Repair Engine Using a Short-Block Opel Combo C

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

Important: Cleanliness is absolutely essential when working on the fuel system because even small dirt particles can lead to disruption of engine operation or the fuel system. On opening fuel system connectors, seal them with appropriate sealing plugs 1) . Sealing plugs are only designed to be used once.

Remove

1. 1. Remove engine
2. 2. Detach manual transmission from engine
3. 3. Remove starter • Detach 2 wiring harnesses – Unscrew 2 nuts • Unscrew 2 bolts (1)

4. 4. Remove thrust plate and clutch disc
5. 5. Lock crankshaft • Insert EN-46778 (1) into cylinder block through flywheel (2)

6. 6. Place collecting basin underneath.
7. 7. Drain engine oil • Remove drain bolt • Tighten drain bolt 20 Nm
8. 8. Turn engine by 90°
9. 9. Detach transmission bracket (2) • Detach cylinder block from base plate – Unscrew 4x bolt (1)

Note. Note differing bolt lengths!

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

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

11. 11. Turn engine by 90°
12. 12. Detach wiring harness on engine intake side • Disconnect 4x wiring harness plug, injector • Disconnect 4x sheathed glow plug wiring harness plugs • Disconnect camshaft sensor wiring harness plug • Disconnect crankshaft sensor wiring harness plug • Disconnect wiring harness plug of coolant temperature sensor
13. 13. Disconnect wiring harness on engine exhaust side • Disconnect common-rail pressure sensor wiring harness plug • Disconnect boost pressure sensor wiring harness plug • Disconnect common-rail pressure regulator wiring harness plug • Disconnect EGR valve wiring harness plug
14. 14. Disconnect engine wiring harness • Unclip 2 harnesses from bracket • Unscrew 3 bolts
15. 15. Place collecting basin underneath.

Important. After disconnecting the pressure lines, seal the openings of the injectors, high-pressure pump and accumulator with protective caps (these can be ordered from the Opel parts catalogue, catalogue no. 45 06 154 / part no. 92 01 697)

16. 16. Remove high-pressure lines • Detach 4 accumulator high pressure lines (1) at injectors – Unscrew 8 union nuts • Detach high pressure pump line (2) at accumulator – Unscrew 2 union nuts • Unclip leak oil line (3)

17. 17. Detach accumulator (2) with bracket • Disconnect 2 wiring harness plugs (1) and (3) • Detach fuel return line from high-pressure pump to accumulator at connection (5) – Release clamp • Detach oil leak line from connection (6) • Unscrew 3x bolt (7) • Detach fuel return line from connection (4) – Disconnect quick-release coupling with KM-796-A – Seal using KM-807

Note. Remove engine transport shackle

18. 18. Detach exhaust gas recirculation valve (1) with radiator EGR • Detach exhaust gas recirculation pipe from intake manifold – Release clamp • Detach coolant hose from thermostat housing – Release clamp • Unscrew 2 bolts

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

20. 20. Detach engine vent oil separator (1) • Detach engine vent hose from timing case – Release clamp – Unclip from bracket • Detach engine vent hose from flange – Release clamp • Unscrew 2 bolts

21. 21. Detach cylinder block ventilation exhaust connector (1) • Unscrew 6 bolts

22. 22. Remove fuel distributor pipe (1) • Detach from heat exchanger – Unscrew 2 bolts • Detach from cylinder block – Remove bolt • Unclip 2 wiring harnesses • Detach coolant hose – Release clamp

23. 23. Detach thermostat housing (1) from cylinder head • Unscrew 2 bolts

24. 24. Remove coolant pipe (1) • Unscrew 2 bolts (2) • Release clamp

25. 25. Detach oil filter housing (1) • Unscrew 4 bolts

26. 26. Remove crankshaft sensor (1) • Remove bolt

27. 27. Detach right-hand engine damping block adapter (1) • Unscrew 4 bolts

28. 28. Remove ribbed V-belt tensioner
29. 29. Remove torsional vibration damper (1) • Unscrew 4 bolts

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

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

31. 31. Detach torsional vibration damper flange • Remove bolt (1) – Counterhold with KM-662-C (2) – Tighten 2 bolts

Note. Left hand thread

32. 32. Remove timing case • Detach engine vent hose (2) from timing case – Release clamp • Unscrew 15x bolts (arrows) • Unscrew 3x nut (1) • Remove gasket.

33. 33. Remove 2 closure bolts from camshaft housing

34. 34. Clean threads (4x) • From closure bolts • From camshaft housing
35. 35. Lock camshafts • Screw in 2 camshaft reference drifts EN-46781 (1) • Check for proper installation position • Turn the camshaft back and forth at camshaft drive pinion bolt until EN-46781 engages in both camshafts

Note. The fixing reference drift must be fitted in a horizontal position. Put guide marks on the reference drifts (arrows).

36. 36. Remove timing chain tensioner • Tighten timing chain tensioner. Lock in pretensioned position using KM-955 • Unscrew 2 bolts (2)

37. 37. Detach timing chain tension rail • Remove bolt
38. 38. Detach timing chain sliding rail • Unscrew 2 bolts
39. 39. Undo camshaft drive gear • Remove bolt • Counterhold at camshaft drive gear with KM-6347 (1) and KM-956-1 (2)

40. 40. Remove timing chain with camshaft drive gear and crankshaft drive gear
41. 41. Detach timing chain oil spray nozzle (1) • Unscrew 2 bolts (2)

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

43. 43. Detach injectors • Remove 2 injector brackets (3) – Unscrew 2 nuts (1) • Remove 4x seal ring

Note. The injectors (2) can only be removed in pairs with the bracket (cylinders 1 and 2 or cylinders 3 and 4)

44. 44. Remove camshaft housing (3) • Unscrew 16x bolt (2) • Unscrew and remove 2x stud bolt (1) • Remove gasket (4)

Note. Note differing bolt lengths!

45. 45. Remove 16 roller cam followers (1) with hydraulic valve lifters (2)

Note. Put down in order of removal

46. 46. Remove 2 x camshaft housing centring pins (1)

47. 47. Loosen cylinder head • Unscrew 10 bolts

Note. Undo bolts in order shown

48. 48. Remove cylinder head

Note. Second person required

49. 49. Remove EN-46778
50. 50. Detach flywheel • Attach KM-652 • Unscrew 8 bolts • Remove KM-652
51. 51. Reassemble short-block
52. 52. Clean parts and sealing surfaces

Install

53. 53. Drive guide sleeves into cylinder block • 4 guide bushings, using KM-427

54. 54. Push rear crankshaft seal ring onto EN-46777-10 • Push on EN-46777-10 (1) • Slide crankshaft seal ring (3) over EN-46777-10 • Remove EN-46777-10

Note. Coat crankshaft seal ring with silicone grease (white)

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

56. 56. Attach flywheel • Attach KM-652 • Tighten 8 bolts 44 Nm – Use new bolts • Remove KM-652
57. 57. Check cylinder head for plane surface • Use straight edge and feeler gauge to check length and breadth of cylinder block sealing surfaces for torsion

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

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

59. 59. Measure piston projection • Place probe of MKM-571-B in position on cylinder block • Set dial to zero – Determine high point by turning crankshaft • Measure piston projection – Measure on all 4 pistons – Carry out measurement on two different locations (3 and 4) or (5 and 6)

Note. Note pretension.

60. 60. Lock crankshaft • Insert EN-46778 (1) into cylinder block through flywheel (2)

61. 61. Check cylinder head for plane surface • Use straight edge and feeler gauge to check length and breadth of cylinder head sealing surfaces for torsion • Maximum deflection is 0,10 mm
62. 62. Measure the height of the cylinder head • Sealing surface to sealing surface • Dimension l: = 105.45 –105.55 mm

Important. The largest piston projection found determines the selection of the cylinder head gasket with appropriate identification.

63. 63. Replace cylinder head gasket • Lay cylinder head gasket in place Piston projection Thickness of cylinder head gasket Code 0.028 - 0.127 mm 0.67 - 0.77 mm no 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 bushings.

64. 64. Insert cylinder head

Note. Second person required

65. 65. Screw in 10x cylinder head bolt • Use new bolts

Note. Do not tighten bolts.

66. 66. Align cylinder head • Use straight edge to align cylinder head (2) with cylinder block (3)

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

Note. Note tightening sequence.

68. 68. Insert 16x roller cam follower

Note. Note the dismantling sequence.

69. 69. Insert camshaft housing • Insert new gasket • Screw in 2 stay-bolts (M8)

Note. Note marking ("TOP")

70. 70. Align camshaft housing (1) • Using straight edge (2), align with cylinder head

71. 71. Tighten camshaft housing • Tighten 2 stay-bolts (M8) (2) and (11) 25 Nm • Tighten 16 (M7) bolts 18 Nm

Note. Note longer bolt (14). Comply with tightening sequence.

72. 72. Clean 4 injector seats with EN-47632 • Loosen dirt with brush side (1) • Remove dirt with sponge side (2)

73. 73. Install 4 injectors • Fit 4 new seal rings to injector shaft • Replace 4 injector seal rings (1) • Tighten 2 nuts 20 Nm

74. 74. Attach oil leak line • Disengage 4 retaining clamps
75. 75. Attach timing chain oil spray nozzle • Tighten 2 bolts 6 Nm
76. 76. Attach timing chain guide rail • Tighten 2 bolts 9 Nm
77. 77. Insert timing chain with camshaft drive gear and crankshaft drive gear
78. 78. Fasten camshaft drive gear • Tighten bolt 150 Nm • Counterhold at camshaft drive gear with KM-6347 and KM-956-1
79. 79. Attach timing chain tension rail • Tighten bolt 9 Nm
80. 80. Attach timing chain tensioner • Tighten 2 bolts 9 Nm • Tension timing chain tensioner – Remove KM-955

Important. The timing case must be installed within 10 minutes of applying the silicone sealant.

81. 81. Insert timing case gasket • Apply silicone sealant (grey) to the transitions between the cylinder head and camshaft housing (1) and the cylinder block and cylinder head (2)
82. 82. Attach timing case. • Centre timing case with EN-46775 (1) – Screw in 2 nuts (2) – Tighten 14 bolts 9 Nm – Tighten 3x nuts 9 Nm • Remove EN-46775 • Attach engine vent hose to timing case – Fasten clamp

83. 83. Push crankshaft seal ring front (2) onto seal ring flange torsional vibration damper (1).

84. 84. Install flange torsional vibration damper (2) with front crankshaft seal ring (1). • Carefully tighten bolt to crankshaft stop. • Remove bolt • Remove torsional vibration damper flange.

85. 85. Press in seal ring with flat side of EN-46775 (2) • Tighten bolt (1) carefully until EN-46775 lies on timing case (arrow).

86. 86. Detach EN-46775 • Remove bolt
87. 87. Attach torsional vibration damper flange • Tighten bolt 50 Nm + 90° – Counterhold using KM-662-C • Remove KM-662-C – Unscrew 2 bolts

Note. Left hand thread

88. 88. Remove EN-46778
89. 89. Check camshaft timing • Unscrew 2 camshaft reference drifts EN-46781 • Turn engine 690° in direction of engine rotation at torsional vibration damper flange bolt • Screw in 2 camshaft reference drifts EN-46781 • Turn engine in direction of engine rotation at torsional vibration damper flange bolt until reference drift EN-46781 engages audibly in both camshafts
90. 90. Check position of crankshaft by inserting EN-46778 through hole in flywheel • Turn crankshaft in direction of engine rotation at torsional vibration damper flange bolt until EN-46778 engages in cylinder block

Note. If EN-46778 cannot be inserted in cylinder block, repeat the adjustment process

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

Note. Complete assembly operations within 10 minutes

93. 93. Install torsional vibration damper • Tighten 4 bolts 25 Nm
94. 94. Attach coolant pump • Tighten 4 nuts 9 Nm

Note. Use new gasket and coat it with silicone grease (white). The coolant pump journal must point to the filler port.

95. 95. Attach ribbed V-belt tensioner
96. 96. Attach right engine damping block adapter • Tighten 4 bolts 60 Nm
97. 97. Install crankshaft sensor • Tighten bolt 9 Nm
98. 98. Install oil filter housing • Use new gasket • Tighten 4 bolts 9 Nm

Note. Note differing bolt lengths!

99. 99. Attach coolant pipe to cylinder block • Tighten 2 bolts 9 Nm

Note. Use new gasket and coat it with silicone grease (white)

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

Note. Coat seal ring with silicone grease (white)

101. 101. Attach thermostat housing coolant pipe to oil filter housing • Attach coolant hose to thermostat housing – Fasten clamp • Attach to oil filter housing – Tighten 2 bolts 9 Nm • Attach to cylinder block – Tighten bolt 9 Nm

Note. Use new gasket

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

Note. Insert engine transport shackle

107. 107. Attach high pressure lines • Use new high pressure lines • Attach 4 accumulator high pressure lines to injectors – Tighten 4 union nuts (M12) 24 Nm – Tighten 4 union nuts M14 28 Nm • Attach high pressure pump line to accumulator – Tighten union nut M12 24 Nm – Tighten union nut M14 28 Nm
108. 108. Attach fuel supply line • Attach fuel line to high pressure pump – Fasten clamp • Tighten 3 bolts • Clip vacuum line into bracket

Note. Take care to avoid the 2 ground cables.

109. 109. Connect engine wiring harness • Clip in bracket (twice) • Tighten 3 bolts
110. 110. Connect wiring harness on engine exhaust side • Connect wiring harness plug of common-rail pressure sensor • Connect wiring harness plug of boost pressure sensor • Connect wiring harness plug of common rail pressure regulator • Connect EGR valve wiring harness plug
111. 111. Attach wiring harness on engine intake side • Connect 4 injector wiring harness plugs • Connect 4 glow plug wiring harness plugs • Connect camshaft sensor wiring harness plug • Connect wiring harness plug of crankshaft sensor • Connect wiring harness plug of coolant temperature sensor
112. 112. Turn engine by 180°
113. 113. Unscrew 2 stay-bolts from timing cover

Note. Replace stay-bolts with bolts when attaching the oil pan

114. 114. Apply sealing compound

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

Important. The oil pan must be installed within 10 minutes of applying the silicone sealant.

115. 115. Attach oil pan • To cylinder block base plate – Tighten 15 bolts 9 Nm • Connect wiring harness plug of engine oil level sensor
116. 116. Attach transmission bracket • To cylinder block base plate – Tighten 4 bolts 30 Nm • On transmission – Tighten 2 bolts 40 Nm

Note. Note differing bolt lengths!

117. 117. Turn engine by 180°
118. 118. Top up and correct engine oil level • Use prescribed quantity of oil
119. 119. Install thrust plate with clutch disk
120. 120. Install starter • Tighten 2 bolts • Attach wiring harness (2x) – Tighten 2x bolts 25 Nm
121. 121. Attach transmission to engine
122. 122. Install engine

1

) Protective caps can be ordered from the Opel parts catalogue, catalogue no. 45 06 154 / part no. 9201697