How to Remove and Install the Crankshaft Opel Combo C

Remove

1. 1. Detach manual transmission from engine
2. 2. Remove ribbed V-belt • Mark running direction • Tension ribbed V-belt tensioner in direction of arrow via bolt (1) • Fix ribbed V-belt tensioner in position at bore (2) • Remove ribbed V-belt

3. 3. Detach wiring trough (4) from front toothed belt cover (upper) • Remove bolt (2) • Detach wiring harness (3) – Disconnect camshaft sensor wiring harness plug – Release 2 clips • Detach vacuum line (1) – Release 2 clips • Unclip wiring trough in direction of arrow – Release clip

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

Note. Counterhold at bolt (2)

5. 5. Remove engine damping block support • Detach from cylinder block – Unscrew 3 bolts (3) • Remove engine damping block adapter (1)

6. 6. Remove coolant pump drive gear (1) • Unscrew 3 bolts

7. 7. Remove front toothed belt cover (lower) (1) • Unscrew 3 bolts (2)

8. 8. Set crankshaft to "1st cylinder TDC" following direction of engine rotation • Fix camshaft sprocket in position using TDC locking bolt (M6) (1) • Fix high pressure pump gear in position using TDC locking bolt (M8) (2)

Note. The mark on toothed belt drive gear must align with lug on oil pump cover (arrows)

9. 9. Remove toothed belt • Mark running direction • Loosen toothed belt tension roller. – Loosen bolt (1) • Tension toothed belt tension roller in direction of arrow using hexagonal bolt (2) • Fasten toothed belt tension roller in pre-tensioned position – Tighten bolt

10. 10. Turn engine by 180° using KM-412-A
11. 11. Remove thrust plate and clutch disc
12. 12. Detach flywheel • Block flywheel using KM-652 (1) • Unscrew 8 bolts • Remove flywheel

13. 13. Place collecting basin underneath.

14. 14. Drain engine oil • Unscrew oil drain bolt (3) • Replace gasket • Tighten oil drain bolt 78.4 Nm
15. 15. Detach bottom part of oil pan (1) from top part of oil pan (2) using KM-J-37228 • Unscrew 15 bolts
16. 16. Detach oil dipstick guide tube from upper part of oil pan • Unscrew 2 bolts (1)

17. 17. Disconnect wiring harness plug (1) of engine oil level sensor

18. 18. Detach upper part of oil pan from cylinder block • Unscrew bolt (2) and (3) • Unscrew nut (1) • Separate upper part of oil pan from cylinder block using a wide putty knife
19. 19. Detach crankshaft seal ring bracket from cylinder block • Unscrew and remove 5x bolts (2) • Separate rear of crankshaft seal ring bracket (1) from cylinder block using a putty knife (3)

Note. Make sure that the sealing surfaces are not damaged

20. 20. Remove oil pump gear (1) • Unscrew nut

Note. Counterhold with socket wrench (2)

21. 21. Remove toothed belt drive gear (2) • Remove bolt • Remove toothed belt drive gear using KM-161-B (1) • Remove woodruff key

Note. Counterhold using KM-662-C

22. 22. Remove oil pump cover (1) • Unscrew 9 bolts • Remove inner and outer rotors (2)

Note. Note differing bolt lengths

23. 23. Remove crankshaft seal ring (1) • Lever out seal ring using appropriate tool

Important. Do not damage sealing surfaces

24. 24. Remove oil pump seal ring (2) • Lever out seal ring using appropriate tool

Important. Do not damage sealing surfaces

25. 25. Remove oil intake pipe • Remove bolt (1)
26. 26. Remove oil baffle plate • Unscrew 5 bolts (arrows)

27. 27. Remove 4 con-rod bearing caps • Undo 8 screw connections • Remove con-rod bearing shells

Note. Pay attention to marking on con-rod bearing cap and con-rod (1). If not present, apply marking.

28. 28. Remove con-rod bearing shells • Mark con-rod bearing shells

Note. Observe order.

29. 29. Remove crankshaft • Remove 5 crankshaft bearing caps – Unscrew 10 bolts

Note. Undo crankshaft bearing cap bolts in sequence illustrated (1 - 10).

Note. Place crankshaft on wooden blocks

30. 30. Remove crankshaft bearing shells • Mark crankshaft bearing shells

Note. Note markings on crankshaft bearing shells.

31. 31. Remove thrust rings

32. 32. Remove crankshaft pulse pickup disc (1) • Unscrew 3 bolts

33. 33. Clean components • Oil pan lower section, oil pan upper section, cylinder block
34. 34. Inspect components

Install

35. 35. Install crankshaft pulse pickup disc • Tighten 3 new bolts 10.8 Nm 1)
36. 36. Insert con-rod bearing shells • In con-rod, con-rod bearing cap – Coat with engine oil

Important. Observe identification and allocation.

37. 37. Insert crankshaft bearing shells • In cylinder block, crankshaft bearing cap – Coat with engine oil
38. 38. Replace thrust rings • Coat with engine oil • Oil grooves face outward

39. 39. Insert crankshaft • Coat crankshaft journal with engine oil

Note. Note installation position.

40. 40. Fit crankshaft bearing cover • Tighten 10 new bolts 88.2 Nm

Important. Note installation position. Arrows point to engine control side.

Note. Note tightening order (1 - 10).

41. 41. Attach 4 con-rod bearing caps • Tighten 8 new bolted connections 24.5 Nm + 100° + 15°

Important. Note cylinder order markings on con-rod bearing cap and con-rod. Narrow bead faces engine timing side.

42. 42. Install oil baffle plate • Tighten 5 bolts 18.6 Nm
43. 43. Install oil intake pipe • Replace gasket • Tighten bolt 18.6 Nm
44. 44. Clean sealing surfaces
45. 45. Install oil pump cover (2) • Apply bead of adhesive sealing compound to sealing surface (shaded area) of oil pump cover • Replace gasket (1) • Insert inner and outer rotor in cylinder block – Coat with oil • Tighten 9 bolts 9.8 Nm

Important. The application of adhesive sealing compound and installation of the oil pump cover, including torque test, must be completed within 10 minutes

Note. Note differing bolt lengths

46. 46. Install crankshaft seal ring • Drive crankshaft seal ring in to the stop using KM-656 (1)

47. 47. Install oil pump seal ring • Insert new seal ring in oil pump cover • Drive in as far as stop using KM-657 (1)
48. 48. Mount oil pump drive gear • At oil pump • Tighten nut 44.1 Nm

Note. Note installation position (arrow)

49. 49. Install toothed belt drive gear • Attach woodruff key • Attach toothed belt drive gear to crankshaft • Tighten bolt 196 Nm

Note. Note woodruff key

Note. Counterhold using KM-662-C

50. 50. Use suitable tool to prise rear crankshaft seal ring (3) out of rear crankshaft seal ring bracket (1)
51. 51. Clean sealing surfaces
52. 52. Remove gasket remnants
53. 53. Apply a bead (2) of adhesive sealing compound to sealing surfaces of rear crankshaft seal ring bracket
54. 54. Attach rear crankshaft seal ring bracket to cylinder block • Tighten 5 bolts 9.8 Nm 1)
55. 55. Insert new rear crankshaft seal ring in rear crankshaft seal ring bracket
56. 56. Drive in rear crankshaft seal ring to end stop using KM-658 (4)

57. 57. Clean sealing surfaces
58. 58. Apply sealing compound
59. 59. Install upper section of oil pan • Apply a bead of silicone sealing compound to sealing surface of upper part of oil pan • Tighten 18 bolts 9.8 Nm
60. 60. Connect wiring harness plug of engine oil level sensor
61. 61. Attach oil dipstick guide tube to upper part of oil pan • Replace gasket • Tighten 2 bolts 9.8 Nm
62. 62. Clean sealing surfaces
63. 63. Apply sealing compound
64. 64. Install lower section of oil pan • Apply a bead of silicone sealing compound to sealing surfaces of lower part of oil pan • Tighten 15 bolts 9.8 Nm
65. 65. Attach flywheel • Position flywheel • Block flywheel using KM-652 (1) • Tighten 8x new bolts 85 Nm +30° + 15°
66. 66. Install thrust plate and clutch disc

67. 67. Turn engine by 180° using KM-412-A
68. 68. Install toothed belt • Position toothed belt – Toothed belt must be tensioned in the direction of the arrow from the toothed belt drive gear (5) via the oil pump drive gear (4), via the high pressure pump drive gear (2) to the camshaft sprocket (1) – Note running direction • Loosen toothed belt tension roller (3) • Remove TDC locking bolt • Rotate crankshaft 60° against direction of engine rotation • Tighten toothed belt tension roller 38Nm

Note. TDC locking bolt must be installed in the camshaft sprocket and marking (6) and (7) must align.

Important. After the test procedure, the TDC locking bolts must be unscrewed

69. 69. Timing, Check • Turn crankshaft 2 revolutions in direction of engine rotation to "1st cylinder TDC" • Fix camshaft sprocket in position using TDC locking bolt (1) • Fix high pressure pump gear in position using TDC locking bolt (2)

Note. The mark on toothed belt drive gear must align with lug on oil pump cover (arrows)

Note. If the TDC locking bolt cannot be inserted, the toothed belt must be refitted

Note. If the TDC locking bolt cannot be inserted, the toothed belt must be refitted

70. 70. Install front toothed belt cover (lower) • Tighten 3 bolts 9.8 Nm
71. 71. Install coolant pump drive gear • Tighten 3 bolts 12.3 Nm
72. 72. Install engine damping block bracket • Attach engine damping block adapter • Attach engine damping block bracket to cylinder block – Tighten 3 bolts 50 Nm

Important. Journal (1) of the toothed belt drive gear must engage in bore (2) of torsional vibration damper

73. 73. Install torsional vibration damper • Tighten 4 bolts 19.6 Nm

Note. Counterhold at toothed belt drive gear bolt

74. 74. Install front toothed belt cover (upper) • Tighten 8 bolts 9.8 Nm • Install camshaft sensor bracket – Tighten bolt 9.8 Nm • Attach vacuum line to toothed belt cover – Fasten 3 clips

Note. Note differing bolt lengths

75. 75. Attach wiring trough to front toothed belt cover (upper) • Attach wiring trough – Fasten clip • Tighten bolt 9.8 Nm • Attach wiring harness – Fasten 2 clips – Connect camshaft sensor wiring harness plug • Attach vacuum line – Fasten 2 clips
76. 76. Install ribbed V-belt • Install ribbed V-belt – I. Ribbed V-belt without AC – II. Ribbed V-belt with AC • Tension ribbed V-belt tensioner in direction of arrow via bolt (1) • Remove fixing devices • Release ribbed V-belt tensioner

Note. Note ribbed V-belt's direction of travel

77. 77. Attach manual transmission to engine

1

) Re-cut thread before reuse and insert bolt coated with bolt locking compound (red). Installation time including torque test must not exceed 10 minutes.