Vauxhall Workshop Service and Repair Manuals

Rear Toothed Belt Cover, Replace (Z 17 DTH, With Air Conditioning, LHD)

  Remove

7.   Remove ribbed V-belt cover •   Unscrew 3 bolts (1) •   Remove clip (arrow)

8.   Attach KM-6394 (1) •   Position KM-6394 (1) at the front on the front axle body (arrows, fig. I) Note:   Both locating pins (arrows) must be seated in the guides 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

9.   Install support •   On KM-6394 – Adjust bracket (2) for support •   Screw on nut (1) 10.   Adjust supports •   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

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

13.   Detach coolant pump ribbed V-belt pulley (1) •   Unscrew 3 bolts

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

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

21.   Detach right engine bracket (1) •   Unscrew 3 bolts Note:   Lower bolt cannot be removed •   With right engine bracket adapter

22.   Remove camshaft sensor bracket (1) •   Remove bolt (2) 23.   Remove upper toothed belt cover (3) 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

25.   Remove torsional vibration damper (1) •   Unscrew 4 bolts

26.   Detach lower part of toothed belt cover •   Unscrew 3 bolts

28.   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

29.   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

33.   Remove high pressure pump drive gear •   Unscrew nut – Counterhold with KM-6603 (1) Note:   Allow KM-6603 to lie in position (2) against toothed belt drive gear Important:   Note woodruff key •   Disengage high pressure pump drive gear using KM-6602 (4) – Counterhold with KM-6603 Note:   Allow KM-6603 to lie in position (3) against toothed belt drive gear

34.   Detach camshaft pulley •   Unscrew TDC fixing bolt (1) •   Use KM-6347 (3) in combination with KM-956-1 (2) •   Remove bolt

  Install

Warning:   The different camshaft sprockets (with different part numbers) have different torques for the camshaft sprocket bolt. 37.   Attach camshaft sprocket with part number 97320335 •   Camshaft journal (2) must engage in the bore in the camshaft sprocket (1) •   Use KM-6347 in combination with KM-956-1 •   Tighten bolt 64 Nm •   Install TDC-fixing bolt 38.   Attach camshaft sprocket with part number 98021306 •   Camshaft journal (2) must engage in the bore in the camshaft sprocket (1) •   Use KM-6347 in combination with KM-956-1 •   Tighten bolt 111 Nm •   Install TDC-fixing bolt

43.   Rotate crankshaft to 1st cylinder TDC •   Screw in TDC fixing bolt (1) •   Mark on toothed belt drive gear (3) must align with cast lug (2) on oil pump cover

44.   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

46.   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). If the TDC fixing bolt cannot be screwed in, basic adjustment must be repeated. •   Unscrew TDC fixing bolt

60.   Install ribbed V-belt Note:   Observe running direction and installation position •   Relieve tension of ribbed V-belt tensioner (1) in the direction of the arrow – Use KM-913 – I Ribbed V-belt without AC – II Ribbed V-belt with AC