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Vauxhall Workshop Service and Repair Manuals

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J313800 Replace toothed belt guide roller (Z 14 XE, Z 16 YNG with air conditioning, LHD) > < J313900 Replace toothed belt (Z 14 XE, Z 16 YNG with air conditioning, LHD)

Corsa C

J313910 Replace toothed belt tension roller (Z 14 XE, Z 16 YNG with air conditioning, LHD)

Note:   KM-6394 must be used as of model year 04 instead of KM-6169-1 .

1. Open bonnet

Important:   On vehicles as of 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)

  • Disconnect wiring harness plug
    • Intake air temperature sensor (4), tank vent valve (2)
  • Unclip tank vent valve
  • Remove air intake hose
  • Detach engine vent hose (5)
  • Remove bolt (3)

4. Loosen front right wheel

5. Raise vehicle

 Object Number: 2410698 Size: DEFAULT

6. Remove front right wheel

  • Remove 4 bolts

7. Raise vehicle

8. Remove ribbed V-belt cover

  • Remove 3 bolts (1)
  • Remove clip (arrow).
 Object Number: 2410600 Size: DEFAULT

9. Remove ribbed V-belt

  • Tension ribbed V-belt tensioner in direction of arrow
    • With KM-913-A (2) (SW 15)
  • Insert KM-6130 (1)
  • Note: Mark running direction
 Object Number: 2410700 Size: DEFAULT

10. Remove ribbed V-belt tensioner

  • Tension ribbed V-belt tensioner.
  • Remove KM-6130 (2)
  • Release ribbed V-belt tensioner
  • Remove bolt (1)
 Object Number: 2410697 Size: DEFAULT

11. Detach crankshaft ribbed V-belt pulley

  • Lever out front closure plug
    • From oil pan
  • Insert KM-911
  • Remove bolt
  • Remove KM-911
 Object Number: 2410695 Size: DEFAULT

12. Release toothed belt cover lower section

  • Remove bolt (arrow)
  • Unclip from rear toothed belt cover
 Object Number: 2411206 Size: DEFAULT

13. Attach KM-6169-3

  • Tighten bolts (95 Nm / 70 lbf. ft.)
 Object Number: 2411202 Size: DEFAULT

14. 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
 Object Number: 2409770 Size: DEFAULT

15. Install support

  • To KM-6169
    • Adjust bracket (2) for support
  • Screw on nut (1)

16. 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)
 Object Number: 2411021 Size: DEFAULT

17. Lower vehicle

18. Remove right engine damping block

  • Loosen engine bracket adapter
    • Remove 2 bolts (1)
  • Loosen engine damping block
    • Remove 2 bolts (2)

19. Remove toothed belt cover upper section

  • Remove 3 bolts (arrows)
  • Unclip from rear toothed belt cover

20. Disconnect wiring harness plug from camshaft sensor.

  • Unclip from bracket
  • Disconnect wiring harness plug

21. Remove toothed belt cover lower section

  • Unclip from rear toothed belt cover
 Object Number: 2410702 Size: DEFAULT

22. Set 1st cylinder to TDC

  • Install crankshaft V-belt pulley bolt
  • Set crankshaft to mark.
    • Turn crankshaft evenly
    • Note: Marks on drive gear toothed belt and rear toothed belt cover must align (III)
  • Fix camshaft sprockets in position.
    • Note: Marks must be opposite one another and aligned with the top edge of the cylinder head (I)
    • Insert KM-852 (II)

23. Remove toothed belt

  • Release toothed belt tension roller (IV)
    • Loosen bolt
    • Turn adjusting eccentric in direction of arrow (clockwise) until pointer (1) of the toothed belt tension roller is located just before left stop.
  • Note: Mark running direction
  • Remove toothed belt.
 Object Number: 2415419 Size: DEFAULT

24. Remove toothed belt tension roller (1)

  • Remove bolt (2)
 Object Number: 2410725 Size: DEFAULT

25. Install toothed belt tension roller

  • Caution: Detent lever (1) of toothed belt tension roller must engage in guide web (2) of oil pump
  • Bolt in bolt
    • Note: Only tighten bolt after adjusting toothed belt tension
 Object Number: 2410711 Size: DEFAULT

26. Check that 1st cylinder is at TDC

  • Install crankshaft V-belt pulley bolt
  • Set crankshaft to mark.
    • Turn crankshaft evenly
    • Note: Marks on drive gear toothed belt and rear toothed belt cover must align

27. Install toothed belt

  • Note: Note running direction and timing marks
  • Position toothed belt
    • Note: Tensioned side must be taut

28. Tension toothed belt

  • Tension toothed belt tension roller
    • Turn adjusting eccentric in direction of arrow (anticlockwise) until pointer of the toothed belt tension roller is located just before left stop
  • Fasten toothed belt tension roller bolt (1)

29. Remove KM-852

 Object Number: 2410723 Size: DEFAULT

30. Timing, Check

  • Turn crankshaft (720°)
    • At crankshaft ribbed V-belt pulley bolt
    • Note: In direction of engine rotation
  • Set crankshaft to mark.
    • Note: Marks on drive gear toothed belt and rear toothed belt cover must align (III)
  • Insert KM-852 (II)
    • Note: Marks must be opposite one another and aligned with the top edge of the cylinder head (I)

31. Remove KM-852

 Object Number: 2396120 Size: DEFAULT

32. Toothed Belt Tension, Adjust

  • Release toothed belt tension roller
    • Loosen bolt
  • Turn adjustment eccentric in the direction of the arrow (clockwise) until pointer (1) is aligned with the notch mark at the toothed belt tension roller (2).
    • Adjust used toothed belts to the marking USED
    • Adjust new toothed belts to the marking NEW
  • Tighten toothed belt tension roller bolt (20 Nm / 15 lbf. ft.)

33. Toothed Belt Tension, Check

  • Turn crankshaft (720°)
  • Note: Pointers on the toothed belt tension roller and notch mark must align
    • Adjust used toothed belts to the marking USED
    • Adjust new toothed belts to the marking NEW
 Object Number: 2410712 Size: DEFAULT

34. Install toothed belt cover lower section

  • Clip to rear toothed belt cover
  • Tighten bolt (4 Nm / 3 lbf. ft)

35. Connect wiring harness plug from camshaft sensor.

  • Connect wiring harness plug from camshaft sensor.
  • Clip to bracket

36. Install toothed belt cover upper section

  • Clip to rear toothed belt cover
  • Tighten bolts (4 Nm / 3 lbf. ft)

37. Install right engine damping block

  • Fasten engine bracket adapter
    • Tighten bolts (60 Nm + 30° - 45°)
  • Fasten engine damping block
    • Tighten bolts (40 Nm / 29.5 lbf. ft.)

38. Raise vehicle

39. Detach supports

  • Engine timing side
  • Transmission side

40. Detach KM-6169

41. Detach KM-6169-3

42. Install ribbed V-belt tensioner

  • Tighten bolt (35 Nm / 26 lbf. ft.)
  • Tension ribbed V-belt tensioner.
    • With KM-913-A
  • Insert KM-6130

43. Attach crankshaft ribbed V-belt pulley

  • Replace bolt
  • Insert KM-911
  • Tighten bolt (90 Nm / 66 lbf. ft. + 30° + 15°.)
  • Remove KM-911
  • Insert front closure plug

44. Install ribbed V-belt

  • Note: Note running direction and installation position
  • Release ribbed V-belt tensioner
    • With KM-913-A
  • Remove KM-6130

 

45. Install ribbed V-belt cover

  • Screw in bolts
  • Install clip

46. Lower vehicle

47. Install front right wheel

  • Screw in bolts

48. Lower vehicle

49. Attach front right wheel

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

50. Install air cleaner housing

  • Tighten bolt
  • Install air intake hose
  • Attach engine vent hose
  • Clip in tank vent valve
  • Connect wiring harness plug.
    • 2 off

51. Connect battery

52. Calibrate steering angle sensor

  • Switch on ignition

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

53. Program volatile memories

54. Close bonnet

J313800 Replace toothed belt guide roller (Z 14 XE, Z 16 YNG with air conditioning, LHD) > < J313900 Replace toothed belt (Z 14 XE, Z 16 YNG with air conditioning, LHD)