Vauxhall Workshop Service and Repair Manuals

J463052 Lower Toothed Belt Cover, Replace (Y 17 DTL, without AC, LHD)

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 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 clamps (5) Remove bolt (2)

4. Loosen front right wheel

5. Raise vehicle

6. Remove front right wheel

• Remove 4 bolts

7. Raise vehicle

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

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

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

11. Remove coolant pump ribbed V-belt pulley

• Remove bolts

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

13. Detach upper toothed belt cover

• Unscrew 3 lower bolts
• Note! Note dissimilar bolt lengths

14. Detach alternator wiring harness Disconnect wiring harness plug (1) Unscrew nut (2) Unclip wiring harness

15. Lower vehicle

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

17. Remove upper toothed belt cover Remove 5 upper bolts Note! Note various lengths of bolts. Pull upper toothed belt cover out of guide bushing of lower toothed belt cover and remove carefully

18. Raise vehicle

19. Remove lower toothed belt cover Loosen 3 bolts

20. Install lower toothed belt cover

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

21. Lower vehicle

22. Attach upper toothed belt cover

• Note! When installing toothed belt cover, pull lower corner forwards. Ensure correct seating of guide bushing. Note various lengths of bolts.
• Tighten 5 bolts (9.8 Nm / 7.2 lbf. ft.)

23. Attach wiring trough

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

24. Raise vehicle

25. Install alternator wiring harness

• Connect wiring harness plug.
• Tighten nuts

26. Fasten upper part of toothed belt cover

• Tighten 3 bolts (9.8 Nm / 7.2 lbf. ft.)
• Note! Note various lengths of bolts.

27. Install torsional vibration damper

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

28. Attach coolant pump ribbed V-belt pulley

• Screw in bolts

29. Install ribbed V-belt

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

30. Tighten coolant pump ribbed V-belt pulley

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

31. Attach ribbed V-belt cover

• Tighten bolts
• Install clip

32. Lower vehicle

33. Mount right front wheel

• Screw in bolts

34. Lower vehicle

35. Fasten right front wheel

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

36. 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

37. Connect battery

38. Calibrate steering angle sensor

• Switch on ignition

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

39. Program volatile memories

40. Close bonnet