Auto Repair Manual Free Download and ReviewsFree download ebook pdf files automotive manual

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Special Precautions Special Precautions Disconnect battery earth lead. DO NOT turn crankshaft or camshaft when timing belt removed. Remove glow plugs to ease turning engine. Turn engine in normal direction of rotation (unless otherwise stated). DO NOT turn engine via camshaft or other sprockets. Observe all tightening torques. Check diesel injection pump timing after belt replacement. Removal Removal 1. Support engine. 2. Remove: Air filter and air intake hoses. Auxiliary drive belts. RH engine mounting. Vacuum pipe bracket. Timing belt upper cover [1]. 3. Turn crankshaft clockwise to TDC on No.1 cylinder. Ensure crankshaft sprocket timing marks aligned [2]. 4. Insert M6 x 1,00 bolt in camshaft sprocket and M8 x 1,25 bolt in injection pump sprocket to lock sprockets in position [3]. NOTE: If locating holes not aligned: Turn crankshaft one turn. 5. Remove: Crankshaft pulley (4 bolts). Timing belt lower cover [4]. 6. Slacken tensioner bolts [6]. Remove tensioner spring [5]. 7. Move tensioner pulley away from belt. Lightly tighten bolts. 8. Remove timing belt. Installation Installation 1. 2. 3. 4. 5. Use crankshaft pulley to check TDC marks aligned [2]. Ensure locking bolts located correctly [3]. Fit timing belt in clockwise direction, starting at crankshaft sprocket. Ensure belt is taut between sprockets. Temporarily fit crankshaft pulley. Ensure timing marks aligned [2]. Fit tensioner spring [5]. Corsa-B/Corsavan/Combo: Slacken tensioner bolts [6]. Allow tensioner to operate. Remove locking bolts [3]. Tighten tensioner bolts to 19 Nm [6]. Turn crankshaft slowly two turns clockwise. Ensure timing marks aligned [2]. 6. Astra-F/Vectra/Cavalier: Slacken tensioner bolts [6]. Temporarily fit crankshaft pulley. Remove locking bolts [3]. Turn crankshaft 60° anti-clockwise (against normal direction of rotation) [7]. Tighten tensioner bolts to 19 Nm [6]. Turn crankshaft slowly two turns + 60° clockwise until timing marks aligned [2]. 7. 8. 9. 10. 11. Ensure timing marks aligned [2]. Ensure locking bolts can be inserted in sprockets [3]. If not: Repeat tensioning procedure. Remove crankshaft pulley. Fit timing belt lower cover [4]. Fit crankshaft pulley. Tighten bolts to 20 Nm. Install components in reverse order of removal.

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REMOVAL & INSTALLATION See Figures 1, 2, 3, 4 and 5 1. Disconnect the negative battery cable. 2. Remove the engine fan/clutch assembly and shroud. 3. Remove the accessory drive belt(s). 4. On those engines with a separate damper and pulley, remove the retaining bolts, then separate the crankshaft damper from the pulley. 5. Remove the pulley-to-crankshaft bolt and washer. Fig. Fig. 1: If necessary on some engines, assemble a puller to the damper … Fig. Fig. 2: … then tighten the center bolt to remove the damper from the crankshaft Fig. Fig. 3: Loosen the crankshaft pulley center nut by installing a small bolt on the outside of the pulley, using a prybar for holding force and a socket and breaker bar Fig. Fig. 4: Remove the crankshaft pulley retaining bolt Fig. Fig. 5: Remove the crankshaft pulley, keep the small bolt in for installation purposes 6. If necessary, use a puller tool to remove the damper/pulley from the crankshaft. 7. If equipped, remove the crankshaft key. To install: WARNING On MPV models equipped with the 3.0L engine, the crankshaft position sensor rotor is on the rear of the damper/pulley and can be easily damaged. 8. Inspect the front cover seal and replace if necessary. 9. On 3.0L (B Series Pick-up) and 4.0L engines, perform the following: a. Coat the rubbing surface of the damper/pulley with clean engine oil. b. Apply a small amount of RTV sealant to the damper keyway groove. c. On the B Series Pick-up with the 3.0L engine, use a crankshaft damper installation tool to press the damper onto the crankshaft. Install and tighten the retaining bolt to 93-121 ft. lbs. (125-165 Nm).

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Removal 1. Remove the supercharger drive belt. 2. Remove the fan blade, clutch and shroud. 3. Raise the vehicle on a hoist. 4. Remove the nut and position the shield aside. 5. Remove the transmission cooler line clip. 6. Remove the two nuts and one bolt. 7. Remove the starter motor. 8. Install the special tool. 9. Remove the accessory drive belt. 10. NOTE: The auxiliary supercharger pulley has left-hand threads. Remove the pulley and brace assembly. 11. Remove the supercharger pulley adapter. 12. Remove the bolt. 13. Using the special tool, remove the crankshaft pulley. Installation 1. NOTE: The crankshaft pulley must be installed within four minutes after applying the silicone. Apply silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley. 2. Using the special tool, install the crankshaft pulley. 3. Install the bolt and washer. Tighten the bolt in four stages. Stage 1: Tighten to 90 Nm (66 ft. lbs.) . Stage 2: Loosen the bolt. Stage 3: Tighten to 50 Nm (37 ft. lbs.) . Stage 4: Tighten an additional 85 – 90° . 4. Install the supercharger pulley adapter. 5. Install the drive belt. 6. NOTE: Coat the threads of the supercharger pulley with anti-seize lubricant. NOTE: The auxiliary supercharger pulley has left-hand threads. Install the pulley and brace assembly. 7. Remove the special tool. 8. Install the starter motor. 9. Position the transcooler line clip and install the two nuts and one bolt. 10. 11. 12. 13. Position the shield and install the nut. Lower the vehicle. Install the fan blade, clutch and shroud. Install the accessory drive belt and the supercharger drive belt.

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REMOVAL Ignition Rotor Removal And Installation 1. 2. 3. Disconnect negative battery terminal, disconnect distributor lead wire at the wiring harness connector. Release distributor cap retainers and lift the distributor cap off. Scribe a mark on the edge of the distributor housing to indicate the position of the rotor. Use the mark as a reference when reinstalling the distributor. Remove the distributor hold down bolt and clamp, and carefully lift the distributor out of the engine. 4. INSTALLATION 1. Clean the top of the cylinder block to insure a good seal between the distributor base and block. If the engine has not been cranked with distributor removed, proceed with step 2. If the engine has been cranked with the distributor removed proceed to step 3. Position the distributor into the engine. Make sure the O-ring seal is in place on the distributor housing. Align the rotor with the mark previously scribed on the distributor housing. Engage the tongue of the distributor shaft with the slot in the distributor oil pump drive gear. Proceed to step 4. If engine has been cranked with distributor removed perform the following: a. Rotate the crankshaft until number one piston is at the top of its compression stroke. The mark on the crankshaft vibration damper should be in line with the “0″ TDC mark on the timing chain case cover. b. Rotate the distributor rotor until it is positioned pointing at the number one distributor cap terminal. c. Lower the distributor into the engine, making sure the O-ring seal is in place. Engage tongue of distributor shaft with slot in the distributor oil pump drive gear. Install the distributor hold down clamp and screw and tighten finger tight. Install distributor cap and wires, making sure all high tension wires are firmly secured in cap towers. Connect pick-up leads and negative battery cable lead. Set ignition timing, refer to ADJUSTMENT PROCEDURES for timing adjustment. 2. 3. 4. 5.

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All vehicles 1. Remove the transmission. For additional information, refer to Section 307-01 for automatic transmissions or Section 308-03 for manual transmissions. Vehicles with manual transmission 2. Remove the clutch disc and pressure plate. For additional information, refer to Section 308-01. All vehicles IN-VEHICLE REPAIR (Continued) 3. Remove the 10 bolts and flexplate or flywheel. • Discard the bolts. 4. NOTICE: Use extreme care when removing the flywheel front adapter to prevent damage to the alignment dowel pin. Remove the flywheel front adapter. 5. NOTICE: To prevent engine damage, do not remove the rear primary crankshaft flange bolts under any circumstances. If the flange is removed and reinstalled, it will result in engine vibration and premature transmission component wear. NOTICE: Drill only deep enough to penetrate the seal. Engine damage will occur if the seal is drilled too deep. NOTE: On original service seals, if equipped, the wear ring will be removed separately. Using a center punch, mark a location for 2 holes 180 degrees apart, 9.53 mm (0.375 in) from the outer diameter of the crankshaft flange. Using a drill bit of the appropriate size for the Slide Hammer being used, drill a hole on each side of the crankshaft rear seal as shown. Drill the holes to a depth of 8.76 mm (0.344 in) to capture the metal case of the crankshaft rear seal as well as the wear ring. 6. Using the 2 drilled holes, the Slide Hammer and a commercially available body dent puller attachment, walk the seal out of the rear cover by alternating from side to side to remove the crankshaft rear seal. • Discard the crankshaft rear seal. Vehicles with an original service seal 7. NOTE: Original equipment seals will not have a wear ring. If a service part has previously been installed, it will have a wear ring. If the service part was a redesigned seal, the wear ring will have been removed with the seal in the previous step. If the service part was an original service seal, the wear ring will remain in the engine after the seal has been removed. If the wear ring remained in the engine after removing the seal, use the Crankshaft Rear Wear Ring Remover to remove and discard the crankshaft rear seal wear ring. All vehicles 8. Clean and inspect the crankshaft sealing surface. Installation Vehicles with an original service seal 1. NOTICE: The crankshaft rear seal and wear ring are a one-piece design and need to be installed as an assembly. Do not separate the wear ring from the crankshaft rear seal or damage to the seal may occur. NOTE: An original service seal will have a wear ring without a flange and pre-applied threadlock. NOTE: Apply a bead of threadlock around the circumference of the outer rear edge of the secondary crankshaft flange.