Vauxhall Workshop Service and Repair Manuals

P501200 Toothed Belt Tension, Check and Correct (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).

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

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)

11. Lower vehicle

12. 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)

13. Remove right engine damping block Remove 4 bolts

14. Detach alternator wiring harness

• Disconnect wiring harness plug
• Unscrew nut

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

16. Loosen upper part of toothed belt cover Remove 8 bolts Note! Note dissimilar bolt lengths

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

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

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

22. Remove torsional vibration damper (1)

• Remove 4 bolts

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

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)

25. Lower vehicle

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)

For toothed belt tension roller with spiral spring: Loosen toothed belt tension roller (1) Loosen bolt (2)

27. Tension toothed belt

• Turn crankshaft approx. 60° against direction of engine rotation
• At fastening bolt
• Tighten bolt of toothed belt tension roller
• For toothed belt tension roller with spiral spring 49 Nm
• For toothed belt tension roller with leaf spring 38.2 Nm

28. 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 Install 2 bolts Note! Mark on torsional vibration damper (3) must align with pin (4) on oil pump cover, if the TDC fixing bolts cannot be inserted, basic adjustment must be repeated Unscrew TDC-fixing bolts Remove torsional vibration damper

29. For toothed belt tension roller with leaf spring: unscrew bolt (M10) from lower bore of toothed belt tensioner

30. Attach lower part of toothed belt cover

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

31. 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.)

32. Fasten upper part of toothed belt cover

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

33. Attach coolant pump ribbed V-belt pulley

• Screw in bolts

34. Raise vehicle

35. Install torsional vibration damper

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

36. Install ribbed V-belt

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

37. Fasten coolant pump ribbed V-belt pulley

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

38. Lower vehicle

39. 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°.)

40. Attach wiring trough

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

41. Attach alternator wiring harness

• Connect wiring harness plug.
• Tighten nuts

42. 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

43. Raise vehicle

44. Detach support

45. Detach KM-6169

46. Install ribbed V-belt cover

• Screw in bolts
• Install clip

47. Lower vehicle

48. Install right front wheel

• Screw in bolts

49. Lower vehicle

50. Fasten right front wheel

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

51. Calibrate steering angle sensor

• Switch on ignition

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

52. Connect battery

53. Program volatile memories

54. Close bonnet