Vauxhall Workshop Service and Repair Manuals

Replace rear toothed belt cover (Y 17 DTL, with air conditioning, LDH)

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).

8.   Detach alternator wiring harness •   Disconnect wiring harness plug (1) •   Unscrew nut (2)

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 (arrow, Fig. III) •   Tighten bolts

10.   Install support •   An KM-6169 •   Adjust bracket (2) for support •   Screw on nut (1) 11.   Adjust supports •   Transmission side Note:   Turn spindles until mounts are positioned at 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)

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

13.   Remove ribbed V-belt •   Tension ribbed V-belt tensioner in direction of arrow •   With KM-913-A 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 Note:   The mark on toothed belt drive gear must align with lug on oil pump cover (arrows) – Camshaft gear (M6) (1) – Injection pump gear (M8) (2)

26.   For toothed belt tension roller with leaf spring: •   loosen toothed belt tensioner – Remove bolt (2) – Remove tension spring (1)

27.   For toothed belt tension roller with spiral spring: •   Remove toothed belt tension roller (1) – Remove bolt (2)

30.   Detach camshaft pulley •   Unscrew TDC-fixing bolt (2) •   Counterhold camshaft pulley with KM-6156 and KM-956-1 •   Remove bolt (1)

31.   Remove injection pump gear •   Unscrew nut •   Unscrew TDC-fixing bolt •   Attach KM-6099 •   Pull off injection pump gear Note:   Note woodruff key

43.   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) •   Screw in TDC-fixing bolts (1, 2) Note:   If the TDC fixing bolts cannot be screwed in, basic adjustment must be repeated •   Unscrew TDC-fixing bolts