Vauxhall Workshop Service and Repair Manuals

Starter  

Starter, Remove and Install  

Notice: 

G 0009 shows X 20 DTL.  

For repairs to the starter: see corresponding operations in Service Instructions "OHC Petrol Engine".     Remove, Disconnect    Remove engine cover and charged air tube (1).   Detach conduction bridges (2) or rear wiring trough from glow plugs together with wiring connections.   Remove fastening bolts (3) and central heat shield.   Remove fastening bolts (4) and left and right heat shield.

  Remove, Disconnect   

Remove fastening bolts (3) and fastening nuts (2) and lower heat shield (starter).   Remove wiring trough from cylinder block (3 fastening bolts) and carefully push away downwards.   Remove exhaust manifold support (1) from exhaust manifold and cylinder block.   Remove wiring connection from starter.   Remove upper starter fastening bolt.   Remove front exhaust pipe.   Remove lower starter fastening bolt and remove starter with starter bracket downwards.

  Install, Connect   

Insert and fasten starter in cylinder block - tightening torque 45 Nm / 33 lbf. ft.  

Connect front exhaust pipe to return manifold with new gasket and new fastening nuts - tightening torque 20 Nm / 15 lbf. ft.  

Connect front exhaust pipe to muffler - tightening torque 12 Nm / 9 lbf. ft.  

Attach exhaust manifold support to exhaust manifold and cylinder block - tightening torque 25 Nm / 18.5 lbf. ft.  

Attach wiring trough to cylinder block (3 fastening bolts).  

Install all heat shields.  

Attach conduction bridges or rear wiring trough to glow plugs together with wiring connections.  

Notice: 

Before assembling components of the intake system (hoses, connections, etc.), they must be cleaned of any possible contamination (grease, oil, etc.). When tightening the hose clamps, be sure to observe exactly the tightening torque of 3.5 Nm / 2.6 lbf. ft.  

  Important!   

It is only ensured that the intake system is free of leaks, thus ensuring operational safety of the engine, if the hose clamps are tightened correctly to the prescribed tightening torque.  

  Install, Connect   

Install charge air pipe with new seal ring.  

Install engine cover on cylinder head cover.  

Check engine oil level, if necessary correct.