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Vauxhall Workshop Service and Repair Manuals

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J435200 Toothed Belt Guide Roller, Replace (Y 17 DTL, without AC, LHD) > < J462400 Toothed Belt, Replace (Y 17 DTL, without AC, LHD)

Corsa C

J435210 Toothed Belt Tension Roller, Replace (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. Detach front right wheel

4. Raise vehicle

5. Remove front right wheel

  • Remove 4 bolts

6. Raise vehicle

7. Remove ribbed V-belt cover

  • Remove 3 bolts (1)
  • Remove clip (arrow).
 Object Number: 2410600 Size: DEFAULT

8. 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
 Object Number: 2409770 Size: DEFAULT

9. Install support

  • To KM-6169
    • Adjust bracket (2) for support
  • Screw on nut (1)

10. 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)
 Object Number: 2411093 Size: DEFAULT

11. Lower vehicle

12. Remove air cleaner housing (1)

  • Detach 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)

13. Remove right engine damping block

  • Remove 4 bolts
 Object Number: 2411064 Size: DEFAULT

14. Alternator wiring harness

  • Disconnect wiring harness plug
  • Unscrew nut
 Object Number: 2411070 Size: DEFAULT

15. Remove wiring trough (1)

  • Unclip vacuum lines (2)
  • Unclip wiring trough
    • 2 clips (arrows)
  • Remove bolt (3)
 Object Number: 2411071 Size: DEFAULT

16. Loosen upper part of toothed belt cover

  • Remove 8 bolts
  • Note! Note dissimilar bolt lengths
 Object Number: 2404431 Size: DEFAULT

17. Detach right engine bracket (1)

  • Remove 3 bolts
  • Remove right engine bracket, right engine bracket adapter, upper part of toothed belt cover

18. Raise vehicle

 Object Number: 2411072 Size: DEFAULT

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

  • Loosen bolts
 Object Number: 2411103 Size: DEFAULT

20. Remove ribbed V-belt

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

21. Detach coolant pump ribbed V-belt pulley

  • Remove bolts
 Object Number: 2411073 Size: DEFAULT

22. Remove torsional vibration damper (1)

  • Remove 4 bolts
 Object Number: 2411100 Size: DEFAULT

23. Detach lower part of toothed belt cover

  • Remove 3 bolts
 Object Number: 2411099 Size: DEFAULT

24. 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)
 Object Number: 2404425 Size: DEFAULT

25. Lower vehicle

26. For toothed belt tension roller with leaf spring:

  • loosen toothed belt tensioner
    • Loosen bolt (2)
    • Remove tension spring (1)
 Object Number: 2411075 Size: DEFAULT

For toothed belt tension roller with spiral spring:

  • Loosen toothed belt tension roller (1)
    • Loosen bolt (2)
 Object Number: 2406524 Size: DEFAULT

27. Remove toothed belt

Note:   Mark direction of rotation

28. Remove toothed belt tension roller

  • Remove tension roller bolt
  • For toothed belt tension roller with leaf spring: remove toothed belt tension roller spring retainer
    • Unscrew 2x bolt

29. Install toothed belt tension roller

Note:   The toothed belt tension roller with leaf spring is replaced by a version (1) with spiral spring

  • For version with leaf spring: tighten stud bolt (3) 18.6 Nm
  • Screw in toothed belt tension roller bolt (2)
 Object Number: 7360928 Size: DEFAULT

30. Install toothed belt

  • Caution! Do not rotate toothed belt drive gear out of adjustment
  • Position toothed belt
    • Caution! Observe running direction
    • Note! Toothed belt must be taut from toothed belt drive gear via oil pump drive gear and injection pump drive gear to camshaft gear
  • Insert tension spring
  • Remove TDC-fixing bolts

31. Tension toothed belt

  • Turn crankshaft approx. 60° against direction of engine rotation
    • At fastening bolt
  • Tighten toothed belt tension roller bolt 49 Nm

32. Timing, Check

  • Turn crankshaft approx. 780° in direction of engine rotation
    • At fastening bolt
  • Mark on toothed belt drive gear (2) must align with casting lug at oil pump cover (1)
  • Screw in TDC-fixing bolts (arrows)
  • Install torsional vibration damper
    • Bolt in bolt
  • Note! Mark on torsional vibration damper (3) must align with pin (4) on oil pump cover. If the TDC fixing bolts cannot be inserted, the basic adjustment must be repeated
  • Unscrew TDC-fixing bolts
  • Remove torsional vibration damper
 Object Number: 2411124 Size: DEFAULT

33. Unscrew lower fastening bolt of toothed belt tension roller

34. Attach lower part of toothed belt cover

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

35. 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.)

36. Fasten upper part of toothed belt cover

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

37. Attach coolant pump ribbed V-belt pulley

  • Screw in bolts

38. Raise vehicle

39. Install torsional vibration damper

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

40. Install ribbed V-belt

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

41. Fasten coolant pump ribbed V-belt pulley

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

42. Lower vehicle

43. 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°.)

44. Attach wiring trough

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

45. Attach alternator wiring harness

  • Connect wiring harness plug.
  • Tighten nuts

46. 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

47. Raise vehicle

48. Detach support

49. Remove KM-6169

50. Install ribbed V-belt cover

  • Screw in bolts
  • Install clip

51. Lower vehicle

52. Install right front wheel

  • Screw in bolts

53. Lower vehicle

54. Fasten right front wheel

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

55. Connect battery

56. Calibrate steering angle sensor

  • Switch on ignition

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

57. Program volatile memories

58. Close bonnet

J435200 Toothed Belt Guide Roller, Replace (Y 17 DTL, without AC, LHD) > < J462400 Toothed Belt, Replace (Y 17 DTL, without AC, LHD)