Replace Coolant Pump (Z 20 NET, AC, Rhd, Mt) Opel Vectra C

Remove

1. 1. Open bonnet
2. 2. Disconnect battery. • Detach ground cable
3. 3. Detach upper engine cover
4. 4. Raise vehicle
5. 5. Detach ribbed V-belt cover • Unscrew 4x bolt

6. 6. Place collecting basin underneath.
7. 7. Unscrew coolant pump coolant drain bolt (arrows)

8. 8. Lower vehicle
9. 9. Drain coolant • Unscrew coolant compensation tank closure cap Warning: Only open coolant compensation tank once engine has cooled down • Place collecting basin underneath. • Open radiator drain plug (arrow) • Drain coolant • Refit radiator drain plug

10. 10. Remove pollen filter housing • Disconnect wiring harness plug for hot film mass air flow meter (1) • Unclip wiring harness (4) • Remove intake pipe – Release clamp (2)
11. 11. Remove air intake hose. • Release clamp (arrow) • Remove wastegate unit hose (3) • Detach tank vent line

12. 12. Remove turbo heat shield • Unscrew 2x bolt • Unclip shield

13. 13. Connect wiring harness plug for mixture regulation oxygen sensor (1)

14. 14. Remove engine vent hose (1) • Release 2x clamp (3)

15. 15. Disconnect 3x wiring harness plug • Catalytic converter control oxygen sensor (1), exhaust temperature sensor (1), solenoid charge pressure unit (2) • Unclip wiring harness plug

16. 16. Remove turbo coolant supply line • Release union nut • Remove bolt • Release clamp

17. 17. Release exhaust manifold heat shield • Unscrew 2x bolt (1) • Unscrew nut (2)

18. 18. Release catalytic converter • Unscrew 3x nut
19. 19. Raise vehicle
20. 20. Remove charge air pipe • Release 2x clamp • Unscrew 2x bolt (1)

21. 21. Remove exhaust system • Remove front exhaust pipe – Unscrew 3x nut (1) • Expose wiring harness

Important. When removing the centre muffler, a catalytic converter, an exhaust manifold, or an exhaust manifold with catalytic converter, secure that portion of the exhaust system remaining on the vehicle against uncontrolled suspension. The exhaust system piece with the flex pipe inside can be secured for this purpose using suitable means, such as a wire on the vehicle underbody. Bends in the flex pipe with an angle as little as 5 – 10 degrees from the intended installation position may result in damage with subsequent total failure of the flex pipe.

Important. Secure front exhaust pipe from hanging over

22. 22. Remove exhaust system • Detach exhaust system – 6x damper ring

Note. 2nd and 3rd mechanics are required

23. 23. Remove catalytic converter support • Unscrew 2x nut • Unscrew 2x bolt
24. 24. Remove catalytic converter • Remove steering gear heat shield – Unscrew 3x bolt
25. 25. Remove turbo coolant return line • Unscrew 2x banjo bolt

26. 26. Detach thermostat housing • Unscrew 3x bolt

Note. Coolant hoses remain attached.

27. 27. Remove coolant pipe
28. 28. Detach coolant pump service cover • Unscrew 4x bolt

29. 29. Secure coolant pump sprocket • Insert KM-J-43651 (1) – Tighten 3x bolt (3) in slots (4) to be able to twist KM-J-43651 clockwise. • Screw in 2x bolt (2) loosely • Twist KM-J-43651 on fixing bolt (6) clockwise to eliminate any play in the timing chain • Tighten 2x bolts (5), (7) while holding bolt (6) to tension

Note. Ensure that there is sufficient space

Important. The following work step must be performed. Failure to do so may lead to overtightening of the timing chain and hence damage to components and noise complaints.

30. 30. Release coolant pump sprocket • Unscrew 3x bolt (3)

31. 31. Loosen coolant pump • Unscrew 2x bolt (1)

32. 32. Remove coolant pump • Unscrew 2x bolt (1) – Unscrew lower bolt – Lower vehicle – Unscrew upper bolt

Note. Lower bolt cannot be removed

33. 33. Raise vehicle
34. 34. Clean sealing surfaces

Install

35. 35. Insert coolant pump For this reason, the setting of the drive flange from the old coolant pump must be transferred to the drive flange of the new coolant pump. • Replace gasket

Note. To guarantee perfect installation, the holes on the chain wheel must align with the threaded holes in the drive flange of the new coolant pump.

Note. Lightly coat gasket with silicone grease (white)

36. 36. Attach coolant pump • Tighten 3x bolt 23 Nm

Note. 2x bolts on back and lower bolt on timing side

37. 37. Lower vehicle
38. 38. Attach coolant pump at the top on the timing side • Tighten top bolt with MKM-6600-2 and MKM-6450-C-13 23 Nm
39. 39. Raise vehicle
40. 40. Secure coolant pump sprocket • Tighten 3x bolt – Tightening torque 8 Nm
41. 41. Detach KM-J-43651
42. 42. Attach coolant pump service cover • Replace gasket • Tighten 4x bolt 7 Nm
43. 43. Replace thermostat housing gasket

Note. Lightly coat gasket with silicone grease (white)

44. 44. Attach coolant pipe • Replace 2x coolant pipe seal ring • Insert coolant pipe. – In thermostat housing

Note. Lightly coat gasket with silicone grease (white)

Note. Lug on coolant pipe engages in recess on thermostat housing

45. 45. Attach thermostat housing • Tighten 3x bolt – Tightening torque 8 Nm
46. 46. Attach turbo coolant return line • Replace 4x seal ring • Tighten 2x banjo bolt – Tightening torque 40 Nm
47. 47. Fit catalytic converter • Attach steering gear heat shield – Tighten 3x bolt
48. 48. Lower vehicle
49. 49. Attach catalytic converter • Replace 3x nut • Screw in 1x nut (1) until dimension I is approx. 1 mm • Screw in 2x nut (2) • Tighten 3x nut – Tightening torque 25 Nm

Note. Use assembly paste.

Note. The tightening sequence must be observed; ensure that the catalytic converter flange and turbo flange do not touch at the edge.

50. 50. Raise vehicle
51. 51. Fit catalytic converter support • Tighten 2x nut – Tightening torque 40 Nm • Tighten 2x bolt – Tightening torque 25 Nm
52. 52. Position exhaust system • Replace gasket

Note. 2nd and 3rd mechanics are required

53. 53. Attach exhaust system • Replace 3x nut • Tighten 3x nut – Tightening torque 16 Nm . • Route wiring harness and clip in
54. 54. Fit charge air pipe • Tighten 2x clamp • Tighten 2x bolt
55. 55. Install ribbed V-belt cover • Screw in 4x bolt
56. 56. Lower vehicle
57. 57. Fit turbo coolant supply pipe • Tighten union nut • Tighten bolt • Fasten clamp
58. 58. Fit exhaust manifold heat shield • Tighten nuts – Tightening torque 20 Nm
59. 59. Connect 3x wiring harness plug • Clip in wiring harness plug • Catalytic converter control oxygen sensor, exhaust temperature sensor, solenoid
60. 60. Install engine vent hose.
61. 61. Disconnect wiring harness plug for oxygen sensor, mixture regulation
62. 62. Attach turbo heat shield • Fit heat shield • Tighten 2x bolt – Tightening torque 20 Nm
63. 63. Install air intake hose. • Attach tank vent line • Attach wastegate hose • Tighten clamp – Tightening torque 3,5 Nm
64. 64. Install air cleaner housing • Install intake pipe – Tighten clamp – Tightening torque 3,5 Nm • Connect wiring harness plug to hot film mass air flow meter • Attach wiring harness
65. 65. Attach upper engine cover
66. 66. Connect battery.
67. 67. Top up coolant • Observe specified coolant quantity

Note. Fill and bleed cooling system

68. 68. Close bonnet
69. 69. Program volatile memories