Vauxhall Workshop Service and Repair Manuals

Mark running direction of ribbed V-belt. Using ribbed V-belt tension roller and KM-913-A, release ribbed V-belt in direction of arrow (clockwise) and remove ribbed V- belt.

Open coolant drain bolt on radiator – collect coolant.

Loosen fastening bolts (1) and (2), remove fastening bolts (3) and (4) from alternator.

Loosen lower alternator fastening bolt – swing alternator aside.

Detach coolant hoses from thermostat housing. Detach coolant hose (3) from coolant outlet port and coolant hose (2) from thermostat housing.

Detach wiring harness plug (1) from coolant temperature sender and wiring harness plug from coolant temperature sensor.

Rear toothed belt cover – see operation "Toothed Belt Cover – Rear, Remove and Install".

Remove thermostat housing (4) with seal ring from cylinder head.

When replacing the thermostat housing – re-install attaching parts.

Coolant temperature sensor to thermostat housing – tightening torque 11 Nm / 8.5 lbf. ft. Coolant temperature sensor to thermostat housing – tightening torque 10 Nm / 7.5 lbf. ft. Coolant outlet port with new gasket to thermostat housing – tightening torque 8 Nm / 6 lbf. ft.

  Clean

Clean sealing surfaces and remove gasket remnants.

  Install

Coat new seal ring (1) with silicon grease (white) and insert in cylinder head.

Attach thermostat housing to cylinder head – tightening torque 15 Nm / 11 lbf. ft.

Install rear toothed belt cover – see operation "Toothed Belt Cover – Rear, Remove and Install".

Attach coolant hose to thermostat housing and coolant hose to coolant outlet port. Attach coolant hoses (1) and (2) to thermostat housing.

Connect wiring harness plug to coolant temperature sender and wiring harness plug to coolant temperature sensor.

Attach support (4) and shackle (3) to intake manifold and alternator – tightening torque 20 Nm / 14.7 lbf. ft. Tighten lower alternator fastening bolt – tightening torque 35 Nm / 25.8 lbf. ft.

Position ribbed V-belt – tension ribbed V-belt via ribbed V-belt tension roller and KM-913-A. Note running direction of ribbed V-belt. Close coolant drain bolt on radiator. Top up cooling system – see operation "Cooling System, Top Up and Bleed" and "Cooling System, Check for Leaks".