Vauxhall Workshop Service and Repair Manuals

Replace front crankshaft sealing ring (Y 17 DTL, with air conditioning, LHD)

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

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

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 •   Tighten bolts (arrows, fig. III)

11.   Adjust supports •   Transmission side Note:   Turn spindles (3) until mounts are positioned at guide journals free of play •   Engine timing side – Insert support pin in cylinder block bore without play (arrows) – Tighten nuts (1)

13.   Remove ribbed V-belt •   Tension ribbed V-belt tensioner in direction of arrow Note:   Mark direction of rotation

16.   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)

17.   Remove right engine damping block •   Remove 4 bolts

18.   Remove wiring trough (1) •   Unclip vacuum lines (2) •   Unclip wiring trough – 2 clips (arrows) •   Remove bolt (3)

19.   Loosen upper part of toothed belt cover •   Remove 8 bolts Note:   Note dissimilar bolt lengths

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

22.   Remove torsional vibration damper (1) •   Remove 4 bolts

23.   Detach lower part of toothed belt cover •   Remove 3 bolts

24.   Set no.1 cylinder to TDC •   Turn crankshaft evenly until TDC-fixing bolts can be inserted – Camshaft gear M6 (1) – Injection pump drive gear M8 (2) Note:   Mark on toothed belt drive gear must align with lug on oil pump cover (arrows)

26.   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)

27.   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)

30.   Remove oil pump drive gear (1) •   Unscrew nut Note:   Counterhold using socket wrench and unscrew nut using spanner (2).

32.   Attach KM-662-C •   Install 2 bolts 33.   Remove toothed belt drive gear •   Remove bolt – Counterhold using KM-662-C •   Remove toothed belt drive gear (1) – Using KM-161-B (2) •   Remove plate 34.   Remove front crankshaft sealing ring Important:   Do not damage sealing surfaces •   Prise out sealing ring (3)

35.   Install front crankshaft sealing ring •   Coat lip of new sealing ring with silicon grease (white) •   Drive in until flush using KM-656 (1)

42.   Timing, Check •   Turn crankshaft approx. 780° in direction of engine rotation – At fastening bolt •   The mark on toothed belt drive gear must align with lug on oil pump cover (arrows) •   Install TDC-fixing bolts (1, 2) Note:   If the TDC fixing bolts cannot be screwed in, basic adjustment must be repeated •   Unscrew TDC-fixing bolts