Replace Flywheel (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. Remove pollen filter housing • Disconnect wiring harness plug for hot film mass air flow meter (1) • Unclip wiring harness (arrows) • Remove intake pipe – Release clamp (2)

5. 5. Detach oxygen sensor (catalytic converter control) (1) cable harness plug • Unclip wiring harness plug

6. 6. Release right front wheel • Release 5x bolt
7. 7. Raise vehicle
8. 8. Disconnect right front wheel. • Unscrew 5x bolt
9. 9. Raise vehicle
10. 10. Detach ribbed V-belt cover • Unscrew 4x bolt

11. 11. Detach ribbed V-belt • Use KM-6151

Note. Mark running direction

12. 12. 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.

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

Note. 2nd and 3rd mechanics are required

14. 14. Release rear reaction member • Remove bolt (arrow)

15. 15. Release front reaction member • Unscrew nut (arrow) • Remove bolt (1)

16. 16. Lower vehicle
17. 17. Insert MKM-883-1 together with MKM-883-2
18. 18. Release adapter for right engine damping block adapter • Unscrew 3x bolt (1)

19. 19. Lower engine

Note. Lift engine until bolt can be removed out of timing case cover.

20. 20. Raise vehicle
21. 21. Remove torsional vibration damper (2) • Remove bolt – Use KM-956 (1), KM-J-38122-A

Install

22. 22. Install torsional vibration damper • Replace bolt • Tighten bolt – Tightening torque 100 Nm + 75° + 15° – Use KM-956 , KM-J-38122-A
23. 23. Lower vehicle

Important. Do not damage attaching parts

24. 24. Lift engine
25. 25. Attach adapter for right engine damping block • Tighten 3x bolt – Tightening torque 55 Nm
26. 26. Remove MKM-883-1 together with MKM-883-2
27. 27. Raise vehicle
28. 28. Attach front reaction member • Tighten nuts – Tightening torque 80 Nm
29. 29. Attach rear reaction member • Tighten bolt – Tightening torque 80 Nm
30. 30. Position exhaust system • Replace gasket

Note. 2nd and 3rd mechanic are required

31. 31. Attach exhaust system • Replace 3x nut • Tighten 3x nut – Tightening torque 16 Nm . • Route wiring harness and clip in
32. 32. Attach ribbed V-belt • Use KM-6151

Note. Tension ribbed V-belt tensioner in direction of arrow

33. 33. Install ribbed V-belt cover • Screw in 4x bolt
34. 34. Lower vehicle
35. 35. Attach right front wheel • Screw in 5x bolt
36. 36. Lower vehicle
37. 37. Secure right front wheel • Tighten 5x bolt – Tightening torque 110 Nm
38. 38. Connect oxygen sensor (catalytic converter control) cable harness plug. • Clip in wiring harness plug
39. 39. 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
40. 40. Attach upper engine cover
41. 41. Connect battery.
42. 42. Close bonnet
43. 43. Program volatile memories