Replace Both Camshafts 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 sealing plugs1. Sealing plugs are intended for single use.

Remove

1. 1. Open bonnet
2. 2. Remove engine cover (1) • Pull off engine cover – Unclip coolant return hose from bracket – Unclip vacuum line (2) from bracket

Note. Rubber retainers (3) must remain on engine cover.

3. 3. Disconnect battery • Detach ground connection (1) from ground terminal – Slacken nut

4. 4. Remove battery tray
5. 5. Remove air cleaner housing (1) with air intake hose (5) • Disconnect 2x wiring harness plugs (2) • Remove air intake hose from turbocharger – Release clamp (4) • Detach oil separator hose from air intake hose – Release clamp (3) • Detach water drain hose from lower part of air cleaner housing – Pull off hose from air cleaner housing • Detach air cleaner housing from wheel housing – Press out from rubber retainer in 3 places

6. 6. Remove coolant expansion tank • Unscrew bolt (1)

7. 7. Remove brake force amplifier vacuum line
8. 8. Detach charge air pipe (1) from throttle valve module (3) • Unscrew 2x bolts (2) • Detach charge air pipe from transmission bracket – Unscrew bolt

9. 9. Disconnect wiring harness connector (black) from glow-control unit • Unclip wiring harness
10. 10. Remove mixture regulation oxygen sensor
11. 11. Detach turbocharger heat shield (1) • Unscrew 2x nut (2) • Undo nut (3)

12. 12. Detach engine vent hose • Unscrew 2x bolts • Disconnect wiring harness connector. • Remove vacuum hose • Separate plug connection
13. 13. Remove dipstick guide tube • Unscrew bolt
14. 14. Remove 2x fuel line • Seal connections with KM-807 or KM-6015
15. 15. Expose engine management wiring harness • Remove 18x wiring harness plug – Camshaft sensor, wastegate unit, high-pressure pump, oil pressure switch, crankshaft sensor, 4x glow plugs, 4x injectors, throttle valve module, coolant temperature sensor, charge air sensor, rail pressure sensor, differential pressure sensor
16. 16. Detach 2x wiring harness brackets from camshaft housing • Unscrew 4x bolts
17. 17. Detach wiring harness from intake manifold • Unscrew 2x bolts • Detach differential pressure pipe bracket • Unscrew bolt
18. 18. Fix wiring harness
19. 19. Detach oil filler port from timing case • Unscrew 2x bolts
20. 20. Remove oil leak line (1) • Detach from fuel return pipe (2) • Unlock 4x retaining clamps (3) in direction of arrow

Important. Counterhold bolt at high pressure pump with open-ended wrench

21. 21. Remove high pressure line of high pressure pump (3) from accumulator (1) • Unscrew 2x union nut

Important. Counterhold bolt at injector with open-ended wrench.

22. 22. Detach 4 high pressure lines from accumulator to injector (4) • Unscrew 8x union nut
23. 23. Detach accumulator • Unscrew 2x bolts (2)

24. 24. Undo 2x front wheels
25. 25. Raise vehicle by half its height
26. 26. Detach 2x front wheels
27. 27. Remove engine splash guard
28. 28. Remove 2x front wheelhouse front liner
29. 29. Lower vehicle
30. 30. Remove engine compartment electronics module (1) • Unclip from bracket • Rotate the fuse box clockwise and release • Release left headlamp wiring harness plug and pull it off • Free the wiring harness in the vicinity of the left headlamp

31. 31. Detach wiring harness bracket (2) • Unclip 2 wiring harnesses (3) • Unscrew nut (1)

32. 32. Use CH-48373-3 (left-hand) • Unfold support (1)

Note. Use a second person to hold the engine compartment electronics module

33. 33. Attach support frame and engine bridge
34. 34. Secure the engine • Attach 2x hooks to engine transport shackle
35. 35. Detach right engine damping block • Unscrew 3 side member bolts (1) • Unscrew 3 bolts (2) from the engine damping block support

36. 36. Screw 3x bolts of engine damping block into side member

Note. Use suitable washers under the bolts to even up height of engine damping block

37. 37. Insert CH-48373-2 (right-hand) from above • Unfold support (1)
38. 38. Raise vehicle by its full height
39. 39. Attach CH-48373-7 (1) to transmission • Tighten 2 bolts (2)

40. 40. Place KM-904 (2) and CH-48373-1 with CH-48373-12 (3) on hydraulic jack (4) • Attach 2x retaining pins • Attach 2x cotter pins (1) • Attach CH-48373-11 (5) • Place probes (arrows) downward
41. 41. Support engine and transmission with hydraulic jack • Connect CH-48373-2 (1) and CH-48373-3 (1) to CH-48373-1 • Tighten 4 bolted connections • Screw support (2) up until it is pressing gently against the rear reaction member bracket • Screw support (3) up until it is pressing gently against CH-48373-7 • Screw support (4) up until it is seated under gentle pressure in the hole provided for it in the cylinder block

42. 42. Extend the hydraulic jack
43. 43. Lower vehicle by its full height
44. 44. Remove the engine bridge and support frame
45. 45. Remove engine damping block adapter (1) • Unscrew 4x bolts (2)

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

47. 47. Remove 4x injector (3) • Remove 2x injector bracket (2) – Unscrew 2x nuts (1) • Remove 4x seal ring (arrows) • Seal 4x injector with protective cap

Note. If the injectors cannot be removed manually, use EN-46786 connected to KM-328-B .

48. 48. Remove closure bolt (arrow) from intake side of camshaft housing

49. 49. Disconnect intake camshaft • Screw in camshaft reference drift EN-46781 (1) • Ensure correct installation position

Note. Apply guidance marking on reference drift (arrow).

Note. Reference drift fixing must be installed in a horizontal position.

50. 50. Lock intake camshaft • Turn crankshaft in direction of engine rotation until EN-46781 engages in camshaft
51. 51. Lock crankshaft • Insert EN-46785 (1) through hole in transmission bell housing • Carefully turn crankshaft bolt until EN-46785 engages in flywheel

52. 52. 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)

Note. The ribbed V-belt must be removed to prevent contamination.

53. 53. Remove closure bolt (1) from timing case
54. 54. Remove chain tensioner closure cap (2) • Unscrew 4x screw (arrows)

Note. Reuse gaskets.

55. 55. Remove high pressure pump
56. 56. Remove vacuum pump

Important. Note loosening sequence. Loosen the intake camshaft bolt first.

57. 57. Slacken 2x camshaft sprocket • Slacken bolt (2) of intake camshaft sprocket • Slacken bolt (1) of exhaust camshaft sprocket

Note. 2. persons required.

58. 58. Undo bolt of exhaust camshaft drive gear

Note. Do not remove the bolt yet.

59. 59. Tension timing chain tensioner • Apply tension to chain tensioner (1) using a suitable tool, lock in pre-tensioned position KM-955-1 (2)

60. 60. Detach exhaust camshaft drive gear • Unscrew fastening bolt • Using a bent piece of rigid wire (1), pull drive gear from exhaust camshaft

Note. Bolt is to be re-used.

61. 61. Release timing case top from camshaft housing • Unscrew 5x bolts (arrows)
62. 62. Detach engine cover bracket • Unscrew bolt (1)

63. 63. Remove camshaft sensor (2) • Unscrew bolt (1)

64. 64. Release camshaft housing (3) • Unscrew 16x bolt (2) • Unscrew 2x threaded pin (1) • Remove gasket (4)

Note. Note different bolt lengths.

65. 65. Remove camshaft housing • Carefully slide camshaft housing from timing case and remove it. • Remove gasket

Note. Carefully lever camshaft housing off timing case gasket with plastic wedge and use a rubber mallet to knock it off the timing case. Place camshaft housing on suitable support

66. 66. Detach EN-46781
67. 67. Unscrew closure bolt from camshaft exhaust side
68. 68. Remove intake camshaft • Unscrew bolt • Remove sprocket

Note. Note marking (IN)

69. 69. Remove exhaust camshaft • Unscrew bolt • Remove sprocket

Note. Note marking (EX)

Install

Important. The plane parallel surfaces (surface pressure) must be free of oil and grease.

70. 70. Install exhaust camshaft • Moisten bearing surfaces with engine oil • Insert camshaft sprocket – Screw in bolt

Note. Note marking (EX)

71. 71. Install intake camshaft • Moisten bearing surfaces with engine oil • Insert camshaft sprocket – Screw in bolt

Note. Note marking (IN)

72. 72. Attach 2x EN-46781 in camshaft housing • Position 2x camshaft • Ensure correct installation position

Note. Reference drift fixing must be installed in a horizontal position.

73. 73. Tighten 2x camshaft bolts • Tighten 2x bolt 20 Nm

Note. This torque merely secures the components.

74. 74. Fix the camshaft housing to a suitable substrate

Note. Secure the camshaft housing to prevent it from slipping or tilting

75. 75. Tighten 2x camshaft bolts • 2x bolt 150 Nm • Remove EN-46781 from the exhaust side

Note. 2. persons required.

76. 76. Install exhaust camshaft closure bolt • Coat closure bolt with locking compound • Tighten closure bolt 15 Nm
77. 77. Remove timing case gasket • Cut into the elastomer sealing lips (arrows) using a sharp knife pressed against the cylinder head, • With a plastic spatula, loosen the seal from the timing case and carefully snap it off at the designated point (1) • Remove gasket • Remove any gasket residue and clean all sealing surfaces thoroughly

Note. Make sure that no residues remain at the joint between the timing case and cylinder head, and that no bits of the gasket fall into the timing case.

78. 78. Fit timing case gasket • Using a sharp knife, cut into the elastomer sealing lips (arrows) at the breaking points of the new gasket

79. 79. Cut the new timing case gasket off at the lower breaking points • Using pincers (1), cut the seal at both breaking points (arrow)

Note. It is essential for the cutting tool to have a straight cutting surface.

Important. The upper new gasket and the old lower gasket must not be allowed to overlap.

80. 80. Fit new timing case gasket • Using the pincers, fit the new gasket (1) to the contact surface between the cylinder block and the timing case until the seal lies flush on the cylinder head and timing case (arrows) and the holes in the gasket and the timing case match up.

81. 81. Clean contact surfaces • Clean any oil and grease off the exhaust camshaft, drive gear, bolt and thread in exhaust camshaft
82. 82. Attach new camshaft housing gasket • Clean all sealing surfaces • Apply sealant to contact surfaces (1) of cylinder head and timing case • Place gasket on camshaft housing

83. 83. Install camshaft housing • Remove 2x fastening bolts and nuts from timing case gasket • Position camshaft housing • Screw in 16x bolts according to tightening sequence until the camshaft housing is lying evenly on the cylinder head, but do not tighten them yet

Note. Note longer bolt (14)

84. 84. Fasten timing case to camshaft housing • Carefully align the camshaft housing on the timing case, using the rubber mallet. • Screw in 5x bolt (arrows) until the camshaft housing is in contact with the timing case

85. 85. Fasten the crankshaft housing • Tighten 16x bolt, observing the correct tightening sequence 18 Nm • Tighten 2x stud bolt 25 Nm

86. 86. Tighten all bolts holding timing case to camshaft housing • Tighten 5x bolts 9 Nm

Important. The exhaust camshaft, drive gear, bolt and thread in exhaust camshaft must be free of oil and grease.

87. 87. Place drive gear on exhaust camshaft • Position drive gear on exhaust camshaft using a suitable tool • Screw in bolt

Note. Don not tighten yet!

88. 88. Tension timing chain tensioner • Release the timing chain tensioner, using a suitable tool • Remove KM-955-1
89. 89. Fasten the exhaust camshaft drive gear • Tighten bolt 150 Nm

Note. A second mechanic must hold the timing chain tensioner (1) under tension with a suitable tool (2) while the gear is being tightened.

90. 90. Install high pressure pump
91. 91. Install vacuum pump
92. 92. Remove the intake camshaft stop • Remove camshaft reference drift EN-46781
93. 93. Remove crankshaft stop • Remove EN-46785
94. 94. Timing, Check • Turn crankshaft in the direction of engine rotation by the bolt on the crankshaft balancer flange by approx. 700 ° (2 revolutions) • Install camshaft reference drift EN-46781 in intake camshaft housing • Turn crankshaft in direction of engine rotation until EN-46781 engages in exhaust camshaft • Turn crankshaft until EN-46785 engages in flywheel • If EN-46785 does not engage in flywheel, the timings must be reset
95. 95. Remove locking tool • Remove EN-46785 and EN-46781
96. 96. Install intake camshaft closure bolt • Coat closure bolt with locking compound • Tighten closure bolt 15 Nm
97. 97. Install timing case closure bolt • Check seal for damage • Tighten closure bolt
98. 98. Install timing case closure cap • Check seal for damage • Tighten 4x bolts 9 Nm
99. 99. Insert ribbed V-belt • Apply tension clockwise to tensioner at tension roller bolt • Remove KM-6130 • Note direction of rotation
100. 100. Install engine damping block adapter • Tighten 4 bolts 60 Nm
101. 101. Install accumulator bracket with engine transport shackle • Tighten 3x bolts
102. 102. Clean 4x injector seat with EN-47632 • Loosen dirt with the brush side (1) • Remove dirt with the sponge side (2)

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

104. 104. Install camshaft sensor • Replace sealing ring • Tighten bolt 7 Nm
105. 105. Attach the engine bridge and support frame
106. 106. Secure the engine • Attach 2x hooks to engine transport shackle
107. 107. Raise vehicle by its full height
108. 108. Bring in hydraulic jack with KM-904 and support CH-48373 • Insert 2x cotter pins
109. 109. Remove CH-48373-2 and CH-48373-3 from CH-48373-1 • Remove 4 bolted connections • Swing out 2x support
110. 110. Bring out hydraulic jack with KM-904 and CH-48373
111. 111. Detach CH-48373-7 from transmission • Unscrew 2x bolts
112. 112. Lower vehicle by its full height
113. 113. Remove CH-48373-2 (right)
114. 114. Remove CH-48373-3

Note. Use a second person

115. 115. Unscrew 3 bolts from side member
116. 116. Fit right-hand engine damping block to longitudinal beam • Tighten 3x bolt 60 Nm
117. 117. Fit right-hand engine damping block to support • Insert 3x new bolts • Tighten 3x bolt 80 Nm + 45°
118. 118. Detach engine
119. 119. Remove the engine bridge and support frame
120. 120. Attach accumulator • Screw in 2x bolts
121. 121. Attach 4x high pressure line from injector to accumulator • Fit 4x new high pressure line • Tighten 8x union nut hand-tight
122. 122. Attach high pressure line of high pressure pump to accumulator • Replace high pressure line • Tighten 2x union nut hand-tight
123. 123. Tighten accumulator • Tighten 2x bolt 25 Nm

Important. Counterhold bolt at injector with open-ended wrench.

124. 124. Fasten 4x high pressure line from injector to accumulator • Tighten 4x union nut M14 28 Nm • Tighten 4x union nut M12 24 Nm

Important. Counterhold bolt at high pressure pump with open-ended wrench

125. 125. Fasten high pressure line from high pressure pump to accumulator • Tighten union nut M14 28 Nm • Tighten union nut M12 24 Nm
126. 126. Install oil leak line • Attach to fuel return pipe
127. 127. Attach engine wiring harness • Install engine cover bracket – Tighten bolt • Attach 2x wiring harness brackets to camshaft housing – Tighten 6x bolts • Push on 18x wiring harness plug
128. 128. Attach 2x fuel line
129. 129. Fit charge air pipe at throttle valve module • Tighten 2x bolt 8 Nm • Attach charge air pipe to transmission bracket – Tighten bolt
130. 130. Connect vacuum line for brake force amplifier
131. 131. Attach engine compartment electronics module • Clip into bracket • Plug in left-hand headlamp wiring harness plug and lock it • Route the wiring harness in the vicinity of the left headlamp
132. 132. Install wiring harness bracket • Clip in 2x wiring harnesses • Tighten nut
133. 133. Install battery holder
134. 134. Attach glow-control unit • Connect wiring harness connector (black) • Lay wiring harness
135. 135. Attach coolant expansion tank • Tighten bolt
136. 136. Attach oil filler port to timing case • Tighten 2x bolts
137. 137. Raise vehicle by half its height
138. 138. Install 2x front wheelhouse front liners
139. 139. Attach right engine splash guard
140. 140. Attach 2x front wheel • Screw in 8 bolts
141. 141. Lower vehicle
142. 142. Tighten 2x front wheels • Tighten 8x bolts 110 Nm
143. 143. Install mixture regulation oxygen sensor in return manifold • Apply special grease to thread • Tighten oxygen sensor 45 Nm • Use km-6129 • Connect wiring harness plug • Attach wiring harness
144. 144. Fasten oil dipstick guide tube • Tighten bolt
145. 145. Install air cleaner housing with air intake hose • Attach air cleaner housing with air intake hose – Push on 2x wiring harness plug • Attach air intake hose to turbocharger – Fasten clamp • Attach oil separator hose to air intake hose – Fasten clamp • Attach water drain hose to lower part of air cleaner housing • Push hose onto air cleaner housing • Attach air cleaner housing to wheelhouse – Press in 3 rubber retainers
146. 146. Install engine cover
147. 147. Connect battery • Attach earth clamp to earth terminal – Tighten nut
148. 148. Program volatile memories
149. 149. Close bonnet