Engine Maintenance Using a Section Engine Opel Corsa D

Warning: When working on the Common Rail system, wait for one minute after switching off the engine. The system reduces the pressure automatically.

Important: When working on the fuel system, pay strict attention to cleanliness as even the smallest particle of dirt may lead to malfunctions in engine operation or the fuel system. Seal opened fuel connections with suitable closure plugs 1) . Closure plugs are intended for single use.

Remove

1. 1. Remove engine
2. 2. Detach transmission from engine For transmission F17-5 and M20-6 For manual transmission M20-6 MTA
3. 3. Detach starter • Detach 2x wiring harness – Unscrew 2x nuts • Unscrew 2x bolts (1)

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

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

Note. Note different bolt lengths!

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

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

11. 11. Turn engine 90°
12. 12. Detach engine wiring harness on intake side • Disconnect 4x injector wiring harness plug • Disconnect 4x glow plug wiring harness plug • Disconnect wiring harness plug for camshaft sensor • Disconnect wiring harness plug of crankshaft sensor • Disconnect wiring harness plug for coolant temperature sensor
13. 13. Disconnect engine wiring harness on 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 regulator • Disconnect wiring harness plug of EGR valve
14. 14. Detach engine wiring harness • Unclip 2x from bracket • Unscrew 3 bolts
15. 15. Place collecting pan underneath.

Important. After detaching the pressure lines, seal the openings of the injectors, the high-pressure pump and the accumulator using protective caps (select suitable protective caps from the spare parts catalogue).

16. 16. Detach high pressure lines • Detach 4x high pressure line (1) from accumulator to injector – Unscrew 8x union nut • Remove high pressure line (2) from high pressure pump to accumulator – Unscrew 2x union nut • Unclip oil leak line (3)

17. 17. Remove accumulator (2) with accumulator bracket • Disconnect 2x wiring harness plug (1) and (3) • Deatch fuel return line (high pressure to accumulator) from connection (5) – Release clamp • Detach oil leak line from connection (6) • Unscrew 3x bolts (7) • Detach fuel return line from connection (4) – Undo quick-release fitting with KM-796-A – Seal with KM-807

Note. Remove engine transport tab.

18. 18. Deatch EGR valve (1) with EGR cooler • Detach EGR pipe from intake manifold – Release clamp • Detach coolant hose from thermostat housing – Release clamp • Unscrew 2x bolts

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

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

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

22. 22. Detach coolant feed pipe (1) • Detach from heat exchanger – Unscrew 2x bolts • Detach from cylinder block – Unscrew bolt • Unclip 2x wiring harness bracket • Detach coolant hose – Release clamp

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

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

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

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

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

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

Note. Counterhold against bolt, torsional vibration damper flange (2).

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

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

Note. Left-handed thread

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

33. 33. Remove 2x closure bolt from camshaft housing

34. 34. Clean 4x threads • From closure bolts • From camshaft housing
35. 35. Lock camshafts • Screw in 2x camshaft reference drift EN-46781 (1) • Ensure correct installation position • Turn camshafts at camshaft drive gear bolt back and forth until EN-46781 engages in both camshafts

Note. Fixing for reference drift must be installed in the horizontal position. To do this, apply marking to reference drift as an aid (arrows).

36. 36. Detach timing chain tensioner • Apply tension to chain tensioner, lock in pre-tensioned position with KM-955 • Unscrew 2x bolts (2)

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

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

42. 42. Remove oil leak line (1) • Release 4x clamp (2) in direction of arrow

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

Note. Injectors (2) can only be removed in pairs (cylinder 1 and 2 or 3 and 4) with bracket.

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

Note. Note different bolt lengths!

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

Note. Set aside in the order removed!

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

47. 47. Slacken cylinder head • Unscrew 10x bolt

Note. Undo bolts in order shown.

48. 48. Remove cylinder head

Note. Use a second person

49. 49. Remove EN-46778
50. 50. Remove flywheel • Insert KM-652 • Unscrew 8x bolts • Remove KM-652
51. 51. Transfer engine short block
52. 52. Clean components and sealing surfaces

Install

53. 53. Tap guide sleeves into cylinder block • 4x guide sleeve with KM-427

54. 54. Place rear crankshaft seal ring on EN-46777-10 • Insert EN-46777-10 (1) • Push crankshaft seal ring (3) over EN-46777-10 • Remove EN-46777-10
55. 55. Install rear crankshaft seal ring (1) with EN-46777-10 (2)

56. 56. Fit flywheel • Insert KM-652 • Tighten 8x bolts 44 Nm – Use new bolts • Remove KM-652
57. 57. Cylinder Block, Check for Plane Surface • Check cylinder block with straightedge and feeler gauge on the sealing surfaces for distortion along their length and diagonals

58. 58. Adjust TDC combustion stroke - cylinder 1 • Insert MKM-571-B (1) in KM-301 (2) • Place KM-301 with MKM-571-B on cylinder block • Place probe of MKM-571-B on piston head • Set dial to zero – Note pre-tension! • Turn engine in 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 on cylinder block • Set dial to zero – Determine highest point by turning the crankshaft • Measure piston projection – Measure on all 4 pistons – Perform measurements at two different points (3 and 4) or )5 and 6)

Note. Note pre-tension!

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

61. 61. Cylinder Head, Check for Plane Surface • Check cylinder head with straightedge and feeler gauge on the sealing surfaces for sag along their length and in the diagonals for distortion • Maximum sag is 0.10 mm
62. 62. Measure height of cylinder head • Sealing surface to sealing surface • Measurement I: = 105.45 - 105.55 mm

Important. The largest piston projection is decisive for the selection of the cylinder head gasket with the corresponding marking!

63. 63. Replace cylinder head gasket • Place cylinder head gasket in position Piston projection Thickness of cylinder head gasket Identification 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!

64. 64. Insert cylinder head

Note. Use a second person

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

Note. Do not tighten bolts!

66. 66. Align cylinder head • Align cylinder head (2) with cylinder block (3) using a straightedge (1)

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

Note. Note correct tightening sequence!

68. 68. Insert 16x roller cam follower

Note. Note removal sequence!

69. 69. Insert camshaft housing • Insert new gasket • Screw in 2x stud bolt (M8)

Note. Note "TOP" marking

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

71. 71. Tighten camshaft housing • Tighten 2x stud bolt (M8) (2) and (11) 25 Nm • Tighten 16x bolt (M7) 18 Nm

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

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

73. 73. Install 4x injector • Replace 4x injector shaft seal ring • Replace 4x injector seal ring (1) • Tighten 2x nut 20 Nm

74. 74. Attach oil leak line • Unlock 4x retaining clamp
75. 75. Attach timing chain oil spray nozzle • Tighten 2x bolt 6 Nm
76. 76. Attach timing chain guide rail • Tighten 2x bolt 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 with KM-6347 and KM-956-1 on camshaft drive gear
79. 79. Attach timing chain tension rail • Tighten bolt 9 Nm
80. 80. Attach timing chain tensioner • Tighten 2x bolt 9 Nm • Tension timing chain tensioner – Remove KM-955

Important. The timing case must be fitted within 10 minutes of applying the silicone sealing compound!

81. 81. Insert timing case gasket • Apply silicone sealant to the transitions between the cylinder head and camshaft housing (1) and the cylinder block and cylinder head (2)

Note. Select a suitable silicone sealing compound from the spare parts catalogue.

82. 82. Attach timing case. • Centre timing case with EN-46775 (1) – Screw in 2x nut (2) – Tighten 14x bolt 9 Nm – Tighten 3x nuts 9 Nm • Remove EN-46775 • Attach engine vent hose to timing case – Fasten clamp

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

84. 84. Attach torsional vibration damper flange • Tighten bolt 50 Nm + 90° – Counterhold with KM-662-C • Detach KM-662-C – Unscrew 2x bolts

Note. Left-handed thread

85. 85. Remove EN-46778
86. 86. Check camshaft timing • Unscrew 2x camshaft reference drift EN-46781 • Turn engine 690° in direction of engine rotation at vibration damper flange bolt • Screw in 2x camshaft reference drift EN-46781 • Turn engine in direction of engine rotation by the bolt on the torsional vibration damper flange until reference drift EN-46781 engages audibly in both camshafts
87. 87. Check crankshaft position EN-46778 . Insert through bore in flywheel. • Turn crankshaft carefully at bolt for torsional vibration damper flange until EN-46778 engages in cylinder block

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

88. 88. Unscrew 2x camshaft reference drift EN-46781
89. 89. Install 2x closure bolt • Coat 2 bolts with locking compound • Tighten 2x closure bolt 15 Nm

Note. Complete assembly within 10 minutes!

Note. Select a suitable locking compound from the spare parts catalogue.

90. 90. Fit torsional vibration balancer • Tighten 4x bolts 25 Nm
91. 91. Attach coolant pump • Tighten 4x nuts 9 Nm

Note. Use new seal. Coat seal with silicone grease. Coolant pump journal must point to oil filler pipe. Select suitable silicone grease from the spare parts catalogue.

92. 92. Attach ribbed V-belt tensioner
93. 93. Attach right engine damping block adapter • Tighten 4 bolts 60 Nm
94. 94. Attach crankshaft sensor • Tighten bolt 9 Nm
95. 95. Attach oil filter housing • Use new seal • Tighten 4x bolts 9 Nm

Note. Note different bolt lengths!

96. 96. Attach coolant pipe to cylinder block • Tighten 2x bolt 9 Nm

Note. Use new seal. Coat seal with silicone grease. Select suitable silicone grease from the spare parts catalogue!

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

Note. Coat gasket with silicone grease. Select suitable silicone grease from spare parts catalogue.

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

Note. Use new gasket

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

Note. Insert engine transport shackle.

104. 104. Install high pressure lines • Use new high pressure lines • Install 4x accumulator high-pressure lines to injector – Tighten 4x union nut M12 24 Nm – Tighten 4x union nut M14 28 Nm • Install high pressure line - high pressure pump to accumulator – Tighten union nut M12 24 Nm – Tighten union nut M14 28 Nm
105. 105. Install fuel supply line • Attach fuel line to high-pressure pump – Fasten clamp • Tighten 3x bolts • Clip vacuum line into bracket

Note. Note 2x ground cable!

106. 106. Attach wiring harness for motor • Clip 2x in bracket • Tighten 3x bolts
107. 107. Connect engine wiring harness on exhaust side • Connect wiring harness plug of rail pressure sensor • Connect charge pressure sensor wiring harness plug • Connect wiring harness plug of rail pressure regulator • Connect EGR valve wiring harness plug
108. 108. Attach engine wiring harness on intake side • Connect 4x injector wiring harness plug • Connect 4x wiring harness plug, sheathed glow plug • Connect wiring harness plug, camshaft sensor • Connect wiring harness plug of crankshaft sensor • Connect coolant temperature sensor wiring harness plug
109. 109. Turn engine by 180°
110. 110. Apply sealing compound

Note. Apply a bead of silicone sealant on the sealing surface of the oil pan.

Note. Select a suitable silicone sealing compound from the spare parts catalogue.

Important. The oil pan must be fitted within 10 minutes of applying the silicone sealing compound

111. 111. Install oil pan • To cylinder block base plate – Tighten 13x bolts 9 Nm – Tighten 2x nut 9 Nm • Connect engine oil level wiring harness plug
112. 112. Install transmission bracket • To cylinder block base plate – Tighten 4x bolts 30 Nm • To transmission – Tighten 2x bolt 40 Nm

Note. Note different bolt lengths!

113. 113. Turn engine by 180°
114. 114. Fill and correct engine oil level • Observe specified oil quantity
115. 115. Install thrust plate with clutch disc
116. 116. Fit starter • Tighten 2x bolts • Attach 2x wiring harness – Tighten 2x bolt 25 Nm
117. 117. Attach transmission to engine For transmission F17-5 and M20-6 For manual transmission M20-6 MTA
118. 118. Install engine

1

) ; protective caps are available in the parts catalogue