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High-Pressure Pump Drive Gear, Remove and Install > < Replace toothed belt drivewheel

Corsa D

Replace rear toothed belt cover

  Remove

1.   Open bonnet
2.   Disconnect battery
•   Detach negative clamp from earth terminal
– Undo nut
3.   Remove air cleaner housing
4.   Remove air intake pipe (1) together with air mass flow meter
•   Release clamp
•   Disconnect wiring harness plug of air-flow meter
Object Number: 10678238 Size: DEFAULT


5.   Attach engine hoist
6.   Remove engine damping block (2)
•   Detach from side member
– Unscrew 3x bolts (1)
•   Detach from engine damping block bracket
– Unscrew 3x bolts (3)
Object Number: 10678292 Size: DEFAULT


7.   Raise engine on timing side using engine bridge
•   Raise the engine until the lower screw of the engine damping block bracket is at the same height as the recess in the side member
8.   Release right engine damping block bracket (1)
•   Unscrew 2x bolts (2)
Object Number: 10678294 Size: DEFAULT


9.   Remove injector wiring harness retaining plate (1)
•   Unscrew bolt (3)
•   Unscrew nut (2)
•   Lay retaining plate aside.
Object Number: 10678293 Size: DEFAULT


10.   Remove camshaft sensor (1)
•   Disconnect wiring harness connector.
•   Unscrew bolt (2)
Object Number: 10678296 Size: DEFAULT


11.   Release upper toothed belt cover (2)
•   Unscrew 6 bolts (arrows)
Note:   Observe different bolt lengths
•   Unclip 4x fuel return line (1)
Object Number: 10678297 Size: DEFAULT


12.   Raise vehicle by its full height
13.   Remove engine cover and right engine splash guard
14.   Remove ribbed V-belt
Note:   Mark direction of rotation
•   Apply tension to ribbed V-belt tensioner via bolt (1) in the direction of the arrow
•   Fix ribbed V-belt tensioner at bore (2) with KM-6130
•   Remove ribbed-V-belt
Object Number: 3447354 Size: DEFAULT


15.   Remove right engine damping block bracket (1)
•   Unscrew bolt (2)
Object Number: 10678295 Size: DEFAULT


16.   Remove upper toothed belt cover (1)
•   Unscrew 2 bolts (arrows)
Note:   Observe different bolt lengths
Object Number: 10678298 Size: DEFAULT


17.   Remove torsional vibration damper (1)
•   Unscrew 4x bolts
Note:   Counterhold at bolt (2)
Object Number: 2412637 Size: DEFAULT


18.   Remove lower toothed belt cover (1)
•   Unscrew 3x bolts (2)
•   Remove engine damping block adapter
Object Number: 2412640 Size: DEFAULT


19.   Set cylinder 1 to TDC of combustion stroke
•   Fix camshaft sprocket in position using TDC locking bolt (M6x25) (1)
•   Turn crankshaft evenly in direction of engine rotation, until mark (3) of toothed belt drive gear is in line with mark (2) on oil pump cover
Object Number: 2412641 Size: DEFAULT


20.   Release toothed belt tension roller (1)
•   Slacken bolt of toothed belt tension roller (2)
•   Turn toothed belt tension roller approx. 90° anticlockwise
•   Tighten bolt, toothed belt tension roller
Object Number: 2406524 Size: DEFAULT


21.   Remove toothed belt
•   Mark direction of rotation
22.   Remove high-pressure pump drive gear
•   Unscrew locking bolt
•   Unscrew nut
Important:   Note spring washer
– Counterhold with KM-6603 (1), allow KM-6603 to rest against position (2) on toothed belt drive gear
•   Remove high-pressure pump drive gear with KM-6602 (4)
– Counterhold with KM-6603
Note:   Allow KM-6603 to rest against position (3) of toothed belt drive gear
Object Number: 7360929 Size: DEFAULT


23.   Remove camshaft sprocket
•   Remove TDC fixing bolt (1)
– Unscrew bolt
Note:   Counterhold it with KM-6347 (3) together with KM-956-1 (2)
Object Number: 2412644 Size: DEFAULT


24.   Remove toothed belt guide roller (1)
•   Unscrew bolt (2)
Object Number: 2411101 Size: DEFAULT


25.   Remove oil pump gear (1)
•   Unscrew nut
Note:   Counterhold with socket wrench (2)
Object Number: 2413409 Size: DEFAULT


26.   Remove rear toothed belt cover (1)
•   Unscrew 6x bolt (2)
Object Number: 10678213 Size: DEFAULT


  Install

27.   Install rear toothed belt cover
•   Tighten 6x bolt 10 Nm
28.   Install oil pump gear
Note:   Note installation position
•   Tighten nut
Note:   Counterhold with socket wrench
– 60 Nm
– Hold for 20 seconds
– Undo nut
– 60 Nm
29.   Install toothed belt guide roller
•   Tighten bolt 80 Nm
30.   Install camshaft sprocket
Note:   Camshaft journal (2) must engage in the bore (1) in the camshaft sprocket
•   Tighten bolt 111 Nm
– Counterhold it with KM-6347 together with KM-956-1
Important:   Do not damage increment disc
•   Screw in TDC fixing bolt
Object Number: 2412650 Size: DEFAULT


31.   Install high-pressure pump drive gear
Note:   Note spring washer
•   Tighten nuts 69 Nm
– Counterhold with KM-6603
32.   Install toothed belt
Note:   TDC locking bolt must be installed in camshaft sprocket (9) and high-pressure pump gear (8) and marks (6) and (7) must align
•   Position toothed belt
Note:   Observe direction of rotation
– Toothed belt must be tensioned in the direction of the arrow from the toothed belt drive gear (5), through the oil pump drive gear (4) and the high-pressure pump drive gear (2) to the camshaft sprocket (1)
•   Slacken the toothed belt tension roller (3)
•   Tighten toothed belt tension roller 49 Nm
Object Number: 10678301 Size: DEFAULT


33.   Timing, Check
•   Remove 2x TDC fixing bolt
•   Turn crankshaft approx. 720° in the direction of rotation of the engine
– To toothed belt drive gear
•   Mark on toothed belt drive gear must be in line with the lug on the oil pump cover
•   Screw in 2x TDC locking bolts
Note:   If it is not possible to screw in a TDC locking bolt, the basic setting must be carried out again.
•   Unscrew 2x TDC fixing bolt
34.   Install lower toothed belt cover
•   Insert engine damping block adapter
•   Tighten 3x bolt 10 Nm
35.   Install torsional vibration damper
•   Tighten 4x bolt 20 Nm
Note:   Counterhold at toothed belt drive gear bolt
36.   Install upper toothed belt cover
•   Tighten 2x bolt 10 Nm
37.   Install right engine damping block bracket
•   Screw in 3 bolts
•   Tighten lower bolt 60 Nm
38.   Insert ribbed V-belt
Note:   Observe direction of rotation
•   Position ribbed V-belt
– I. Ribbed V-belt without air conditioning
– II. Ribbed V-belt with air conditioning
•   Apply tension to ribbed V-belt tensioner via bolt (1) in the direction of the arrow
– Remove KM-6130
Object Number: 10678212 Size: DEFAULT


39.   Install engine compartment cover and/or right engine splash guard
40.   Lower vehicle by its full height
41.   Fasten top of toothed belt cover
•   Tighten 6x bolt 10 Nm
Note:   Observe different bolt lengths
•   Clip in 4x fuel return line
42.   Install camshaft sensor
•   Replace seal ring
•   Tighten bolt 10 Nm
•   Fix wiring harness plug
43.   Fasten right engine damping block bracket
•   Tighten 2x bolt 60 Nm
44.   Install injector wiring harness retaining plate
•   Tighten bolt
•   Tighten nut
45.   Lower engine on timing side using engine bridge
46.   Install engine damping block
•   Attach to side member
– Tighten 3x bolt 60 Nm
•   Attach engine damping block to mount
– Tighten 3 new bolts 80 Nm + 45°
47.   Detach engine hoist
48.   Install air intake pipe together with air mass flow meter
•   Tighten clamp 3.5 Nm
•   Connect mass air flow meter wiring harness plug
49.   Install air cleaner housing LUREF_1.gif
50.   Connect battery
•   Attach earth clamp to earth terminal
– Tighten nut
51.   Program volatile memories
52.   Close bonnet

High-Pressure Pump Drive Gear, Remove and Install > < Replace toothed belt drivewheel