Refurbish Engine Using Engine Short Block 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. Remove engine
2. 2. Detach transmission from engine
3. 3. Remove starter • Detach 2 wiring harnesses – Unscrew 2x nuts • Unscrew 2x bolt (1)

4. 4. Remove thrust plate with clutch disc
5. 5. Block crankshaft • Insert EN-46778 (1) through flywheel (2) in cylinder block

6. 6. Place collecting basin underneath.
7. 7. Drain engine oil • Unscrew drain bolt • Tighten drain bolt 20 Nm
8. 8. Rotate engine 90°
9. 9. Remove transmission bracket (2) • Detach from cylinder block base plate – Unscrew 4x bolts

Note. Note different bolt lengths!

10. 10. Remove oil pan (2) • Unscrew 13x screws • Unscrew 2x nuts

Note. Carefully detach oil pan (2) from cylinder block base plate using KM-J-37228 (1)

11. 11. Rotate engine 90°
12. 12. Detach wiring harness, engine intake side • Disconnect 4 injector wiring harness plugs • Disconnect 4 glow plug wiring harness plugs • Detach wiring harness plug of camshaft sensor • Disconnect wiring harness plug of crankshaft sensor • Disconnect wiring harness plug of coolant temperature sensor
13. 13. Detach wiring harness, engine exhaust side • Disconnect wiring harness plug of rail pressure sensor • Disconnect wiring harness plug of boost pressure sensor • Disconnect wiring harness plug of rail pressure sensor • Disconnect wiring harness plug of EGR valve
14. 14. Detach engine wiring harness • 2x unclip from bracket • Unscrew 3x bolt
15. 15. Place collecting basin underneath.
16. 16. Detach fuel supply line (1) • Unclip vacuum line (3) • Detach fuel line (2) from high pressure pump – Loosen clamp • Unscrew 3 bolts (4)

Note. Note 2 ground cables

Important. After the pressure lines are detached, the openings of the injectors, high pressure pump and pressure chamber must be sealed with protective caps (protective caps are available from Opel Parts Catalogue. See catalogue number 45 06 154 / part number: 92 01 697).

17. 17. Detach high pressure lines • Detach 4 high pressure lines (1) from the injector pressure chamber – Unscrew 8 union nuts • Detach high pressure line (2), high pressure pump to pressure chamber – Unscrew 2 union nuts • Unclip oil leak line (3)

18. 18. Remove pressure chamber (2) with bracket • Disconnect 2 wiring harness plugs - (1) and (3) • Detach high pressure line, high pressure pump to pressure chamber, from connection (5) – Loosen clamp • Detach oil leak line from connection (6) • Unscrew 3 bolts (7) • Detach fuel return line from connection (4) – Open quick-release fitting with KM-796-A – Close with KM-807

Note. Remove engine transport shackle

19. 19. Detach EGR valve (1) with EGR cooler • Detach EGR pipe from intake manifold – Loosen clamp • Detach coolant hose from thermostat housing – Loosen clamp • Unscrew 3x bolt

20. 20. Detach dipstick guide tube (1) with dipstick (2) • Remove bolt (3)

21. 21. Detach oil separator (1) of engine vent • Detach engine vent hose from timing case – Loosen clamp – Unclip from bracket • Detach engine vent hose from flange – Loosen clamp • Unscrew 2x bolt

22. 22. Detach exhaust port for cylinder block ventilation (1) • Unscrew 6 bolts

23. 23. Remove coolant feed pipe (1) • Detach from heat exchanger – Unscrew 2x bolt • Remove from cylinder block – Remove bolt • Unclip 2 wiring harness brackets • Detach coolant hose – Loosen clamp

24. 24. Detach thermostat housing (1) from cylinder head • Unscrew 2x bolt

25. 25. Remove coolant pipe (2) • Remove bolt (1) • Loosen clamp

26. 26. Remove oil filter housing (1) • Unscrew 4x bolts

27. 27. Detach crankshaft sensor (1) • Remove bolt

28. 28. Remove right engine damping block adapter (1) • Unscrew 4x bolts

29. 29. Remove ribbed V-belt (1) • Tension ribbed V-belt tensioner in direction of arrow (clockwise) • Insert KM-6130 (2) • Remove ribbed-V-belt

Note. Mark running direction

30. 30. Remove ribbed V-belt tensioner (1) • Tension ribbed V-belt tensioner in direction of arrow (clockwise). Remove KM-6130 . • Remove bolt (2)

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

Note. Counterhold at the flange bolt of the torsional vibration damper (2)

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

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

Note. Left-threaded

34. 34. Remove timing case • Detach engine vent hose (2) from timing case – Loosen clamp • Unscrew 15 bolts (arrows) • Unscrew 3 nuts (1) • Remove gasket

35. 35. Remove 2 closure bolts from camshaft housing

36. 36. Clean threads x4 • From closure bolts • from camshaft housing
37. 37. Block camshaft • Turn 2 camshaft reference drifts EN-46781 (1) • Make sure installation position is correct • Use camshaft drive gear bolt to turn camshaft back and forth until EN-46781 engages in both camshafts

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

38. 38. Remove timing chain tensioner • Tension timing chain tensioner. Block in pretensioned position using KM-955 • Unscrew 2x bolt (2)

39. 39. Remove timing chain tension rail • Remove bolt (1)

40. 40. Remove timing chain sliding rail (2) • Unscrew 2x bolt (1)

41. 41. Loosen camshaft drive gear • Remove bolt • Counterhold on the camshaft drive gear using KM-6347 (1) and KM-956-1 (2)

42. 42. Remove timing chain (1) with camshaft drive gear and crankshaft drive gear

43. 43. Detach timing chain oil spray nozzle (1) • Unscrew 2x bolt (2)

44. 44. Detach oil leak line (1) • Release 4 clamps (2) in direction of arrow

45. 45. Remove injectors • Remove 2 injector brackets (3) – Unscrew 2x nut (1) • Remove 4 seal rings

Note. Injectors (2) can only be removed with bracket in pairs (1st/2nd cylinder and 3rd/4th cylinder)

46. 46. Detach camshaft housing (3) • Unscrew 16 bolts (2) • Unscrew 2 stud bolts (1) • Remove gasket (4)

Note. Note different bolt lengths!

47. 47. Remove 16 roller cam followers (1) with hydraulic valve lifter (2)

Note. Put to one side in order of removal!

48. 48. Remove 2 camshaft housing centring pins (1)

49. 49. Loosen cylinder head • Unscrew 10x screw

Note. Loosen bolts in the order illustrated

50. 50. Remove cylinder head

Note. 2nd mechanic

51. 51. Remove EN-46778
52. 52. Detach flywheel • Attach KM-652 (1) • Unscrew 8 bolts (arrows) • Remove KM-652

53. 53. Transfer engine short block
54. 54. Clean components and sealing surfaces

Install

55. 55. Drive guide sleeve into cylinder block • 4 guide sleeves with KM-427

56. 56. Insert rear crankshaft seal ring on EN-46777-10 • Attach EN-46777-10 (1) • Slide crankshaft seal ring (3) across EN-46777-10 • Remove EN-46777-10

Note. Apply silicon grease (white) to crankshaft seal ring

57. 57. Install rear crankshaft seal ring (1) with EN-46777-10 (2)

58. 58. Attach flywheel • Remove KM-652 • Tighten 8x bolt 44 Nm – Use new bolts • Remove KM-652
59. 59. Check cylinder block flatness • Check cylinder head for distortion along its length and diagonal using a straightedge and feeler gauge at the sealing surfaces.

60. 60. Set 1st cylinder to TDC • Insert MKM-571-B in KM-301 • Position KM-301 on cylinder block with MKM-571-B • Position probe of MKM-571-B on piston head • Set the dial to zero – Note pretension! • Turn engine in its direction of rotation

Note. Determine highest point of 1st cylinder by turning crankshaft.

61. 61. Measure piston projection • Position probe of MKM-571-B on cylinder block • Set the dial to zero – Determine highest point by turning crankshaft • Measure piston projection – Measure at all 4 pistons – Measure two different points (3 and 4) or (5 and 6)

Note. Note pretension!

62. 62. Block crankshaft • Insert EN-46778 (1) through flywheel (2) in cylinder block

63. 63. Check cylinder head flatness • Check cylinder head for deflection along its length and distortion along the diagonal using a straightedge and feeler gauge at the sealing surfaces. • Maximum sag 0.10 mm
64. 64. Measure cylinder head height • Sealing surface to sealing surface • Measurement I: = 105.45 –105.55 mm

Important. The largest piston projection is used to select cylinder head gasket with corresponding designation!

65. 65. Replace cylinder head gasket • Position cylinder head gasket Piston projection Cylinder head gasket thickness Designation 0,028 - 0,127 mm 0,67 - 0,77 mm without hole 0,128 - 0,227 mm 0,77 - 0,87 mm one hole 0,228 - 0,327 mm 0,87 - 0,97 mm two holes

Note. Note guide sleeves!

66. 66. Insert cylinder head

Note. 2nd mechanic

67. 67. Screw in 10 cylinder head bolts • Use new bolts

Note. Do not tighten the bolts!

68. 68. Align cylinder head • Align cylinder head (2) to cylinder block (3) using straightedge

69. 69. Fasten cylinder head • Tighten 10 cylinder head bolts 40 Nm + 90°+ 90°

Note. Observe tightening sequence

70. 70. Insert 16 roller cam followers

Note. Note order of removal!

71. 71. Insert camshaft housing • Insert new gasket • Screw in 2 stud bolts (M8)

Note. Note ("TOP") marking

72. 72. Align camshaft housing (1) • Align with cylinder head using straightedge (2)

73. 73. Fasten camshaft housing • Tighten 2 stud bolts (M8) (2) and (11) 25 Nm • Tighten 16 bolts (M7) 18 Nm

Note. Note longer bolt lengths (14). Observe tightening sequence!

74. 74. Clean 4 injectors with EN-47632 • Loosen dirt with the brush side (1) • Remove dirt with the sponge side (2)

75. 75. Install 4 injectors • Replace 4 injector shaft seal rings • Replace 4 injector seal rings (1) • Tighten 2 nuts 20 Nm

76. 76. Attach oil leak hose • Release 4 retaining clamps
77. 77. Install timing chain oil spray nozzle • Tighten 2x bolt 6 Nm
78. 78. Attach timing chain guide rail • Tighten 2x bolt 9 Nm
79. 79. Insert timing chain with camshaft drive gear and crankshaft drive gear
80. 80. Tighten camshaft drive gear • Tighten bolt 150 Nm • Counterhold on the camshaft drive gear using KM-6347 and KM-956-1
81. 81. Attach timing chain tension rail • Tighten bolt 9 Nm
82. 82. Attach timing chain tensioner • Tighten 2x bolt 9 Nm • Tension timing chain tensioner – Remove KM-955

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

83. 83. 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)
84. 84. Attach timing case. • Centre timing case with EN-46775 (1) – Tighten 2 nuts (2) – Tighten 14 bolts 9 Nm – Tighten 3x nut 9 Nm • Remove EN-46775 • Attach engine vent hose to timing case – Tighten clamp

85. 85. Install front crankshaft seal ring with EN-46776 (1)

Note. Apply silicon grease (white) to seal ring

86. 86. 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

87. 87. Remove EN-46778
88. 88. Check camshaft timing • Unscrew 2 camshaft reference drifts EN-46781 • Use flange bolt of torsional vibration damper to turn engine 690° in direction of engine rotation • Turn 2 camshaft reference drifts EN-46781 • Use flange bolt of torsional vibration damper to turn engine in direction of engine rotation until reference drift EN-46781 audibly engages in both camshafts
89. 89. Check crankshaft position. Insert EN-46778 through bore in flywheel • Use flange bolt of torsional vibration damper to carefully turn crankshaft until EN-46778 engages in cylinder block

Note. If EN-46778 cannot engage in cylinder block, repeat adjustment process

90. 90. Unscrew 2 camshaft reference drifts EN-46781
91. 91. Install 2 closure bolts • Coat 2 bolts with thread locking compound (red) • Tighten 2 closure bolts 15 Nm

Note. Complete assembly within 10 minutes

92. 92. Attach torsional vibration damper • Tighten 4x bolt 25 Nm
93. 93. Detach coolant pump • Tighten 4x nut 9 Nm

Note. Use new gasket. Apply silicon grease (white) to gasket. Coolant pump journal must point toward oil filler port

94. 94. Attach ribbed V-belt tensioner • Tighten bolt 50 Nm • Tension ribbed V-belt tensioner clockwise • Insert KM-6130
95. 95. Attach right engine damping block adapter • Tighten 4x bolt 60 Nm
96. 96. Attach crankshaft sensor • Tighten bolt 9 Nm
97. 97. Attach oil filter housing • Use new gasket • Tighten 4x bolt 9 Nm

Note. Note different bolt lengths!

98. 98. Attach coolant pipe to cylinder block • Tighten bolt 9 Nm

Note. Use new gasket. Apply silicon grease (white) to gasket!

99. 99. Attach thermostat housing to cylinder head • Use new gasket • Tighten 2x bolt 25 Nm

Note. Apply silicon grease (white) to seal ring.

100. 100. Attach coolant pipe of thermostat housing to oil filter housing • Attach coolant hose to thermostat housing – Tighten clamp • Attach to oil filter housing – Tighten 2x bolt 9 Nm • Attach to cylinder block – Tighten bolt 9 Nm

Note. Use new gasket.

101. 101. Attach exhaust port for cylinder block ventilation • Use 3 new gaskets • Tighten 6x bolt 9 Nm
102. 102. Attach engine vent oil separator • Attach engine vent hose to timing case – Tighten clamp – Clip into bracket • Attach engine vent hose to flange – Tighten clamp • Tighten 2x bolt 9 Nm
103. 103. Install oil dipstick guide tube • Use new gasket • Tighten bolt 9 Nm
104. 104. Attach EGR valve with EGR cooler • Use new gasket • Tighten 2x bolt 22 Nm • Attach bracket to cylinder block – Tighten bolt 22 Nm • Attach EGR pipe to intake manifold – Tighten clamp 9 Nm • Attach coolant hose to thermostat housing – Tighten clamp
105. 105. Install pressure chamber with bracket • Tighten 3x bolt 25 Nm • Attach fuel return line to high pressure pump – Tighten clamp • Attach fuel return line – Remove KM-807 – Connect quick-release fitting • Attach oil leak hose • Connect 2 wiring harness plugs

Note. Insert engine transport shackle

106. 106. Install high pressure lines • Use new high pressure lines • Install 4 high pressure lines, pressure chamber to injector – Tighten 4x union nut M12 24 Nm – Tighten 4x union nut (M14) 28 Nm • Install high pressure line, high pressure pump to pressure chamber – Tighten union nut (M12) 24 Nm – Tighten union nut M14 28 Nm
107. 107. Install fuel supply line • Attach fuel line to high pressure pump – Tighten clamp • Tighten 3 bolts • Clip vacuum line into bracket

Note. Note 2 ground cables!

108. 108. Attach engine wiring harness • 2x clip in bracket • Tighten 3 bolts
109. 109. Attach wiring harness, engine exhaust side • Connect wiring harness plug of rail pressure sensor • Connect wiring harness plug of boost pressure sensor • Connect wiring harness plug of rail pressure regulator • Connect wiring harness plug of EGR valve
110. 110. Attach wiring harness, engine intake side • Connect 4 injector wiring harness plugs • Connect 4 glow plug wiring harness plugs • Connect wiring harness plug of camshaft sensor • Connect wiring harness plug of crankshaft sensor • Connect wiring harness plug of coolant temperature sensor
111. 111. Rotate engine 180°
112. 112. 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.

113. 113. Attach 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
114. 114. 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!

115. 115. Rotate engine 180°
116. 116. Top up engine oil and correct • Observe specified engine oil quantity
117. 117. Install thrust plate with clutch disc
118. 118. Install starter • Tighten 2x bolt • Attach 2 wiring harnesses – Tighten 2x bolt 25 Nm
119. 119. Attach transmission to engine
120. 120. Install engine

1

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