How to Remove and Install the Timing Case Opel Agila A

Warning: When working with the common rail system, wait one minute after switching off the engine. The system relieves the pressure itself.

Important: When working on the fuel system, cleanliness is vital because even the smallest dirt particles can lead to faults in engine operation or in the fuel system. Seal open fuel connections with suitable sealing plugs 1) . Sealing plugs are only intended to be used once.

Remove

1. 1. Open bonnet
2. 2. Disconnect battery • Detach ground clamp from ground terminal – Unscrew nut
3. 3. Remove air cleaner housing
4. 4. Remove resonator (1) • Unscrew 2x bolt

5. 5. Remove charge air hose (1) • Detach from intercooler – Loosen clamp • Detach from charge air pipe – Loosen clamp

6. 6. Remove fuel filter (4) • Disconnect wiring harness plug (1) • Detach 2 fuel supply lines (2) using KM-796-A – Unclip from bracket • Detach fuel return line (3) using KM-796-A • Remove from bracket

Note. Seal fuel lines and fuel filter with KM-807 or KM-6015

7. 7. Loosen 2 front wheels
8. 8. Raise vehicle by half-height
9. 9. Remove 2 front wheels
10. 10. Raise vehicle by half-height
11. 11. Place collecting basin underneath.
12. 12. Drain coolant • Open drain bolt (1) • Tighten drain bolt

13. 13. Detach catalytic converter from exhaust system • Loosen clamp (1)

14. 14. Remove exhaust system • Detach 4 damper rings

Note. 2nd mechanic

15. 15. Remove ribbed V-belt tensioner
16. 16. Detach catalytic converter (1) from transmission bracket • Remove bolt (2)

17. 17. Remove transmission bracket (2) • Detach from cylinder block base plate – Unscrew 4x bolts • Detach from transmission – Unscrew 2x bolt

Note. Note differing bolts.

18. 18. Place collecting basin underneath.
19. 19. Drain engine oil • Unscrew oil drain bolt • Tighten oil drain bolt 20 Nm
20. 20. Remove oil pan (2) • Disconnect wiring harness plug of engine oil level sensor • Unscrew 13x screws • Unscrew 2x nuts

Note. Carefully detach oil pan from cylinder block base plate using KM-J-37228 (1)

21. 21. Remove torsional vibration damper (1) • Unscrew 4x bolts

Note. Counterhold at bolt (2)

22. 22. On version with AC: detach compressor (1) from support • Unscrew 3x bolt

Note. Do not detach refrigerant lines

23. 23. Remove coolant pump (1) • Unscrew 4 nuts

24. 24. Block crankshaft. Insert EN-46785 (1) through bore of transmission bell housing. • Use flange bolt of torsional vibration damper to turn crankshaft in direction of engine rotation until EN-46785 engages in flywheel

Note. Insert bolt

25. 25. Remove flange of torsional vibration damper • Remove bolt (1) – Counterhold with KM-662-C (2) – Tighten 2x bolt

Note. Left-threaded

26. 26. Lower vehicle by full height

27. 27. Insert engine bridge MKM-883-1 (2)

Note. 2nd mechanic

Important. Comply with manufacturer's instructions

28. 28. Fasten engine bridge MKM-883-1 • Attach hooks MKM-883-4 (1)
29. 29. Fasten engine to engine bridge MKM-883-1 • At engine transport shackle (3) and (4)
30. 30. Raise vehicle by full height
31. 31. Remove rear engine damping block adapter (2) • Detach from engine damping block – Remove bolt (1) • Detach from engine damping block bracket – Unscrew 3 bolts (3)

32. 32. Attach bracket (3) with drilled holes (2) to KM-6103-A (1) • Tighten 2 screw connections

33. 33. Insert holder KM-6103-A • Position holder (3) on stabiliser – Tighten 2 bolts • Insert rod (1) through holder (4) and right wheel housing • Insert rod (2) through left wheel housing and right rod

Note. 2nd mechanic

34. 34. Attach holder KM-6103-A • Attach front bracket – Tighten 2x bolt • Attach rear support KM-6054-2 (1) – Position spindle in cylinder block bore (2) – Adjust spindle – Tighten nut • Insert front support KM-6054-2 (3) – Position spindle under cylinder block base plate bolt (4) – Adjust spindle – Tighten nut • Tighten 2 base plates – Tighten 4x bolt

35. 35. Lower vehicle by full height
36. 36. Detach engine bridge MKM-883-1 • Detach hooks MKM-883-4
37. 37. Remove engine bridge MKM-883-1

Note. 2nd mechanic

38. 38. Place collecting basin underneath.
39. 39. Detach fuel line • Remove bolt (1)

40. 40. Detach wiring harness for engine management • Disconnect 4 injector wiring harness plugs (2) • Disconnect 4 glow plug wiring harness plugs (3) • Detach wiring harness plug of camshaft sensor (1) • Unscrew 3x bolt

41. 41. Remove right engine damping block with bracket (1) • Detach from wheel housing – Remove bolt • Detach from longitudinal member – Unscrew 2x bolt • Detach from engine damping block adapter – Unscrew 3x bolt

Note. Note different bolt lengths.

42. 42. Remove engine damping block adapter (1) • Unscrew 4 bolts (2)

43. 43. Remove timing case • Detach engine vent hose (2) – Loosen clamp • Unscrew 14 bolts (arrows) • Unscrew nut (1)

44. 44. Raise vehicle by full height
45. 45. Remove front crankshaft seal ring from timing case

Note. Lever out using suitable tool.

46. 46. Remove timing case • Unscrew 2x nut (1) • Remove gasket

47. 47. Lower vehicle by full height
48. 48. Remove closure bolt from camshaft housing, exhaust side

49. 49. Clean threads x2 • From closure bolt • from camshaft housing
50. 50. Define exhaust camshaft • Turn camshaft reference drift EN-46781 (1) • Make sure installation position is correct

Note. The fixing reference drift must be fitted in a horizontal position. Apply guide marks to the reference drift (arrow) as an aid

51. 51. Block exhaust camshaft • Turn exhaust camshaft in the direction of rotation of the engine by the bolt for the camshaft drive gear until EN-46781 engages in the exhaust camshaft
52. 52. Clean sealing surface

Install

Important. The timing case must be installed within 10 minutes of silicone sealing compound application.

53. 53. Insert timing case gasket • Apply silicone sealing compound (grey) to the transitions between the cylinder head and camshaft housing (1) and between the cylinder block and cylinder head (2)
54. 54. Raise vehicle by full height
55. 55. Insert timing case • Centre timing case with EN-46775 (1) • Tighten 2 nuts (2)

56. 56. Lower vehicle by full height
57. 57. Attach timing case. • Tighten 14 bolts 9 Nm • Tighten nut 9 Nm • Attach engine vent hose – Tighten clamp
58. 58. Raise vehicle by full height
59. 59. Tighten 2 nuts 9 Nm
60. 60. Remove EN-46775
61. 61. Install front crankshaft seal ring with EN-46776 (1)

Note. Apply silicon grease (white) to seal ring

62. 62. Attach flange of torsional vibration damper • Tighten bolt 230 Nm – Counterhold with KM-662-C • Detach KM-662-C – Unscrew 2x bolt

Note. Left-threaded

63. 63. Remove EN-46785
64. 64. Lower vehicle by full height
65. 65. Check camshaft timing • Unscrew and remove camshaft reference drift EN-46781 • Use flange bolt of torsional vibration damper to turn engine 690° in direction of engine rotation • Screw in camshaft reference drift EN-46781 on the exhaust side • Use flange bolt of torsional vibration damper to turn engine in direction of engine rotation until reference drift EN-46781 engages audibly in exhaust camshaft
66. 66. Raise vehicle by full height
67. 67. Check crankshaft position. Insert EN-46785 (1) through the bore in the transmission bell housing • Use flange bolt of torsional vibration damper to carefully turn crankshaft until EN-46785 engages in flywheel • If EN-46785 is not engaged in flywheel, repeat adjustment process

68. 68. Remove EN-46785 • Remove bolt
69. 69. Lower vehicle by full height
70. 70. Unscrew and remove camshaft reference drift EN-46781
71. 71. Install closure bolt coated with bolt locking compound (red) • Tighten closure bolt 15 Nm

Note. Complete assembly operations within 10 minutes

72. 72. Install engine damping block adapter • Tighten 4x bolt 60 Nm
73. 73. Install right engine bearing block • Tighten 6x bolt 55 Nm

Note. Note differing bolts

74. 74. Attach fuel line • Tighten bolt

75. 75. Insert engine bridge MKM-883-1 (2)

Note. 2nd mechanic

Important. Comply with manufacturer's instructions

76. 76. Fasten engine bridge MKM-883-1 • Attach 2 hooks MKM-883-4 (1)
77. 77. Fasten engine to engine bridge MKM-883-1 • At engine transport shackle (3) and (4)
78. 78. Raise vehicle by full height
79. 79. Detach holder KM-6103-A • Detach 2 supports KM-6054-2 – Screw in 2 spindles – Unscrew 4x bolts • Detach from stabiliser – Unscrew 2x bolt
80. 80. Remove holder KM-6103-A • Remove 2 rods

Note. 2nd mechanic

81. 81. Install rear engine damping block bracket • Attach to engine damping block – Tighten bolt 55 Nm • Attach to engine damping block adapter – Tighten 3x bolt 55 Nm
82. 82. Clean sealing surfaces • Cylinder block base plate and oil pan
83. 83. Apply sealing compound

Note. Apply a bead of silicone sealing compound (grey) to sealing surface of oil pan

Important. The oil pan must be installed within 10 minutes of silicone sealing compound application.

84. 84. Install oil pan • To cylinder block base plate – Tighten 13x bolt 9 Nm – Tighten 2 nuts 9 Nm • Connect wiring harness plug of engine oil level sensor
85. 85. Install transmission bracket • To cylinder block base plate – Tighten 4x bolt 30 Nm • On transmission – Tighten 2x bolt 40 Nm

Note. Note different bolt lengths

86. 86. Clean sealing surface
87. 87. Install coolant pump • Use new gasket • Tighten 4x nut 9 Nm
88. 88. On version with AC: attach compressor • To compressor support – Tighten 3x bolt 22 Nm
89. 89. Install torsional vibration damper • Tighten 4x bolt 25 Nm

Note. Counterhold at flange bolt of torsional vibration damper

90. 90. Install ribbed V-belt tensioner
91. 91. Attach catalytic converter to bracket • Tighten bolt 25 Nm
92. 92. Install exhaust system • Attach 4 damper rings

Note. 2nd mechanic

93. 93. Attach exhaust system to catalytic converter • Tighten clamp
94. 94. Lower vehicle by half height
95. 95. Mount 2 front wheels
96. 96. Lower vehicle by half height
97. 97. Tighten 2 front wheels 110 Nm
98. 98. Install fuel filter • Insert in bracket • Attach 2 fuel supply lines – Clip into bracket • Attach fuel return line • Connect wiring harness plug
99. 99. Fit charge air hose • Tighten 2x clamp 3.5 Nm
100. 100. Install resonator • Tighten 2x bolt
101. 101. Install air cleaner housing
102. 102. Top up engine oil and correct • Note prescribed capacity
103. 103. Connect battery • Attach ground clamp to ground terminal – Tighten nut 5.5 Nm
104. 104. Top up coolant and correct coolant level • Observe specified quantity of coolant
105. 105. Program volatile memories
106. 106. Close bonnet.

1

) Protective caps are available in the Opel Parts Catalogue under catalogue number: 45 06 154 / part number: 9201697