Repair Engine Using a Short Block 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. Remove manual transmission from engine
3. 3. Remove thrust plate with clutch disc
4. 4. Attach engine to KM-412 • Hitch engine up to engine crane. • Attach KM-412 to cylinder block on transmission side • Detach engine from engine crane
5. 5. Remove ribbed V-belt (1) • Mark direction of rotation • Apply tension clockwise to tensioner at tension roller bolt (arrow) • Lock tensioner with KM-6130 (2)

6. 6. Remove ribbed V-belt tensioner (1) • Apply tension to ribbed V-belt tensioner clockwise at bolt of tension roller of tensioner, remove KM-6130 • Unscrew bolt (2)

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

Note. Counterhold at bolt (2)

8. 8. Remove coolant pump • Unscrew 4x nuts

9. 9. Remove right engine damping block adapter (1) • Unscrew 4x bolts (3) • Remove engine transport shackle (2)

10. 10. Remove turbocharger heat shield (1) • Unscrew 3x bolts (2)

11. 11. Remove catalytic converter oxygen sensor (1) • Unclip oxygen sensor wiring harness connector from bracket • Unclip oxygen sensor wiring harness from retaining clip • Unscrew oxygen sensor from catalytic converter (2) using KM-6179

12. 12. Remove diesel particulate filter temperature sensor • Unclip wiring harness plug from bracket (3) • Unscrew temperature sensor from diesel particulate sensor (1)

13. 13. Remove catalytic converter with diesel particulate filter (4) from turbocharger (1) • Detach differential pressure sensor hose (2) – Release clamp (5) • Release clamping collar (3) • Unscrew 2x nuts (6) from diesel particulate filter bracket (7)

14. 14. Detach turbocharger oil return hose (2) • Release 2x clamps (3) from turbocharger (1) and oil cooler (4)

15. 15. Detach oil feed line (4) • Unscrew banjo bolt (2) from turbocharger (1) – Remove 2x seal rings (3) • Unscrew banjo bolt (5) from oil cooler (7) – Remove 2x seal rings (6)

16. 16. Detach turbocharger (1) • Unscrew 3x nut (3) • Remove gasket (2)

17. 17. Detach exhaust manifold heat shield (2) • Detach engine transport shackle (3) – Unscrew bolt (4) • Unscrew 2x nuts (5) from exhaust manifold (1)

18. 18. Detach exhaust manifold (2) • Unscrew 10x nut • Remove gasket

19. 19. Detach coolant line, oil cooler thermostat housing (2) • Unscrew 2x bolts (1) from oil cooler • Unscrew bolt (4) from cylinder block • Release clamp (3) from thermostat housing • Remove gasket

20. 20. Detach oil filter housing oil cooler (1) • Unscrew 4x bolts (2) • Remove gasket (3)

21. 21. Detach glow plug wiring harness (1) • Disconnect 4x wiring harness connectors (3) • Unscrew 2x bolts (2) from bracket

22. 22. Detach compressor (1) from compressor bracket (2) • Unscrew 3x bolts (3)

23. 23. Detach compressor support (1) • Unscrew 4x bolts

24. 24. Detach water pump coolant line (1) • Unscrew 2x bolts

25. 25. Detach retaining plate, diesel particulate filter catalytic converter (1) • Unscrew 2x bolts

26. 26. Remove crankshaft sensor (1) • Unscrew bolt (2)

27. 27. Unscrew oil temperature sensor (1)

28. 28. Remove alternator • Unscrew 3 bolts

29. 29. Detach vacuum line, vacuum pump to vacuum tank • Unclip from bracket in 4 places
30. 30. Detach vacuum tank (1) • Detach 2x vacuum lines • Unscrew 2x bolts (2)

31. 31. Detach oil dipstick guide tube (1) • Unscrew bolts (2) from intake manifold • Pull oil dipstick guide tube out of cylinder block

32. 32. Detach engine vent hose (1) • Unscrew 2x bolts (2) • Disconnect engine vent hose quick-release fitting (3) from oil separator

33. 33. Detach alternator support (1) • Unscrew 3x bolts (2)

34. 34. Detach oil separator (3) • Unscrew 2x bolts (5) from flange on cylinder block – Remove gasket • Unscrew 2x bolts (4) oil separator on intake manifold • Unclip timing case vent hose from retaining clip (1) • Release clamp (2)

35. 35. Detach pipe, diesel particulate filter differential pressure line (2) • Unscrew 2x bolts • Release clamp differential pressure sensor

36. 36. Detach throttle valve module bracket (1) • Unscrew 2x bolts (2)

37. 37. Detach metal pipe for exhaust gas recirculation (3) • Unscrew 2x bolts (1) from flange of exhaust gas recirculation valve • Unscrew 3x bolts (5) from intake manifold • Remove gasket (4) • Remove seal ring (2)

38. 38. Detach exhaust gas recirculation cooler (2) • Unscrew 3x bolts (3) • Remove gasket (1)

39. 39. Detach starter • Unscrew 2x bolts (1)

40. 40. Detach 4x high pressure lines (1) from pressure reservoir to injectors • Unscrew 8x union nuts
41. 41. Detach high pressure line (2) of high pressure pump to the pressure reservoir • Unscrew 2x union nut

42. 42. Detach pressure reservoir (3) with pressure reservoir bracket (4) • Unscrew 3x bolts (1) • Remove engine transport shackle (2)

43. 43. Remove oil leak line (1) • Detach fuel return pipe (2) – Unscrew bolt from vacuum pump – Release clamp high-pressure pump • Unlock 4x retaining clamps (3) in direction of arrow

44. 44. Remove 4x injectors (1) • Detach 2x injector bracket (7) – Unscrew 2x nut (2) – Remove 2x washers (3) – Remove 2x conical washers (4) • Remove 4x seal rings (5) • Remove 4x seals (6) from camshaft housing • Seal 4x injector with protective cap

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

45. 45. Place collecting pan underneath.
46. 46. Drain engine oil • Unscrew drain bolt • Tighten drain bolt 20 Nm
47. 47. Turn engine 180°
48. 48. Remove transmission bracket (2) • Detach from cylinder block base plate – Unscrew 4x bolts (1)

Note. Note different bolt lengths!

49. 49. 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).

50. 50. Turn engine 180°
51. 51. Remove 2x closure bolt from camshaft housing

52. 52. Clean 4x threads • From closure bolts • From camshaft housing
53. 53. 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).

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

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

Note. Left-handed thread.

56. 56. Detach timing case (2) • Unscrew 14x bolts (3) • Unscrew 3x nut (4) • Remove gasket (1)

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

58. 58. Remove timing chain tension rail • Unscrew bolt (1)

59. 59. Remove timing chain sliding rail (2) • Unscrew 2x bolts (1)

60. 60. Slacken camshaft drive gear • Unscrew bolt • Counterhold with KM-6347 (1) and KM-956-1 (2) on camshaft drive gear

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

63. 63. Detach bracket (1) from camshaft housing • Unscrew 2x bolts

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

Note. Note different bolt lengths!

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

Note. Set aside in the order removed!

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

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

Note. Undo bolts in order shown.

68. 68. Remove cylinder head

Note. Use a second person

69. 69. Remove cylinder head gasket

70. 70. Remove EN-46778
71. 71. Remove flywheel • Attach EN-652 • Unscrew 8x bolts • Detach EN-652
72. 72. Transfer short block engine to KM-412
73. 73. Clean components and sealing surfaces

Install

74. 74. Tap guide sleeves into cylinder block • 4x guide sleeves with EN-427

75. 75. 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
76. 76. Install rear crankshaft seal ring (1) with EN-46777-10 (2)

77. 77. Fit flywheel • Attach EN-652 • Tighten 8x bolts 44 Nm – Use new bolts • Detach EN-652
78. 78. 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

79. 79. Adjust TDC combustion stroke - cylinder 1 • Insert KM-571-B into KM-301 • Position KM-301 with KM-571-B on cylinder block • Position probe of KM-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.

80. 80. Measure piston projection • Position probe of KM-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!

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

81. 81. 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!

82. 82. Lock crankshaft • Insert EN-46778 (1) through flywheel (2) into cylinder block – Turn crankshaft until EN-46778 can be locked

83. 83. 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
84. 84. Measure height of cylinder head • Sealing surface to sealing surface • Measurement I: = 105.45 - 105.55 mm

85. 85. Insert cylinder head

Note. Use a second person

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

Note. Do not tighten bolts!

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

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

Note. Note correct tightening sequence!

89. 89. Insert 16x roller cam follower

Note. Note removal sequence!

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

Note. Note "TOP" marking!

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

92. 92. 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!

93. 93. Attach wiring harness bracket to camshaft housing • Tighten 2x bolt 9 Nm
94. 94. Attach timing chain oil spray nozzle • Tighten 2x bolt 6 Nm
95. 95. Insert timing chain with camshaft drive gear and crankshaft drive gear
96. 96. Attach timing chain sliding rail • Tighten 2x bolt 9 Nm
97. 97. Attach timing chain tension rail • Tighten bolt 9 Nm
98. 98. Attach timing chain tensioner • Tighten 2x bolt 9 Nm • Tension timing chain tensioner – Remove KM-955
99. 99. Fasten camshaft drive gear • Tighten bolt 150 Nm • Counterhold with KM-6347 and KM-956-1 on camshaft drive gear

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

100. 100. 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)
101. 101. 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

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

103. 103. 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.

104. 104. Remove EN-46778
105. 105. 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 crankshaft balancer flange until reference drift EN-46781 engages audibly in both camshafts
106. 106. Check crankshaft position EN-46778 . Insert through bore in flywheel. • Turn crankshaft carefully by the bolt on the crankshaft balancer flange until EN-46778 engages in cylinder block

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

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

Note. Complete assembly within 10 minutes.

109. 109. Turn engine by 180°
110. 110. Apply sealing compound

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

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
113. 113. Turn engine by 180°
114. 114. Clean 4x injector seat with EN-47632 • Loosen dirt with the brush side (1) • Remove dirt with the sponge side (2)

115. 115. Install 4x injector • Remove 4x injector protective caps • Replace 4x injector shaft seal ring • Replace 4x injector seal ring (1) • Attach 2x injector brackets – Insert 2x conical washers – Insert 2x washers – Tighten 2x nut 20 Nm

116. 116. Install oil leak line • Attach fuel return pipe – Tighten screw on vacuum pump 9 Nm – Fasten clamp on high-pressure pump • Lock 4x retaining clamps
117. 117. Attach pressure reservoir with pressure reservoir bracket • Insert engine transport shackle • Tighten 3x bolts 25 Nm
118. 118. Attach 4x high pressure lines from pressure reservoir to injectors • Tighten 4x union nut M14 28 Nm • Tighten 4x union nut M12 24 Nm
119. 119. Install high pressure line from high pressure pump to accumulator • Use new high pressure line • Tighten union nut M14 28 Nm • Tighten union nut M12 24 Nm
120. 120. Fit starter • Tighten 2x bolt 25 Nm
121. 121. Attach exhaust gas recirculation cooler • Insert new gasket • Tighten 3 bolts 22 Nm • Insert new gasket
122. 122. Attach metal pipe, exhaust gas recirculation • Check seal ring for damage • Insert new gasket • Tighten 2x bolts on flange of exhaust gas recirculation valve 9 Nm • Tighten 3x bolts on intake manifold 9 Nm
123. 123. Attach throttle valve module bracket • Tighten 2x bolt 9 Nm
124. 124. Attach pipe, diesel particulate filter differential pressure line • Fasten clamp on differential pressure sensor • Tighten 2x bolt 9 Nm
125. 125. Attach oil separator • Tighten 2x bolts, flange on cylinder block 9 Nm – Insert new gasket • Tighten 2x bolts, oil separator on intake manifold 9 Nm • Fasten clamp • Clip timing case vent hose into retaining clip
126. 126. Attach alternator support • Tighten 3 bolts 22 Nm
127. 127. Attach engine vent hose • Tighten 2x bolt 8 Nm • Connect quick-release fitting, engine vent hose to oil separator
128. 128. Attach dipstick guide tube • Tighten bolt on intake manifold 9 Nm • Insert new gasket • Insert oil dipstick guide tube into cylinder block
129. 129. Attach vacuum tank • Attach 2x vacuum line • Tighten 2x bolt 9 Nm
130. 130. Attach vacuum line, vacuum pump to vacuum tank • Clip in bracket in 4 places
131. 131. Install alternator • Tighten 3 bolts 22 Nm
132. 132. Tighten oil pressure sensor 32 Nm
133. 133. Attach crankshaft sensor • Tighten bolt 9 Nm
134. 134. Attach retaining plate, diesel particulate filter catalytic converter • Tighten 2x bolt 25 Nm
135. 135. Attach water pump coolant line • Tighten 2x bolt 9 Nm
136. 136. Attach compressor support • Tighten 4x bolts 22 Nm
137. 137. Attach compressor to compressor bracket • Tighten 3 bolts 22 Nm
138. 138. Attach glow plug wiring harness • Connect 4x wiring harness plugs • Tighten 2x bolts on bracket 9 Nm
139. 139. Attach oil filter housing oil cooler • Insert new gasket • Tighten 4x bolts 9 Nm
140. 140. Attach coolant line, oil cooler thermostat housing • Insert new gasket • Tighten 2x bolts on oil cooler 9 Nm • Tighten bolt on cylinder block 9 Nm • Fasten clamp on thermostat housing
141. 141. Attach exhaust manifold • Clean sealing surfaces. – From exhaust manifold to cylinder head – From exhaust manifold to turbocharger • Insert new gasket • Tighten 10x nuts 15 Nm + 30°
142. 142. Attach exhaust manifold heat shield • Tighten 2x nuts on exhaust manifold 9 Nm • Fit engine transport shackle – Tighten bolt 25 Nm
143. 143. Attach turbocharger • Clean sealing surface • Insert new gasket • Tighten 3x nut 25 Nm
144. 144. Attach oil feed line • Tighten banjo bolt on turbocharger 12 Nm – Insert 2x new seal rings • Tighten banjo bolt on oil cooler 12 Nm – Insert 2x new seal rings
145. 145. Attach turbocharger oil return hose • Fasten 2x clamps to turbocharger and oil cooler
146. 146. Attach catalytic converter with diesel particulate filter to turbocharger • Set up clamp • Tighten 2x nuts on diesel particulate filter bracket 25 Nm • Tighten clamp 25 Nm • Attach differential pressure sensor hose – Fasten clamp
147. 147. Install diesel particulate filter temperature sensor • Clip wiring harness connector into bracket • Tighten temperature sensor on diesel particulate filter 45 Nm
148. 148. Install catalytic converter oxygen sensor • Tighten oxygen sensor on catalytic converter with KM-6179 45 Nm • Clip oxygen sensor wiring harness into retaining clip • Clip oxygen sensor wiring harness connector into bracket
149. 149. Install turbocharger heat shield • Tighten 3x bolt 9 Nm
150. 150. Attach right engine damping block adapter • Insert engine transport shackle • Tighten 4 bolts 60 Nm
151. 151. Install coolant pump • Use new gasket • Tighten 4x nuts 9 Nm
152. 152. Install torsional vibration damper • Tighten 4x bolts 25 Nm

Note. Counterhold against bolt, torsional vibration damper flange.

153. 153. Install ribbed V-belt tensioner • Tighten bolt 50 Nm • Apply tension to ribbed V-belt tensioner clockwise at bolt of tension roller of tensioner, insert KM-6130
154. 154. Insert ribbed V-belt • Observe rotational direction of ribbed V-belt • Position ribbed V-belt • Apply tension to ribbed V-belt tensioner clockwise at the tension roller bolt • Remove KM-6130
155. 155. Fill and correct engine oil level • Observe specified oil quantity
156. 156. Detach engine from KM-412 • Hitch engine up to engine crane. • Detach KM-412 from cylinder block on transmission side • Hitch engine up to engine crane.
157. 157. Install thrust plate with clutch disc
158. 158. Attach manual transmission to engine
159. 159. Install engine

1

) ; protective caps are available in the Opel parts catalogue.