belt drive gear
• Using KM-161-B
• Remove woodruff key

43. Remove oil pump cover (1) Remove 9 bolts Note! Note dissimilar bolt lengths Remove inner and outer rotors (2)

44. Clean sealing surfaces Cylinder block, oil pump cover

45. Inspect components

• Oil pump cover, cylinder block, inner rotor, outer rotor

46. Remove oil pump sealing ring (2)

• Lever out seal ring
• Caution! Do not damage sealing surfaces

47. Remove crankshaft front seal ring (1)

• Lever out seal ring
• Caution! Do not damage sealing surfaces

48. Install oil pump seal ring Lightly coat sealing lip of new seal ring with silicone grease (white) Drive in until flush using KM-657

49. Install oil pump cover (2)

• Insert inner and outer rotor
• Coat with engine oil
• Clean thread.
• Replace gasket (1)
• Apply adhesive sealing compound (black) (shaded area)
• Attach oil pump cover
• Tighten bolts (9.8 Nm / 7.2 lbf. ft.)

50. Install crankshaft front seal ring (1) Lightly coat sealing lip of new seal ring with silicone grease (white) Drive in until flush using KM-656 (2)

51. Install toothed belt drive gear

• Install sheet metal panel
• Insert toothed belt drive gear in place
• Note woodruff key
• Tighten bolt (198 Nm / 146 lbf. ft.)

52. Remove KM-662-C

53. Lower vehicle

54. Install oil pump drive gear

• Note! Observe installation position
• Tighten nut (44.1 Nm/32.6 lbf. ft.)

55. Turn crankshaft

• Turn crankshaft to 1st Cylinder TDC
• At fastening bolt

56. 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

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

58. Set 1st cylinder to TDC of combustion stroke Turn crankshaft approx. 780° in direction of engine rotation At fastening bolt 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) Unscrew TDC-fixing bolts

59. Unscrew lower fastening bolt of toothed belt tension roller

60. Attach lower part of toothed belt cover

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

61. 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.)

62. 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°.)

63. Fasten upper part of toothed belt cover

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

64. Attach coolant pump ribbed V-belt pulley

• Tighten bolts

65. Raise vehicle

66. Install torsional vibration damper

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

67. Install ribbed V-belt

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

68. Fasten coolant pump ribbed V-belt pulley

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

69. Detach support

70. Remove KM-6169

71. Clean sealing surfaces

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

72. Install upper part of oil pan

• 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 (9.8 Nm / 7.2 lbf. ft.)
• Tighten nuts (9.8 Nm / 7.2 lbf. ft.)
• Bolts (M10) (40 Nm / 29.5 lbf. ft.)

73. Attach lower part of oil pan

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

74. Insert front exhaust pipe

• Into isolator rings
• Note! 2. mechanic

75. Fasten front exhaust pipe

• Replace gasket
• Tighten 2 nuts (65 Nm / 47.9 lbf. ft.)

76. Insert rear muffler

• Note! 2. mechanic

77. Fasten rear muffler

78. Attach ribbed V-belt cover

• Install 3 bolts
• Install clip

79. Lower vehicle

80. Install right front wheel

• Screw in bolts

81. Lower vehicle

82. Fasten right front wheel

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

83. Insert oil dipstick guide tube

• Replace seal ring

84. Raise vehicle

85. Install oil dipstick guide tube

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

86. Lower vehicle

87. Install oil dipstick guide tube

• Tighten upper bolt

88. Attach wiring trough

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

89. Attach alternator wiring harness

• Connect wiring harness plug.
• Tighten nuts

90. Install air cleaner housing

• Tighten bolt
• Fasten air intake hose.
• Fasten clamp
• Connect wiring harness plug to hot film mass air flow meter

91. Connect battery

92. Calibrate steering angle sensor

• Switch on ignition

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

93. Top up engine oil

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

94. Program volatile memories

95. Close bonnet