Repair Engine Using a Short Block Engine Opel Meriva A

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

Important: When working with fuel systems, cleanliness must be ensured at all times since even the smallest dirt particles can lead to disruptions of engine operation or in the fuel system. Plug open fuel fittings with suitable sealing plugs. 1) Sealing plugs are intended for single use only.

Remove

1. 1. Remove engine
2. 2. Detach manual transmission from engine
3. 3. Detach starter • Detach 2x wiring harnesses – Unscrew 2x nut • Unscrew 2x bolt (1)

4. 4. Remove thrust plate with clutch disc
5. 5. Block 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 through 90°
9. 9. Remove transmission bracket (2) • Detach from cylinder block base plate – Unscrew 4x bolt (1)

Note. Note different bolt lengths!

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

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

11. 11. Turn engine through 90°
12. 12. Detach intake side engine wiring harness • Disconnect 4x injector wiring harness plugs • Separate 4x sheathed glow plug wiring harness plugs • Disconnect wiring harness plug of camshaft sensor • Disconnect crankshaft sensor wiring harness plug • Disconnect wiring harness plug for coolant temperature sensor
13. 13. Detach exhaust side engine wiring harness • Disconnect rail pressure sensor wiring harness plug • Disconnect charge pressure sensor wiring harness plug • Disconnect rail pressure controller wiring harness plug • Disconnect exhaust gas recirculation wiring harness plug
14. 14. Detach engine wiring harness • Unclip 2x from bracket • Unscrew 3x bolt
15. 15. Place collecting basin underneath

Important. After removing the pressure lines, plug the openings of the injectors, high pressure pump and accumulator with protective caps (protective caps can be ordered from the parts catalogue).

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

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

Note. Remove engine transport shackle

18. 18. Detach exhaust gas return valve (1) with exhaust gas recirculation cooler • Detach exhaust gas recirculation tube from intake manifold – Release clamp • Detach coolant hose from thermostat housing – Release clamp • Unscrew 2x bolt

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

21. 21. Detach cylinder block ventilation outlet connection (1) • Unscrew 6 bolts

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

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

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

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

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

27. 27. Detach right engine damping block adapter (1) • Unscrew 4x bolt

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

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

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

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

Note. Left hand thread

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

33. 33. Remove 2x screw plugs from camshaft housing

34. 34. Clean 4x threads • From closure bolts • From camshaft housing
35. 35. Lock camshafts in position • Screw in 2x camshaft reference drift EN-46781 (1) • Ensure correct installation position • Turn camshafts to and fro at camshaft drive gear bolt 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 and 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 bolt
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 clamps (2) in direction of arrow

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

Note. Injectors (2) can only be removed in pairs (cylinders 1 and 2 or cylinders 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. Unfasten bolts in the order shown

48. 48. Remove cylinder head

Note. Use a second person

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

Install

53. 53. Drive guide sleeves into cylinder block • 4x guide sleeves 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

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

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. Set cylinder no.1 ignition TDC • Insert MKM-571-B in KM-301 • Place KM-301 with MKM-571-B onto cylinder block • Place tip of MKM-571-B onto piston head • Set dial to zero – Note pre-tension! • Rotate engine in direction of rotation

Note. Determine cylinder no.1 highest point 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 – Take measurements at two different points (3 and 4) or (5 and 6)

Note. Note pre-tension!

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

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 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 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

67. 67. Fasten cylinder head • Tighten 10x new 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 mark ("TOP")

70. 70. Align camshaft housing (1) • Align in relation to cylinder head with straight edge (2)

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

Note. Pay attention to longer bolt (14). Pay attention to tightening order!

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

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

74. 74. Attach oil leak line • Release 4x retaining clamps
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. Fit timing chain tension rail • Tighten bolt 9 Nm
80. 80. Fit timing chain tensioner • Tighten 2x bolt 9 Nm • Relax 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 sealing compound (grey) to the transitions between the cylinder head and camshaft housing (1) and between the cylinder block and cylinder head (2)
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. Push front crankshaft seal ring (2) onto sealing surface torsional vibration damper flange (1).

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

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

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

Note. Left hand thread

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

Note. If EN-46778 cannot be inserted into cylinder block, the adjusting procedure must be repeated

91. 91. Unscrew 2x camshaft reference bolts EN-46781
92. 92. Install 2x screw plugs • Coat 2x plugs with screw locking compound (red) • Tighten 2x closure bolt 15 Nm

Note. Complete installation within 10 minutes

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

Note. Use new gasket, coat seal with silicone grease, coolant pump journal must point toward oil filler neck.

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

Note. Note different bolt lengths!

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

Note. Use new gasket, coat seal with silicone grease!

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

Note. Coat gasket with silicone grease.

101. 101. Attach coolant pipe of thermostat housing 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 seal.

102. 102. Attach cylinder block ventilation outlet connection • Use 3x new seals • Tighten 6x 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 2x bolt 9 Nm
104. 104. Attach oil dipstick guide tube • Use new seal • Tighten bolt 9 Nm
105. 105. Attach exhaust gas recirculation valve with exhaust gas recirculation cooler • Use new seal • Tighten 2x bolts 22 Nm • Attach exhaust gas recirculation pipe to intake manifold – Tighten clamp • Attach coolant hose to thermostat housing. – Fasten clamp
106. 106. Install accumulator with bracket • Tighten 3x bolt 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 plug

Note. Insert engine transport shackle

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

Note. Note the 2x ground cables!

109. 109. Attach engine wiring harness • Clip 2x in bracket • Tighten 3 bolts
110. 110. Attach exhaust side engine wiring harness • Connect wiring harness plug of rail pressure sensor • Connect charge pressure sensor wiring harness plug • Connect wiring harness plug of rail pressure sensor • Connect exhaust gas recirculation valve wiring harness plug
111. 111. Attach intake side engine wiring harness • Connect 4 injector wiring harness plugs • Connect 4x sheathed glow plug wiring harness plugs • Connect wiring harness plug of camshaft sensor • Connect crankshaft sensor wiring harness plug • Connect coolant temperature sensor wiring harness plug
112. 112. Rotate engine by 180°
113. 113. Apply sealing compound

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

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

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

Note. Note different bolt lengths!

116. 116. Rotate engine by 180°
117. 117. Top up engine oil and correct oil level • Note prescribed oil quantity
118. 118. Install thrust plate with clutch disc
119. 119. Attach starter • Tighten 2 bolts • Attach 2x wiring harnesses – Tighten 2x bolt 25 Nm
120. 120. Attach transmission to engine
121. 121. Install engine

1

) Protective caps can be ordered from the parts catalogue