Contents: Removal ⬇ Installation ⬇
Note: Starting from year 04, KM-6394 must be used instead of KM-6169-1.
Removal
Open the hood.
Disconnect the battery terminals.
Note: On cars from year 04 with ESP - after each battery disconnection the steering wheel angle sensor loses its basic setting. It needs to be recalibrated.
Disconnect the ground wire.
Remove the air filter housing 1.
Disconnect the 2 wiring harness connectors, the hot film air flow meter 3 and the tank vent valve 2.
Release the tank vent valve.
Remove the suction pipe 4.
Unscrew 2 nuts.
Remove the engine crankcase ventilation hose 5.
On Z10XEP engines: Remove the air intake hose.
Release the clamp.
Remove the bolt (arrow).
Free the front wheel on the right.
Unscrew the 4 mounting bolts.
Raise the car.
Remove the front wheel on the right.
Unscrew the 4 mounting bolts.
Raise the car.
Remove the poly V-belt cover.
Note: On the "ECO" model variant, remove the engine compartment cover at the bottom.
Remove 3 mounting bolts 1.
Remove the clamp (arrow).
Install the KM-6169-2 tool on the gearbox.
Tighten the 2 mounting bolts to 95 Nm.
Install fixture KM-61691.
KM-6169 is mounted on the left side of the front axle housing (arrows I).
The guide pin must be located in the hole in the front axle housing.
Install both holders on the right side onto the front axle housing (arrows II).
The guide pin must be located in the hole in the front axle housing (arrow III).
Tighten the 8 mounting bolts
Install the support on the KM-6169 fixture.
Install the support bracket 2.
Tighten nut 1.
Adjust the supports on the gearbox side.
Tighten the spindles so that the fasteners 3 on the guide journals fit without any gap.
From the engine control side, insert the support journal into the cylinder block hole without any gap (arrow).
Tighten nut 1.
Unscrew the motor holder on the right.
Loosen the bolt at the bottom 1.
Lower the car.
Remove the motor mount on the right.
Release the engine shock absorber block.
Unscrew 2 mounting bolts 1.
Unscrew the 2 mounting bolts (arrows).
Remove the poly V-belt.
Using KM-6131 2, tighten the poly V-belt tensioner in the direction of the arrow.
Insert the KM-955-21 tool.
Loosen the tension of the poly V-belt tensioner 1.
Installation
Install the poly V-belt.
Using KM-6131 2, tighten the poly V-belt tensioner in the direction of the arrow.
Remove the KM-955-21 tool.
Loosen the tension of the poly V-belt tensioner 1.
Install the motor holder on the right.
Insert the bolt at the bottom.
Tighten the 2 top mounting bolts to 60 Nm.
Secure the engine shock absorber block – tighten the 2 mounting bolts to a torque of 40 Nm.
Raise the car.
Secure the motor holder to the right.
Tighten the bolt at the bottom to 60 Nm.
Remove the supports from the engine and gearbox control sides.
Remove fixtures KM-6169, KM-6169-2.
Install the poly V-belt cover.
Note: On the "ECO" model, install the engine compartment cover at the bottom I.
Tighten the 3 mounting bolts.
Install the clamp.
Lower the car.
Install the front wheel on the right.
Tighten the 4 mounting bolts.
Lower the car.
Secure the front wheel on the right.
Tighten the 4 mounting bolts to 110 Nm.
Install the air filter housing.
Tighten the bolt.
Secure the suction pipe.
Replace the sealing ring.
Tighten the 2 nuts.
On Z10XEP engines: Install the air intake hose.
[Material provided by this website OPELBOOK]
Tighten the clamp to a torque of 3.5 Nm.
Install the engine crankcase ventilation hose.
Connect the tank vent valve.
Connect the 2 wire harness connectors.
Connect the battery terminals.
Program volatile memory.
Close the hood.
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