Repair Engine Using an Engine Short Block (Y 17 DT) Opel Combo C

1. 1. Remove engine

Note. See operation "J 450100 Removing and installing engine".

2. 2. Detach manual transmission from engine

Note. See operation "J 450100 007 Detaching and attaching manual transmission from/to engine".

3. 3. Drain engine oil • Place collecting basin underneath. • Unscrew oil filter housing cover (1) • Remove oil filter element • Unscrew oil drain bolt

4. 4. Remove air intake pipe • Remove 2 bolts • Release clamp • Detach engine vent hose (1) – From cylinder head cover • Unclip wiring harness (arrow)

5. 5. Remove ribbed V-belt • Tension ribbed V-belt tensioner in direction of arrow – With KM-913-A

Note. Mark direction of rotation

6. 6. Remove starter alternator wiring harness • Disconnect alternator – Unscrew nut (2) – Disconnect wiring harness plug (1) • Expose wiring harness – 6 clips – Remove bolt • Remove bracket with wiring harness – Remove 2 nuts • Detach starter – Unscrew bolt and nut

7. 7. Remove alternator • Remove 2 bolts (1) • Expose vacuum line – Solenoid, vacuum pump • Remove oil feed line – Unscrew banjo bolt – Remove sealing ring • Detach oil return line

8. 8. Remove oil dipstick guide tube bracket • Unscrew 2 nuts, bolt
9. 9. Remove lower coolant hose • Release clamp • Place collecting basin underneath.
10. 10. Remove oil dipstick guide tube • Remove 2 bolts
11. 11. Remove exhaust manifold heat shield • Remove 4 bolts

12. 12. Remove turbocharger heat shield • Remove 3 bolts
13. 13. Detach vacuum hose from waste gate unit
14. 14. Remove turbocharger oil return hose (1) • Release clamp – At engine block

15. 15. Remove turbocharger oil feed line • Unscrew banjo bolt (1) • Unscrew nut • Remove seal rings

Note. Counterhold at threaded connection

16. 16. Remove exhaust recirculation pipe • Remove 2 bolts (1) • Remove gasket.

17. 17. Loosen turbocharger bracket • Remove bolt
18. 18. Remove exhaust manifold • Unscrew 7 bolts, 2 nuts (1) • Remove gasket.

19. 19. Remove alternator bracket • Remove 4 bolts (arrows)

20. 20. Remove coolant pipe (1) • Remove thermostat housing coolant hoses (2, 3) • Remove bolt • Pull coolant tube out of coolant flange

21. 21. Remove coolant flange • Remove 2 bolts
22. 22. Remove coolant drain screw • At engine block
23. 23. Remove oil circuit connecting pieces • 2 off
24. 24. Remove engine control unit • Unscrew 2 bolts (2), 2 nuts (3) • Remove wiring harness plug bracket – Remove 2 bolts (1)

25. 25. Remove engine control unit bracket • Unscrew 2 bolts (2), nut (1) • Unclip wiring harness (arrows)

26. 26. Remove injection pump insulators • Rear insulator – Remove bolt • Remove lower insulator
27. 27. Remove engine management wiring harness • Disconnect wiring harness plug – Coolant temperature sensor, oil pressure switch, injection pump, exhaust gas recirculation solenoid valve, sheathed glow plugs, charge pressure sensor • Undo 6 clips
28. 28. Remove upper charge air pipe (1) • Remove 2 bolts (arrows) • Remove studs (2)

29. 29. Remove exhaust recirculation valve (1) • Unscrew studs (3) • Remove 2 bolts (arrows) • Detach vacuum hose (2) • Remove gasket.

30. 30. Remove oil filter housing • Detach oil return line – From cylinder block • Detach coolant hoses – From cylinder block – From oil filter housing • Remove bolt (1)

31. 31. Remove thermostat housing • Remove 2 bolts (arrows)

32. 32. Remove turbocharger vacuum hose • Remove bracket – Remove bolt – From cylinder head
33. 33. Remove oil pressure switch
34. 34. Remove starter • Remove lower bolt
35. 35. Remove right rear engine transport shackle • Remove bolt
36. 36. Remove injection pump insulator
37. 37. Remove injection pipe spacers (1) • Remove 3 bolts

Note. Mark spacer positions

38. 38. Remove injection lines • With KM-6098 • 4 off – Unscrew 8 union nuts

39. 39. Remove oil leak line hose • Release 2 clamps
40. 40. Remove intake manifold • Unscrew 7 bolts (1), 2 nuts (2) • Remove gaskets

41. 41. Detach right engine bracket (1) • Remove 3 bolts

42. 42. Remove coolant pump ribbed V-belt pulley • Remove 3 bolts
43. 43. Remove coolant pump (1) • Place collecting basin underneath. • Remove 5 bolts • Remove coolant pump plastic insert

44. 44. Remove upper toothed belt cover • Remove 8 bolts • Remove adapter for right engine bracket

Note. Note dissimilar bolt lengths

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

46. 46. Detach lower part of toothed belt cover • Remove 3 bolts

47. 47. For toothed belt tension roller with leaf spring: • Remove toothed belt tensioner – Remove bolt (2) – Remove tension spring (1)

48. 48. For toothed belt tension roller with spiral spring: • Remove toothed belt tension roller (1) – Remove bolt (2)

49. 49. Detach camshaft pulley • Unscrew TDC-fixing bolt (2) • Counterhold camshaft pulley with KM-6156 and KM-956-1 • Remove bolt (1)

50. 50. Remove drive gear injection pumps • Unscrew nut • Unscrew TDC-fixing bolt • Attach KM-6099 • Removing injection pump drive gear

Important. Note woodruff keys

51. 51. Remove toothed belt deflection pulley (1) • Remove bolt (2)

52. 52. Remove toothed belt tension roller spring retainer • Remove 2 bolts
53. 53. Remove rear toothed belt cover • Remove 4 bolts
54. 54. Remove oil pump drive gear (1) • Unscrew nut

Note. Counterhold with socket wrench (2).

55. 55. Remove crankshaft toothed belt drive gear (1) • Attach KM-662-C • Remove bolt • Remove KM-662-C • Attach KM-161-B (2) – Remove plate

56. 56. Remove clutch

Note. See operation "Removing and installing pressure plate and clutch disk (without SAC)" in group "K".

57. 57. Detach flywheel • Block using KM-652 • Remove 8 bolts

58. 58. Remove injection pump holder (arrow) • Remove 4 bolts

59. 59. Remove injection pump • Remove 2 nuts (arrows) • Remove front injection pump insulation

60. 60. Remove crankshaft sensor(1) • Remove bolt (2)

61. 61. Remove oil pressure control valve (1) • Remove bolt

62. 62. Remove safety valve • Remove bolt
63. 63. Remove 2 engine transport shackles • Remove 2 bolts
64. 64. Remove 4 outer injection nozzle seals • Remove 8 bolts

65. 65. Remove camshaft housing cover • Unscrew 7 bolts (1), 3 studs (2)

66. 66. Remove inner oil leak line • Unscrew 5 banjo bolts (1)

Note. Note sealing rings.

Important. Ensure that upon removal of injector nozzles heat protection sleeves remain in their position on the cylinder head. Otherwise, heat protection sleeves must be removed completely and installed again using new sealing rings. This is the only way to ensure that no coolant can reach the combustion chamber, which would inevitably cause engine damage. Replace heat protection sleeves – see operation "Replace heat protection sleeves" in document "Check and measure cylinder head".

67. 67. Remove injector nozzles
68. 68. Remove injector nozzles • Remove injection nozzle bracket – Remove 2 nuts (1) • Remove injector nozzles

69. 69. Remove camshaft housing cover • Loosen bolts, stud bolts (180°) • Unscrew 2 stud bolts, 15 bolts • Remove gasket.

Important. Follow order.

70. 70. Remove cup tappets • With KM-845 • Important! Note allocation and installation position
71. 71. Remove cylinder head bolts • Remove 10 bolts

Note. Undo bolts in depicted order (180° to 360°).

Important. Place cylinder head on wooden blocks. Note sheathed glow plugs.

72. 72. Remove cylinder head • Remove cylinder head gasket

Note. 2nd mechanic.

73. 73. Turn engine • 180°
74. 74. Screw in oil drain screw • Replace seal ring • Tighten oil drain screw ( 78.4 Nm )
75. 75. Detach oil pan lower part • Remove 15 bolts • Remove using KM-J-37228

76. 76. Detach oil pan upper part • Remove 14 bolts • Remove 2 nuts

Note. Note dissimilar bolt lengths

Note. Use wide spatula.

77. 77. Detach oil intake pipe • Remove bolt (1) • Remove gasket.
78. 78. Remove oil baffle plate • Remove 5 bolts (arrows)

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

Note. Note dissimilar bolt lengths

80. 80. Clean components • Oil pan lower section, oil pan upper section, cylinder head, exhaust manifold, exhaust recirculation valve, coolant connections, oil pump cover
81. 81. Inspect components
82. 82. Remove cylinder block • Attach transport shackles • Attach KM-2358 • Unscrew cylinder block – From KM-412 – With workshop crane • Put down cylinder block • Remove KM-2358 • Remove transport shackles
83. 83. Attach cylinder block • Attach transport shackles • Attach KM-2358 • Lift cylinder block • Attach cylinder block – An KM-412 • Remove KM-2358 • Remove transport shackles
84. 84. Drive in engine number
85. 85. Drive guide bushings into cylinder block • 4 off • With KM-427
86. 86. Remove oil pump cover sealing rings • Front crankshaft sealing ring (1), oil pump sealing ring (2) – Prise out sealing rings

Important. Do not damage sealing surfaces.

87. 87. Attach oil pump cover (2) • Insert inner and outer rotor – Coat with engine oil • Replace gasket (1) • Apply adhesive sealing compound (black) (shaded area) • Attach oil pump cover – Tighten bolts ( 9.8 Nm )

Note. Note guide bushings and differing bolt lengths.

88. 88. Install oil pump seal ring • Replace seal ring • Coat sealing lip with silicon grease (white) • Drive in until flush using KM-657
89. 89. Install front crankshaft sealing ring (1) • Replace seal ring • Coat sealing lip with silicon grease (white) • Drive in until flush using KM-656 (2)

90. 90. Install oil baffle plate • Tighten bolts ( 18.6 Nm )
91. 91. Attach oil intake pipe • Replace seal ring • Tighten bolt ( 18.6 Nm )
92. 92. Clean thread. • Oil pan upper section – 14 off • Oil pan lower section – 15 off
93. 93. Attach oil pan upper part • Apply silicon sealing compound (grey) • Tighten bolts, nuts ( 9.8 Nm )

Important. The application of silicone sealing compound (grey) and installation of lower part of oil pan including torque test must be performed within 10 minutes!

94. 94. Attach oil pan lower section • Apply silicon sealing compound (grey) • Tighten bolts ( 9.8 Nm )
95. 95. Turn engine • 90°
96. 96. Attach flywheel • Renew bolts • Block using KM-652 • Tighten bolts ( 29,4 Nm + 60° + 15° )
97. 97. Install clutch

Note. See operation "Removing and installing pressure plate and clutch disk (without SAC)" in group "K".

98. 98. Turn engine • 90°
99. 99. Attach crankshaft toothed belt drive gear • Install sheet metal panel • Insert toothed belt drive gear in place – Note woodruff key • Counterhold using KM-662-C • Tighten bolt ( 196 Nm )
100. 100. Check for plane surface • Cylinder head, cylinder block • With straightedge, feeler gauge

101. 101. Measure piston projection • Insert MKM-571-B (1) into KM-301 (2) – Note pretension • Set dial to zero – Place probe on cylinder block • Measure piston projection on all four pistons – Carry out measurement on two different locations (3 and 4) or (5 and 6) – Determine high point by turning crankshaft • Turn crankshaft – approx. 60° before TDC of cylinder-1

102. 102. Replace cylinder head gasket Piston projection Thickness of cylinder head gasket Code 0.630 – 0.696 mm 1.45 mm no hole 0.697 – 0.763 mm 1.50 mm one hole 0.764 – 0.830 mm 1.55 mm two holes • Lay cylinder head gasket in place – Note guide bushings

Important. The largest determined piston projection determines the selection of the cylinder head gasket with appropriate identification (arrows).

103. 103. Attach cylinder head

Note. 2nd mechanic.

104. 104. Fasten cylinder head • Replace cylinder head bolts – Screw in bolts by several threads • Tighten cylinder head bolts ( 39.2 Nm + 60° + 13°+ 60° + 13° )

Important. Note tightening order.

105. 105. Insert cup tappets • Coat with engine oil

Important. Note order and allocation.

106. 106. Install camshaft housing • Replace gasket • Tighten bolts M8 ( 21.6 Nm ) • Tighten bolts M10 ( 43.1 Nm )

Important. Follow order.

107. 107. Install safety valve • Replace seal ring • Tighten bolt ( 39.2 Nm )
108. 108. Install oil pressure control valve • Replace seal ring • Tighten oil pressure regulating valve ( 29.4 Nm )
109. 109. Install crankshaft sensor • Replace seal ring • Tighten bolt ( 9.8 Nm )
110. 110. Install injection pump • Insert front injection pump insulation • Tighten nuts

Note. Note central position of stud in injection pump flange.

111. 111. Attach rear toothed belt cover • Tighten bolts ( 9.8 Nm )
112. 112. Attach toothed belt clamping roller spring retainer • Tighten bolts ( 9.8 Nm )
113. 113. Install oil pump drive gear • Tighten nut ( 44.1 Nm )

Note. Pay attention to installation position

114. 114. Install toothed belt guide roller • Tighten bolt ( 80.4 Nm )
115. 115. Install injection pump drive gear 1. Tighten nut 60 Nm 2. Loosen nut 3. Waiting time: 60 sec 4. Tighten nut 60 Nm •

Important. Observe tightening sequence

116. 116. Attach camshaft pulley • Block using KM-6156 and KM-956-1 • Tighten bolt ( 63.7 Nm ) • Install TDC-fixing bolt
117. 117. Install toothed belt tension roller • Screw in toothed belt tension roller bolt • For toothed belt tension roller with leaf spring: unscrew bolt (M10) from lower bore of toothed belt tensioner
118. 118. Set no.1 cylinder to TDC • Mark on toothed belt drive gear (2) must align with casting lug at oil pump cover (1)

119. 119. Install toothed belt • Position toothed belt • For toothed belt tension roller with leaf spring: – Attach leaf spring • Unscrew TDC-fixing bolt • Rotate crankshaft 60° against direction of engine rotation • Tighten bolt of toothed belt tension roller – For toothed belt tension roller with spiral spring 49 Nm – For toothed belt tension roller with leaf spring 38.2 Nm • For toothed belt tension roller with leaf spring: unscrew bolt (M10) from lower bore of toothed belt tensioner

Note. Toothed belt must be taut from toothed belt drive gear via oil pump drive gear and injection pump drive gear

120. 120. Timing, Check • Turn crankshaft approx. 780° in direction of engine rotation – At toothed belt drive gear bolt • The mark on toothed belt drive gear must align with lug on oil pump cover (arrows) • Install TDC-fixing bolt – Camshaft gear M6 (1) – Injection pump drive gear M8 (2) • Unscrew TDC-fixing bolts

Note. If the TDC fixing bolts cannot be screwed in, basic adjustment must be repeated

121. 121. Remove bolt (M 10)
122. 122. Attach KM-798 • Turn crankshaft in direction of engine rotation to 45° before no.1 cylinder TDC – At toothed belt drive gear bolt • Remove central bleeder screw • Install KM-798 under pre-tension • Determine BDC position of injection pump plunger by turning crankshaft back and forth • Set dial gauge to "0".

Note. Dial gauge needle must not move

123. 123. Adjust injection pump • Turn crankshaft to no.1 cylinder TDC • Loosen diesel injection pump • Turn diesel injection pump until 0.33 mm adjustment value is accomplished – Value too high – turn injection pump towards engine – Value too low – turn injection pump away from engine • Tighten diesel injection pump ( 19.6 Nm )

Note. Mark on toothed belt drive gear must align with casting lug at oil pump cover.

124. 124. Check start of feed • Remove KM-798 • Turn crankshaft approx. 675° • Install KM-798 under pre-tension • Determine BDC position of injection pump plunger by turning crankshaft back and forth • Set dial gauge to "0". • Turn crankshaft to 1st Cylinder TDC • Read test value – Test value: 0.28 – 0.38 mm

Note. Dial gauge needle must not move

Note. Mark on toothed belt drive gear must align with casting lug at oil pump cover.

Important. Repeat adjustment if test value is not achieved!

125. 125. Remove KM-798 • Remove dial gauge • Tighten central bleeder screw ( 23.5 Nm ) – Replace seal ring
126. 126. Attach injection pump bracket • Tighten bolts to cylinder block ( 53.9 Nm ) • Tighten bolt to injection pump ( 18.6 Nm )
127. 127. Turn crankshaft • Turn crankshaft until cam pairs (1) and (2) point upwards

128. 128. Check valve clearance • Using feeler gauge – Test values: Intake valves/Exhaust valves (0.35 – 0.45 mm)
129. 129. Adjust valve clearance • Turn cup tappet until tappet groove points outwards • Press down cup tappets using KM-6090 – Mark – IN = Intake side – Mark – EX = Exhaust side • Remove adjustment shim Example for determination of shim thickness 1. Thickness of installed shim 3.15 mm 2. Measurement between cam and cup tappets + 0.45 mm = 3.60 mm 3. Nominal valve play - 0.40 mm 4. Thickness of new shim = 3.20 mm

Important. Ensure that valves do not interfere with piston head

Note. Note different tool versions for intake and exhaust valves

130. 130. Insert adjustment shim • Coat new shim (7) with engine oil and insert in cup tappet with identification mark facing downwards

131. 131. Check and adjust valve clearance • Turn crankshaft • In direction of engine rotation by 180° – Check and adjust valve pair (6) and (2) • In direction of engine rotation by 180° – Check and adjust valve pair (5) and (3) • In direction of engine rotation by 180° – Check and adjust valve pair (4) and (1)

Note. Clearance of all adjusted valves must be re-checked

132. 132. Install injector nozzles • Replace seal rings (1) • Replace copper seal rings (2) • Insert injection nozzles in cylinder head. • Install injection nozzle bracket • Attach injection nozzle bracket ( 22.1 Nm )

133. 133. Install inner oil leak line • Renew seal rings • Tighten banjo bolt ( 14.7 Nm )
134. 134. Install camshaft housing cover • Replace gasket • Apply adhesive sealant compound (white) – Areas (1, 3) • Tighten bolts, studs ( 9.8 Nm )

Important. Oil return bore (2) must not be covered with adhesive sealing compound or by the camshaft housing cover gasket

135. 135. Install outer injection nozzle seal • Replace seals • Tighten bolts

Note. Pay attention to installation position

136. 136. Attach engine transport shackles • 2 off • Tighten bolts ( 24.5 Nm )
137. 137. Install lower toothed belt cover • Tighten bolts ( 9.8 Nm )
138. 138. Install torsional vibration damper • Tighten bolts ( 19.6 Nm )
139. 139. Install right engine bracket adapter • Insert lower bolt – Into right engine bracket and right engine bracket adapter • Insert right engine bracket, right engine bracket adapter, upper part of toothed belt cover • Install 2 upper bolts • Tighten 3 bolts( 40 Nm )
140. 140. Install upper toothed belt cover • Tighten bolts ( 9.8 Nm )

Note. Note dissimilar bolt lengths

141. 141. Install coolant pump • Replace gasket • Tighten bolts ( 23.5 Nm )
142. 142. Install coolant pump ribbed V-belt pulley • Tighten bolts ( 9.8 Nm )
143. 143. Install intake manifold • Replace gasket • Tighten bolts, nuts ( 24.5 Nm )
144. 144. Install oil leak line hose
145. 145. Install injection lines • Important! Injection lines must be installed without tension. Hand-tighten at injector nozzles and injection pump. • Tighten union nut ( 22.5 Nm )
146. 146. Install injection line spacers • 3 off

Note. Pay attention to spacer positions

147. 147. Install starter • Tighten lower bolt ( 38.2 Nm )
148. 148. Attach oil filter housing • Renew seal rings – 2 off • Tighten bolt ( 23.5.5 Nm ) • Attach oil return line • Attach coolant hose
149. 149. Install oil filter element • Tighten oil filter housing cover ( 23.5 Nm )
150. 150. Install right rear engine transport shackle • Tighten bolt ( 24.5 Nm )
151. 151. Install exhaust gap return valve • Replace gaskets • Tighten studs, bolts – At intake manifold ( 24.5 Nm ) • Connect vacuum hose.
152. 152. Attach upper charge air pipe • Clean sealing surface • Replace gasket • Tighten studs, bolts • Upper charge air pipe bracket to camshaft housing – Tighten bolt ( 24.5 Nm )
153. 153. Install oil pressure switch • Apply silicon sealing compound (grey) to thread • Tighten oil pressure switch ( 20.6 Nm )

Note. Clean thread in cylinder head.

154. 154. Install turbocharger vacuum hose • Attach bracket – Bolt in bolt
155. 155. Attach thermostat housing • Replace gasket • Tighten bolts ( 23.5 Nm ) • Attach coolant hose – At oil cooler
156. 156. Install motor management wiring harness • Connect wiring harness plug. – Coolant temperature sensor, oil pressure switch, injection pump, exhaust gas recirculation solenoid valve, sheathed glow plugs, charge pressure sensor • Attach 6 clips
157. 157. Install injection pump insulation • 3 off • Tighten bolt
158. 158. Install engine control unit bracket • Tighten bolts, nut ( 9.8 Nm ) • Attach engine management wiring harness bracket • Clip in engine management wiring harness
159. 159. Install engine control unit • Tighten bolts, nuts ( 5.9 Nm ) • Attach engine management wiring harness plug • Install wiring harness plug bracket – Tighten 2 bolts

Note. Note installation direction.

160. 160. Attach coolant drain screw
161. 161. Attach oil circuit connection pieces • 2 off
162. 162. Attach coolant flange • Apply adhesive sealant compound (light grey) • Tighten bolts
163. 163. Attach coolant pipe • Replace gasket • Tighten bolt ( 95.1 Nm ) • Attach coolant hoses
164. 164. Attach alternator bracket • Tighten bolts M10 ( 48 Nm ) • Tighten bolts M14 ( 67.6 Nm )
165. 165. Attach exhaust manifold • Replace gasket • Tighten bolts, nuts ( 23.5 Nm )
166. 166. Attach turbocharger bracket • Tighten bolt
167. 167. Attach exhaust gas recirculation pipe • Replace gasket • Tighten bolts( 28.4 Nm )
168. 168. Attach turbocharger oil feed line • Renew seal rings • Tighten banjo bolt ( 9.8 Nm ) • Tighten nuts ( 9.8 Nm)

Note. Counterhold at threaded connection

169. 169. Install turbocharger oil return hose • Fasten clamp
170. 170. Attach waste gate unit vacuum hose
171. 171. Install turbocharger heat shield • Tighten bolts ( 11.7 Nm )
172. 172. Install exhaust manifold heat shield • Tighten bolts ( 11.7 Nm )
173. 173. Install oil dipstick guide tube • Replace gasket • Tighten bolts ( 9.8 Nm )
174. 174. Attach lower coolant hose • Fasten clamp
175. 175. Install oil dipstick guide tube bracket • Tighten nuts ( 9.8 Nm ) • Tighten bolt
176. 176. Attach alternator • Tighten bolts – M10 ( 46.1 Nm ) – M8 ( 18.6 Nm ) • Attach oil return line • Install oil feed line – Renew seal rings – Tighten banjo bolt ( 21.6 Nm ) • Route vacuum lines
177. 177. Install starter alternator wiring harness • Starter – Tighten bolt – Tighten nuts ( 9.8 Nm ) • Attach bracket with wiring harness – Tighten nuts • Route wiring harness and clip in – Tighten bolt • Connect alternator – Tighten nuts – Connect wiring harness plug.
178. 178. Install ribbed V-belt • Release ribbed V-belt tensioner

Note. Observe running direction

179. 179. Install air intake pipe • Tighten bolts • Fasten clamp ( 5 Nm ) • Attach engine vent hose – Fasten clamp • Attach wiring harness
180. 180. Pour in engine oil • Observe specified engine oil quantity
181. 181. Attach manual transmission to engine

Note. See operation "J 450100 007 Detaching and attaching manual transmission from/to engine".

182. 182. Install engine

Note. See operation "J 450100 Removing and installing engine".