Vauxhall Workshop Service and Repair Manuals

J491700 Injection Pump, Replace (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. 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 hose clamp (5)
• Remove bolt (2)

4. Loosen front right wheel

5. Raise vehicle

6. Remove front right wheel

• Remove 4 bolts

7. Raise vehicle

8. Remove ribbed V-belt cover Remove 3 bolts (1) Remove clip (arrow).

9. 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

10. Install support To KM-6169 Adjust bracket (2) for support Screw on nut (1)

11. Adjust supports

• Transmission side
• Note! Turn spindles until the mounts (3) are positioned at the guide journals free of play
• Engine timing side
• Insert support pin in cylinder block bore without play (arrows)
• Tighten nuts (1)

12. Lower vehicle

13. Remove right engine damping block Remove 4 bolts

14. Detach alternator wiring harness

• Disconnect wiring harness plug (1)
• Unscrew nut (2)

15. Detach vacuum hoses from vacuum pump (3) Brake servo Exhaust gas recirculation solenoid valve

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

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

18. Detach right engine bracket (1) Remove 3 bolts Remove right engine bracket, right engine bracket adapter, upper part of toothed belt cover

19. Raise vehicle

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

21. Remove ribbed V-belt

• Tension ribbed V-belt tensioner in direction of arrow
• With KM-913-A
• Note! Mark running direction

22. Detach coolant pump ribbed V-belt pulley

• Remove bolts

23. Remove torsional vibration damper (1) Remove 4 bolts

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

25. 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)

26. Lower vehicle

27. 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) Remove tension spring (1)

For toothed belt tension roller with spiral spring: Loosen toothed belt tension roller (1) Rotate toothed belt tension roller anticlockwise approx. 90° Tighten bolt (2)

28. Remove toothed belt

• Mark direction of rotation

29. Remove injection pump gear Unscrew nut Unscrew TDC-fixing bolt Attach KM-6099 Pull off injection pump gear Note! Note woodruff key

30. Remove wiring harness plug for engine control unit 3 off Release 2 wiring harness plugs in direction of arrow Unclip wiring harness

31. Remove air intake pipe Remove 3 bolts Remove vent hose (1) From cylinder head cover Detach air intake pipe from turbocharger

32. Remove charge air hose

• From turbocharger, centre charge air pipe
• Loosen 2 hose clamps

33. Remove engine control unit Unclip wiring harness for engine management Remove wiring harness plug bracket Remove 2 bolts (1) Unscrew 2 bolts (2), 2 nuts (3)

34. Remove engine control unit bracket Unscrew 2 bolts (2), nut (1) Unclip wiring harness (arrows)

35. Detach starter/alternator wiring harness bracket

• From exhaust recirculation valve
• Remove 2 nuts

36. Remove centre charge air pipe (1) Unscrew studs, 2 bolts

37. Remove wiring harness plug

• from sheathed glow plugs
• 4 off

38. Remove exhaust recirculation valve (1) Remove exhaust recirculation pipe Remove 2 bolts Unscrew studs (3), 2 bolts Detach vacuum hose (2) Remove gaskets

39. Remove exhaust recirculation solenoid valve Detach vacuum hose (1) Detach wiring harness plug (2). Remove 2 bolts

40. Remove right rear engine transport shackle

• Remove bolt

41. Remove charge pressure sensor (2) Disconnect wiring harness plug (1) Remove bolt

42. Remove oil filter insert Place collecting basin underneath. Unscrew oil filter housing cover (1)

43. Detach oil return line

• From oil filter housing
• Release clamp

44. Remove injection line spacers (1) Remove 3 bolts

45. Remove injection lines

• 4 off
• With KM-6098

46. Detach outer oil leak line Unscrew 1 banjo bolt (3), 1 bolt (2) Remove oil leak hose (1) Release clamp

47. Remove wiring harness plug

• From diesel injection pump
• 3 off

48. Remove two piece intake manifold Unscrew 7 bolts, 2 nuts Remove gaskets

49. Remove fuel lines

• From diesel injection pump

50. Remove fuel return connection Note! Do not unscrew check valve (SW 14) from banjo bolt. Carefully unscrew banjo bolt (1) (SW 17) Close off return bore using blind plugs

51. Remove outer diesel injection pump insulation

• Remove bolt

52. Remove wiring harness for engine management

• Disconnect wiring harness plug
• Unclip wiring harness

53. Remove inner diesel injection pump insulation

• Lever off carefully

54. Remove diesel injection pump bracket Remove 4 bolts

55. Remove diesel injection pump Remove 2 nuts Disconnect wiring harness plug

56. Install diesel injection pump

• Insert diesel injection pump
• Connect wiring harness plug.
• Tighten 2 nuts with washers (19.6 Nm/14.5 lbf. ft.)

57. Install diesel injection pump bracket

• Install 4 bolts
• Tighten 2 bolts at cylinder head (53.9 Nm / 39.8 lbf. ft.)

58. Install injection pump gear

Note:   Observe tightening sequence

59. Check TDC position for 1st cylinder Mark on toothed belt drive gear (2) must align with casting lug at oil pump cover (1)

60. Install toothed belt

Note:   Toothed belt must be taut from toothed belt drive gear via oil pump drive gear and injection pump drive gear

• Position toothed belt

• For toothed belt tension roller with leaf spring:
• Attach leaf spring

• Unscrew TDC-fixing bolt
• Rotate crankshaft 60° against direction of engine rotation
• 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

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

62. Timing, Check Turn crankshaft approx. 780° in direction of engine rotation At toothed belt drive gear bolt Mark on toothed belt drive gear (2) must align with casting lug at oil pump cover (1) Install TDC-fixing bolt 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, the basic adjustment must be repeated Unscrew TDC-fixing bolts

63. Attach KM-798 Turn crankshaft in direction of engine rotation to 45° before 1st cylinder TDC At toothed belt drive gear bolt Remove central bleeder screw Install KM-798 under pre-tension Determine BDC position of injection pump plunger by turning crankshaft back and forth Note! The dial gauge indicator must not move Set dial gauge to "0".

64. Adjust diesel injection pump

• Turn crankshaft to 1st Cylinder TDC
• Note! The pin on the oil pump must align with the mark on the pulley
• Loosen diesel injection pump
• Turn diesel injection pump until 0.33 mm adjustment value is accomplished
• Value too high – turn injection pump towards engine.
• Value too low – turn injection pump away from engine.
• Tighten diesel injection pump (19.6 Nm / 14.4 lbf. ft.)

65. Check start of feed

• Remove KM-798
• Turn crankshaft approx. 675°
• Install KM-798 under pre-tension
• Determine BDC position of injection pump plunger by turning crankshaft back and forth
• Note! The dial gauge indicator must not move
• Set dial gauge to "0".
• Turn crankshaft to 1st Cylinder TDC
• Note! The pin on the oil pump must align with the mark on the pulley
• Read test value
• Test value: 0.28 – 0.38 mm
• Caution! If test value is not achieved, adjustment must be repeated

66. Remove KM-798

• Remove dial gauge
• Tighten centre bleeder screw (25 Nm / 18.4 lbf. ft.)
• Replace seal ring

67. Install diesel injection pump bracket

• Tighten 2 bolts (18.6 Nm / 13.7 lbf. ft.)

68. Remove torsional vibration damper

• Remove 2 bolts

69. Insert inner diesel injection pump insulation

• 2 off

70. Attach wiring harness for engine management

• Connect wiring harness plug.
• Attach wiring harness

71. Install outer diesel injection pump insulation

• Tighten bolt

72. Attach fuel line connection

• Renew seal rings

73. Attach fuel lines

74. Clean sealing surfaces

75. Install two piece intake manifold

• Replace gaskets
• Tighten bolts, nuts (24.5 Nm/18.7 lbf. ft.)

76. Connect wiring harness plug

• To injection pump

77. Install outer oil leak line

• Renew seal rings
• Tighten bolt, banjo bolt (14.7 Nm / 10.8 lbf. ft.)
• Install oil leak hose

78. Install injection lines

• Caution! Injection lines must be installed without tension. Hand-tighten at injector nozzles and injection pump.
• Tighten union nuts (22.5 Nm/16.6 lbf. ft.)

79. Install injection line spacers

• Note! Note spacer positions
• 3 off

80. Attach oil return line

• To oil filter housing

81. Install oil filter insert

• Replace seal ring
• Tighten oil filter housing cover (25 Nm/18.5 lbf. ft.)

82. Install charge control sensor

• Tighten bolt (9.8 Nm / 7.2 lbf. ft.)
• Connect wiring harness plug.

83. Install exhaust recirculation solenoid valve

• Rework threads
• Tighten 2 bolts
• Insert bolts with locking compound
• Connect wiring harness plug.
• Connect vacuum hose.

84. Install right rear engine transport shackle

• Tighten bolt (20 Nm / 15 lbf. ft.)

85. Install exhaust recirculation valve

• Clean sealing surfaces.
• Insert exhaust recirculation valve
• Tighten studs, 2 bolts (24.5 Nm/18.1 lbf. ft.)
• Replace gasket
• Connect vacuum hose.
• Attach exhaust gas recirculation pipe
• Tighten 2 bolts (28.4 Nm / 21 lbf. ft.)
• Replace gasket

86. Install centre charge air pipe

• Clean sealing surface
• Tighten studs, 2 bolts
• Replace gasket

87. Attach starter/alternator wiring harness bracket

• Tighten 2 nuts

88. Attach wiring harness plug

• To sheathed glow plugs

89. Install engine control unit bracket

• Tighten 2 bolts (24.5 Nm / 18 lbf. ft.)
• Tighten nut (9.8 Nm/7.2 lbf. ft.)
• Clip in wiring harness

90. Install engine control unit

• Install engine control unit
• Tighten 2 bolts, 2 nuts (5.9 Nm/4.4 lbf. ft.)
• Install wiring harness plug bracket
• Tighten 2 bolts
• Connect wiring harness plug.

91. Install air intake pipe

• Tighten 3 bolts
• Fasten hose clamp
• Attach engine vent hose
• Fasten hose clamps
• Attach wiring harness

92. Attach charge air hose

• Fasten 2 hose clamps

93. Attach engine control unit wiring harness plug

• Route wiring harness
• Connect wiring harness plug.
• Attach wiring harness

94. Attach lower part of toothed belt cover

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

95. 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.)

96. Fasten upper part of toothed belt cover

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

97. Attach coolant pump ribbed V-belt pulley

• Screw in bolts

98. Raise vehicle

99. Install torsional vibration damper

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

100. Install ribbed V-belt

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

101. Fasten coolant pump ribbed V-belt pulley

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

102. Lower vehicle

103. 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°.)

104. Attach wiring trough

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

105. Attach alternator wiring harness

• Connect wiring harness plug.
• Tighten nuts

106. Install vacuum hoses from vacuum pump

• Route lines and clip in
• Tighten union nut (18 Nm/13.3 lbf. ft.)

107. Install air cleaner housing

• Tighten bolt
• Fasten air intake hose.
• Tighten clamp
• Connect wiring harness plug to hot film mass air flow meter

108. Raise vehicle

109. Detach support

110. Remove KM-6169

111. Install ribbed V-belt cover

• Screw in bolts
• Install clip

112. Lower vehicle

113. Install right front wheel

• Screw in bolts

114. Lower vehicle

115. Fasten right front wheel

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

116. Connect battery

117. Calibrate steering angle sensor

• Switch on ignition

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

118. Top up engine oil

• Observe specified engine oil quantity
• Start engine and allow to run until oil pressure telltale extinguishes.
• Check engine oil level, if necessary correct.

119. Program volatile memories

120. Close bonnet