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K Clutch and Transmission > < Toothed Belt Tension Roller, Replace (Z 17 DTH, with AC, LHD)

Corsa C

Toothed Belt Guide Roller, Replace (Z 17 DTH, with AC, LHD)

  Remove

1.   Open bonnet
Important:   In vehicles as of model year 04 with ESP - every time the battery is disconnected, the steering angle sensor loses its basic setting and must be recalibrated
2.   Disconnect battery
•   Detach ground cable
3.   Detach front right wheel
4.   Raise vehicle
5.   Remove right front wheel
•   Unscrew 5 bolts
6.   Raise vehicle
7.   Remove ribbed V-belt cover
•   Unscrew 3 bolts (1)
•   Remove clip (arrow)
Object Number: 2410600 Size: DEFAULT


8.   Attach KM-6394
•   Position KM-6394 (1) at the front on the front axle body
Note:   Both locating pins (arrows) must be seated in the holes in the front axle body
•   Push front bracket (2) in the direction of the arrow
•   Place rear bracket (4), right hand side, on front axle body
•   Attach rear bracket (3), left hand side
– Screw in 2x bolt
•   Tighten 6 bolts
Object Number: 2408346 Size: DEFAULT


Object Number: 2411021 Size: DEFAULT

9.   Install support
•   On KM-6394
– Adjust bracket (2) for support
•   Screw on nut (1)
10.   Adjust 3x support
•   Transmission side
Note:   Turn spindles until mounts (3) are positioned at guide journals free of play
•   Engine timing side
– Insert journal of the support in the bore of the cylinder block free of play (arrow)
– Tighten nuts (1)

11.   Loosen coolant pump ribbed V-belt pulley (1)
•   Undo 3 bolts
Object Number: 2406521 Size: DEFAULT


12.   Remove ribbed V-belt
•   Tension ribbed V-belt tensioner in direction of arrow
– Use KM-913-A
Note:   Mark running direction.
Object Number: 2411073 Size: DEFAULT


13.   Detach coolant pump ribbed V-belt pulley
•   Unscrew 3 bolts
14.   Detach starter wiring harness
•   Electrically disconnect starter
– Unscrew 2 nuts
– Remove bolt
•   Disconnect wiring harness plug of fuel pressure sensor
15.   Lower vehicle
16.   Remove air cleaner housing
Object Number: 2408126 Size: DEFAULT

17.   Remove wiring trough
•   Unclip vacuum line (4)
•   Unclip wiring trough (5)
– 2 clips
•   Remove bolt (3)
•   Disconnect 2 wiring harness plugs
– Camshaft sensor (2)
– Charge pressure sensor (1)
•   Unclip wiring harness
18.   Remove camshaft sensor
•   Remove bolt (arrow)

19.   Remove right engine damping block (1)
•   Unscrew 4 bolts
Object Number: 2408139 Size: DEFAULT


20.   Detach right engine bracket (1)
•   Unscrew 3 bolts
Note:   Lower bolt cannot be removed
•   With right engine bracket adapter
Object Number: 2411072 Size: DEFAULT


21.   Remove upper toothed belt cover
Important:   Take care not to damage the increment counter on the camshaft sprocket when removing the upper toothed belt cover
•   Unscrew 8 bolts
Note:   Note dissimilar bolt lengths
Object Number: 2404431 Size: DEFAULT


22.   Raise vehicle
23.   Remove torsional vibration damper (1)
•   Unscrew 4 bolts
Object Number: 2411100 Size: DEFAULT


24.   Detach lower part of toothed belt cover
•   Unscrew 3 bolts
Object Number: 2411099 Size: DEFAULT


25.   Remove right engine bracket
26.   Set 1st cylinder to TDC
•   Turn crankshaft evenly until TDC fixing bolt (1) can be screwed in
Note:   Mark (3) on toothed belt drive gear must align with mark (2) on oil pump cover
Object Number: 2412641 Size: DEFAULT


27.   Loosen toothed belt tension roller (1)
•   Loosen bolt of toothed belt tension roller (2)
•   Rotate toothed belt tension roller anticlockwise approx. 90°
•   Tighten bolt of toothed belt tension roller
28.   Remove toothed belt
Note:   Mark running direction.
Object Number: 2406524 Size: DEFAULT


29.   Remove toothed belt deflection pulley (1)
•   Remove bolt (2)
Object Number: 2411101 Size: DEFAULT


  Install

30.   Install toothed belt guide roller
•   Tighten bolt 80.4 Nm
31.   Install toothed belt
Note:   TDC locking bolt must be installed in the camshaft sprocket and marking (6) and (7) must align.
•   Position toothed belt
– Toothed belt must be tensioned in the direction of the arrow from the toothed belt drive gear (5) via the oil pump drive gear (4), via the high pressure pump drive gear (2) to the camshaft sprocket (1)
– Note running direction
•   Loosen toothed belt tension roller (3)
•   Remove TDC locking bolt
•   Rotate crankshaft 60° against direction of engine rotation
•   Tighten toothed belt tension roller 38Nm
Object Number: 2412651 Size: DEFAULT


32.   Timing, Check
•   Turn crankshaft approx. 780° in direction of engine rotation
•   Mark on toothed belt drive gear (3) must align with cast lug (2) on oil pump cover
•   Screw in TDC fixing bolt (1)
Note:   If the TDC fixing bolt cannot be screwed in, basic adjustment must be repeated
•   Unscrew TDC-fixing bolt
Object Number: 2412641 Size: DEFAULT


33.   Attach right engine bracket
•   Insert lower bolt
– Into right engine bracket and right engine bracket adapter
•   Fit right engine bracket with adapter
34.   Attach lower part of toothed belt cover
•   Tighten 3 bolts 9.8 Nm
35.   Lower vehicle
36.   Install upper toothed belt cover
•   Tighten 8 bolts 9.8 Nm
Note:   Note dissimilar bolt lengths
•   Clip in vacuum hose
37.   Fasten right engine bracket
•   Screw in 3 bolts
•   Tighten 2 upper bolts 40 Nm
38.   Install camshaft sensor
•   Replace seal ring
•   Tighten bolt 9.8 Nm
39.   Attach wiring trough
•   Route wiring harness
•   Clip-in wiring trough
•   Clip in vacuum hose
•   Tighten bolt 6 Nm
•   Connect 2 wiring harness plugs
40.   Install right engine damping block
•   To side member
– Tighten 2 bolts 40 Nm
•   On engine bracket
– Tighten 2 bolts 60 Nm + 30° + 15°
41.   Raise vehicle
42.   Fasten right engine bracket
•   Tighten lower bolt 40 Nm
43.   Attach coolant pump ribbed V-belt pulley
•   Screw in 3 bolts
44.   Install torsional vibration damper
•   Tighten 4 bolts 19.6 Nm
45.   Install ribbed V-belt
Note:   Observe running direction and installation position
•   Release tension from ribbed V-belt tensioner (1)
– I Ribbed V-belt without AC
– II Ribbed V-belt with AC
Object Number: 2415977 Size: DEFAULT


46.   Fasten coolant pump ribbed V-belt pulley
•   Tighten 3 bolts 9.8 Nm
47.   Detach supports
48.   Detach KM-6394
49.   Attach starter wiring harness
•   Electrically connect starter
– Tighten 2 nuts
– Tighten bolt
•   Connect fuel pressure sensor wiring harness plug
•   Route wiring harness
50.   Attach ribbed V-belt cover
•   Tighten 3 bolts
•   Install clip
51.   Lower vehicle
52.   Attach front right wheel
•   Screw in 5 bolts
53.   Lower vehicle
54.   Fasten right front wheel
•   Tighten 5 bolts 110 Nm
55.   Install air cleaner housing
•   Fasten clamp 5 Nm
56.   Connect battery
57.   Calibrate steering angle sensor
•   Turn on ignition
Note:   Rotate the steering wheel one time from its right-hand to its left-hand stop
58.   Close bonnet
59.   Program volatile memory

K Clutch and Transmission > < Toothed Belt Tension Roller, Replace (Z 17 DTH, with AC, LHD)