Repair Engine Using a Part-Engine Opel Omega B

Remove

1. 1. Remove engine • see operation "Engine, Remove and Install"
2. 2. Attach engine to engine assembly stands ( KM-412 ) • see operation "Manual Transmission from Engine, Detach and Reattach"
3. 3. Drain engine oil • Place collecting tray underneath • Remove oil drain bolt
4. 4. Remove engine wiring harness • from alternator – Remove 2 nuts • from starter – Remove 2 nuts • Pull off 2 turbocharger control vacuum pipes – from vacuum reservoir, solenoid valve • Detach wiring harness plug for sheathed glow plugs (2) – Use KM-717 (1) • Disconnect wiring harness plug – Oil pressure switch, pressure sensor - intake pipe, pulse pick-up - crankshaft, coolant temperature sensor, sensor - dynamic oil level monitoring, oil temperature sensor, compressor

5. 5. Detach ribbed V-belt • Tension ribbed V-belt tensioner at hex lug (1) anti-clockwise (arrow) • Remove ribbed V-belt

Note. Mark direction of rotation

6. 6. Remove ribbed V-belt tensioner • Remove 2 bolts (1), (2)

Important. Damper (3) may only be stored in upright position. Incorrectly stored dampers may be bled by repeated compression in installation position.

7. 7. Remove support, auxiliary units • Unscrew fastening bolts (1) • Remove with pump, auxiliary power steering

8. 8. Remove alternator • Remove 2 bolts • Remove 1 nut • Remove coolant hose bracket
9. 9. Remove compressor (1) • Remove 3 bolts
10. 10. Remove compressor main bracket • Remove 2 bolts

11. 11. Remove timing case cover (1) • Remove 6 bolts

Important. Carefully separate timing case cover from timing case using wide spatula (2) Do not lever off timing case cover or use force to separate it from timing case, as permanent deformation results in leakage.

12. 12. Remove turbocharger heat shield • Remove 3 bolts (1)
13. 13. Detach 2 heat shield plates of exhaust manifold • Remove 2 bolts (2)

Note. Carefully remove right heat shield upwards

14. 14. Detach turbocharger oil feed line (1) • Place collecting tray underneath • Detach union nut

15. 15. Detach exhaust manifold support • Release upper bolt • Remove lower bolt
16. 16. Detach turbocharger oil return line • From cylinder block connection – Detach union nut
17. 17. Remove starter • Remove 1 bolt
18. 18. Detach upper bracket for alternator (coolant flange) • Remove 3 bolts (1) • Remove gasket.

19. 19. Remove cylinder block coolant flange (2) • Remove 2 bolts • Detach coolant hose (1) • Release clamp • Remove gasket.

20. 20. Use KM-977-1 , KM-956-1 (2)

Note. Turn crankshaft until KM-977-1 and KM-956-1 can be installed

21. 21. Release crankshaft ribbed V-belt pulley (1) • Loosen bolt • Remove KM-977-1 and KM-956-1

Note. 2nd person required

22. 22. Detach crankshaft ribbed V-belt pulley • Remove bolt
23. 23. Remove clutch

Note. See operation "Thrust Plate and Clutch Disc, Remove and Install (F 17/F 23/F 35)" in group "K"

24. 24. Remove flywheel • Use KM-652 (1) • Remove 10 bolts

25. 25. Detach injection line brackets • Remove 2 bolts (2)

Note. Mark position of brackets

26. 26. Remove injection lines (1) • Remove 8 union nuts • Use KM-6098

Note. Note installation position.

27. 27. Detach thermostat housing (1) • Detach coolant hose – Release clamp • Remove 4 bolts • Remove gasket.

28. 28. Remove oil dipstick guide tube • Remove 1 bolt
29. 29. Remove oil filter housing (heat exchanger housing) • Open cover of oil filter housing (2) • Attach cover to oil filter housing – Tightening torque 25 Nm / 18 lbf. ft. • Disconnect coolant hoses from heat exchanger housing (1) • Unscrew fastening bolts (3)

Note. Engine oil flows from the oil filter housing into the oil filter housing

Important. Collect escaping fuel

30. 30. Remove 2 fuel lines (1) • Disconnect leak oil hose (2) • Remove 2 banjo bolts (3)

31. 31. Detach vacuum line • From switchover valves vacuum unit • Unclip from brackets
32. 32. Detach vacuum pump (2) • Remove 4 bolts (1) • Remove gasket (3)

33. 33. Disconnect cylinder head cover. • Remove 8 bolts • Remove gasket.
34. 34. Tighten oil drain bolt • Replace seal ring – Tightening torque 10 Nm
35. 35. Remove crankshaft pulse pickup (1) • Remove 1 bolt • Remove Seal ring

36. 36. Fit crankshaft ribbed V-belt bolt
37. 37. Move engine to 1st cylinder ignition TDC

Note. Turn crankshaft uniformly in direction of engine rotation. Mark on crankshaft ribbed V-belt pulley (3) must be located just before the lug (2) on the timing case. Both cams for 1st cylinder (1) must point upwards

38. 38. Use KM-929 (1)

Note. Insert KM-929 into bore for crankshaft pulse pick-up. Turn crankshaft uniformly in direction of engine rotation. KM-929 must latch in to the stop. Marks on crankshaft ribbed V-belt pulley and lug on timing case must align (2).

39. 39. Use KM-927 (3)

Note. Arrow (1) on Simplex fuel injection pump gear must align with the recess in injection pump flange and injection pump retaining bore (2). Insert KM-927 into injection pump retaining bore.

40. 40. Use KM-932 (3)

Note. Place KM-932 on cylinder head. Pin (2) must engage in camshaft bore (1).

41. 41. Remove Simplex chain tensioner (3) • Remove bolt (1), seal ring (2), chain tensioner (3)

Note. Note installation position.

42. 42. Remove guide rail for Simplex chain tensioner (1) • Remove 2 bolts (2) • Remove guide rail upwards

Important. Heat bolts intensively with hot air blower and remove. Use suitable heat shielding

Note. Note installation position.

43. 43. Remove KM-927 and KM-932
44. 44. Remove camshaft sprocket • Remove 1 bolt

Note. Counterhold camshaft at hexagonal section. Attach Simplex timing chain at a suitable place.

45. 45. Loosen cylinder head • Remove 4 bolts (M8) (arrows) • Remove 10 bolts (M12)

Important. Loosen cylinder head bolts in illustrated sequence by first 1/4, then 1/2 turn

Note. Observe different bolt lengths

Important. Place cylinder head on wooden blocks. Do not damage injectors, glow plugs or valves.

46. 46. Remove cylinder head.

Note. 2nd person required

47. 47. Remove cylinder head gasket
48. 48. Remove Duplex chain tensioner (3) • Remove bolt (1), seal ring (2), chain tensioner (3)

Note. Note installation position.

49. 49. Remove Simplex injection pump gear • Remove 4 bolts (1) • Lower Simplex timing chain downwards • Remove Simplex injection pump gear at side • Remove Simplex timing chain upwards

50. 50. Release injection pump • Remove 4 bolts (1) • Use MKM-604-30
51. 51. Remove engine block coolant drain connection • Place collecting tray underneath
52. 52. Remove injection pump • Remove cylinder block bolt – From bracket (2)

53. 53. Remove coolant pump • Place collecting tray underneath • Ribbed V-belt pulley (1) – Remove 3 bolts • Coolant pump (2) – Remove 3 bolts

54. 54. Rotate engine 180°
55. 55. Remove oil pan • Remove 17 bolts • Remove gasket.
56. 56. Detach balancer shaft unit cover (1) • Remove 4 bolts
57. 57. Use KM-978 and KM-979 • Move engine to 1st cylinder ignition TDC • Insert KM-979 (3) • Insert KM-978 (2)

Note. At side in balancer shaft unit

Note. Push back chain tensioner by hand. Insert KM-978 into bores

58. 58. Detach sprocket (4) • Remove bolt (5)

59. 59. Detach balancer shaft unit • Remove 7 bolts (1), (2)

Important. Release bolts from outside inwards

Note. Guide rail (4) and chain tensioner (3) must be transferred when replacing the balancer shaft unit

60. 60. Rotate engine 90°
61. 61. Remove bolt of crankshaft ribbed V-belt pulley
62. 62. Remove timing case • Remove 13 bolts

Note. Observe different bolt lengths

63. 63. Detach tension rail (5) • Remove 1 bolt
64. 64. Detach guide rail for Duplex timing chain (3) • Remove 3 bolts
65. 65. Remove Duplex chain drive • Timing chain (2), crankshaft pulley (4), injection pump gear (1)
66. 66. Remove timing case gasket (6)

Important. Edge seal ring out of timing case with suitable tool – ensure that sealing surfaces are not damaged

67. 67. Remove crankshaft front seal ring, timing case seal ring
68. 68. Remove cylinder block • Use KM-2358 • Suspend engine on workshop crane. • Detach from KM-412-16 and KM-412-8-1 – Remove 6 bolts

Install

69. 69. Attach cylinder block • Use KM-2358 • Raise engine. • Attach KM-412-16 and KM-412-8-1 to engine – Insert 6 bolts – Detach KM-2358
70. 70. Clean sealing surfaces • Timing case, cylinder block, cylinder head, oil pan
71. 71. Inspect components
72. 72. Clean thread. • 2x guide rails for simplex chain tensioner • 6x clutch thrust plates

Important. A spacer washer (1) may be installed on the injection pump flange (2) to adjust the axial dimension. This spacer washer is allocated to the corresponding fuel injection pump and must always be left on the fuel injection pump flange. When installing a new fuel injection pump, this is supplied with the axial dimension adjusted, i.e. with or without spacer washer (1)

73. 73. Insert injection pump. • Replace seal ring • Insert 4 bolts (3)

Note. Coat with silicon grease (white)

74. 74. Secure injection pump • Tighten 4 bolts (3) – Use MKM-604-30 – Tightening torque 25 Nm / 18 lbf. ft. • Attach injection pump bracket – Tightening torque 20 Nm

75. 75. Fit engine block coolant drain connection • Replace seal ring
76. 76. Rotate engine 180°
77. 77. Use KM-929 • Fit crankshaft ribbed V-belt bolt • Turn crankshaft to cylinder 1 TDC • Remove bolt of crankshaft ribbed V-belt pulley

Important. Pull balancer shaft unit chain upwards

78. 78. Rotate engine 90°
79. 79. Insert timing case gasket (1) • Replace gasket

Important. Note guide sleeves. Fuel injection pump flange recess (2) must align with fuel injection pump retaining bore (3)

Important. Ensure that recess is positioned in fuel injection pump flange and that retaining bore (1) is centrally positioned in oblong hole (2) on duplex fuel injection pump gear – tension side (I) must be taut.

80. 80. Insert Duplex chain drive

Note. Check state of crankshaft sprocket spring washer, replace if necessary. Place crankshaft sprocket (6) with Duplex timing chain (5) and Duplex fuel injection pump gear (3) on crankshaft or fuel injection pump flange

81. 81. Attach guide rail for Duplex timing chain (4) • Tighten 3 bolts – Tightening torque 8 Nm
82. 82. Attach 2x tension rail (7) • Tighten 1 bolt – Tightening torque 20 Nm

83. 83. Attach timing case. • Tighten 13 bolts – Tightening torque 20 Nm

Note. Observe different bolt lengths. Tighten bolts uniformly

Important. Lightly coat sealing lip of the new seal ring with silicon grease (white).

84. 84. Install crankshaft front seal ring / timing case seal ring • Use KM-935-1 (1) • Use KM-935-2 (2)

Note. Position seal ring straight in timing case

Note. Press in seal ring until it lies flush in timing case. Use crankshaft ribbed V-belt pulley bolt

85. 85. Rotate engine 90°
86. 86. Attach balancer shaft unit • Replace 7 bolts • Tighten 2 bolts (2) – Tightening torque 20 Nm / 15 lbf. ft. + 60° • Tighten 5 bolts (1) – Tightening torque 20 Nm / 15 lbf. ft. + 30°

Note. Guide rail (4) and chain tensioner (3) must be transferred when replacing the balancer shaft unit. Tighten bolts from inside outwards

87. 87. Attach sprocket • Replace 1 bolt • Tighten 1 bolt – Tightening torque 90 Nm / 66 lbf. ft. + 30°
88. 88. Remove KM-978 and KM-979
89. 89. Attach balancer shaft unit cover • Tighten 4 bolts – Tightening torque 8 Nm
90. 90. Apply adhesive sealant

Note. Apply a bead of adhesive sealing compound (black) to joints (arrows) of timing case and rear crankshaft bearing cap.

91. 91. Install oil pan • Replace gasket • To cylinder block, timing case – Tighten 17 bolts – Tightening torque 20 Nm

Important. Hand-tighten all bolts

92. 92. Rotate engine 90°

Important. Clean thread in crankshaft before attaching flywheel

93. 93. Install flywheel • Replace 10 bolts • Use KM-652 • Tighten 10 bolts – Tightening torque 45 Nm / 33 lbf. ft. + 30° + 15°
94. 94. Install clutch • See operation "Pressure Plate and Clutch Disc, Remove and Install (F 17/F 23/F 35)" in group "K"
95. 95. Rotate engine 180°
96. 96. Attach crankshaft ribbed V-belt pulley • Replace 1 bolt • Insert 1 bolt
97. 97. Secure crankshaft ribbed V-belt pulley • Use KM-977-1 and KM-956-1 • Tighten 1 bolt – Tightening torque 150 Nm / 111 lbf. ft. + 45° + 15°

Note. 2nd person required

98. 98. Install coolant pump • Coolant pump – Tighten 3 bolts – Tightening torque 20 Nm • Ribbed V-belt pulley – Tighten 3 bolts – Tightening torque 20 Nm

Note. Replace gasket

Important. Arrow (2) on simplex fuel injection pump sprocket must align with recess in fuel injection pump flange and lock bore (3) in fuel injection pump.

99. 99. Install Simplex injection pump gear • Use KM-927 (4)

Note. Insert simplex timing chain with simplex injection pump wheel and tighten simplex injection pump wheel with fastening bolts (1) hand tight.

100. 100. Tighten Simplex injection pump gear • Remove KM-927 • Tighten 4 bolts (1) – Tightening torque 28 Nm / 21 lbf. ft.

101. 101. Install Duplex chain tensioner • Replace gasket (2) • Tighten bolt (1) – Tightening torque 60 Nm

Note. Note installation position. Closed side of chain tensioner (3) must point to tension rail

102. 102. Check for plane surface • Cylinder head – With straightedge, feeler gauge – Measure cylinder head height – Sealing surface to sealing surface: Dimension (I) = 140 mm

Note. Check sealing surfaces in length and width for deformation and check for warping along the diagonals

Important. Resurfacing of the cylinder head is not permitted.

103. 103. 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 at all four pistons

Note. Measure the projection at two different points (3) and (4) or (5) and (6) for each piston. To do this, place measuring bridge with the dial gauge above the cleaned piston head on the cylinder block. Determine the highest point by turning the crankshaft.

Important. The largest determined piston projection is used for the selection of the cylinder head gasket with corresponding identification. The identification (notch) is located in position (1). Do not insert cylinder head gasket with sealing compound.

104. 104. Replace cylinder head gasket • Piston projection 0.51 – 0.60 mm – Gasket with 1 notch – Thickness of gasket 1.3 mm • Piston projection 0.61 – 0.70 mm – Gasket with 2 notches – Thickness of gasket 1.4 mm • Attach cylinder head gasket – Note guide bushings

105. 105. Use KM-932 (3)

Note. Place KM-932 on cylinder head. Pin (2) must engage in camshaft bore (1).

Important. Approx. 60° before cylinder 1 TDC

106. 106. Turn crankshaft
107. 107. Position cylinder head

Note. 2nd person required. Pay attention to simplex timing chain

108. 108. Attach cylinder head • Insert 10 bolts • Tighten 10 cylinder head bolts – Tightening torque 25 Nm / 18 lbf. ft. + 65° + 65° + 65° + 65° + 15° – Use KM-470-B • Replace 4 bolts (arrows) • Tighten 4 bolts – Tightening torque 20 Nm / 15 lbf. ft. + 30° + 5°

Note. Replace cylinder head bolts

Note. Note tightening sequence.

109. 109. Move engine to 1st cylinder ignition TDC

Note. Turn crankshaft uniformly in direction of engine rotation. Mark on crankshaft ribbed V-belt pulley (3) must be located just before the lug (2) on the timing case. Both cams for 1st cylinder (1) must point upwards

110. 110. Use KM-929 (1)

Note. Insert KM-929 into bore for crankshaft pulse pick-up. Turn crankshaft uniformly in direction of engine rotation. KM-929 must latch in to the stop. Marks on crankshaft ribbed V-belt pulley and lug on timing case must align (2).

111. 111. Use KM-927 (3)

Note. Arrow (1) on Simplex fuel injection pump gear must align with the recess in injection pump flange and injection pump retaining bore (2). Insert KM-927 into injection pump retaining bore.

112. 112. Insert camshaft sprocket • Replace bolt • Position Simplex timing chain • Insert 1 bolt

Important. Camshaft sprocket must rest flush against the camshaft.

113. 113. Install guide rail for Simplex timing chain (1) • Replace 2 bolts (2) • Tighten 2 bolts – Tightening torque 8 Nm

Important. Note installation position of guide rail

114. 114. Attach KM-933 (4) • Insert carrier (1) • Insert 2 bolts

Note. Position upright in camshaft sprocket

Important. It must be possible to remove and install KM-927 under suction. If this is not possible, the pressure on the adapter plate must be slightly reduced using the adjustment screw (3).

115. 115. Adjust KM-933 (4)

Note. Use handle (2) to exert slight pressure on the carrier in the direction of arrow (counter engine rotational direction) and fix in place with holder bolt (3).

116. 116. Secure camshaft sprocket • Tighten bolt – Tightening torque 90 Nm / 66 lbf. ft. + 60° + 30°
117. 117. Install Simplex chain tensioner (3) • Replace gasket (2) • Tighten bolt (1) – Tightening torque 60 Nm

Note. Note installation position.

118. 118. Remove KM-927 , KM-932 , KM-933 and KM-929 • Remove KM-933 – Remove 2 bolts – Remove carrier
119. 119. Turn crankshaft

Note. Turn crankshaft slowly and uniformly two turns (720°) in direction of engine rotation until just before cylinder 1 TDC. Mark on crankshaft ribbed V-belt pulley (3) must be located just before lug (2) on timing case. Both cylinder 1 cams (1) must be facing upwards

120. 120. Use KM-929 (1)

Note. Insert KM-929 into bore for crankshaft pulse pick-up. Turn crankshaft uniformly in direction of engine rotation. KM-929 must latch in to the stop. Marks on crankshaft ribbed V-belt pulley and lug on timing case must align (2).

121. 121. Use KM-927 (3)

Note. Arrow (1) on Simplex fuel injection pump gear must align with the recess in injection pump flange and injection pump retaining bore (2). Insert KM-927 into injection pump retaining bore.

122. 122. Use KM-932 (3)

Note. Place KM-932 on cylinder head. Pin (2) must engage in camshaft bore (1).

123. 123. Remove KM-932 , KM-927 and KM-929
124. 124. Install crankshaft pulse pick-up • Replace seal ring • Tighten bolt – Tightening torque 8 Nm
125. 125. Attach cylinder head cover • Replace gasket • Tighten 8 bolts – Tightening torque 8 Nm

Note. Gasket (2) must be inserted in the gap (1) between cylinder head cover and sleeve. Apply adhesive sealing compound (black) to the sealing surfaces (arrows)

126. 126. Install vacuum pump • Replace gasket • Tighten 4 bolts – Tightening torque 8 Nm
127. 127. Attach vacuum line • To vacuum unit change-over valves • Clip in 2 brackets
128. 128. Install 2 fuel lines • Replace 4 sealing rings • Tighten 2 banjo bolts – Tightening torque 25 Nm / 18 lbf. ft. • Connect leak oil hose
129. 129. Install oil filter housing (heat exchanger housing) • 4 bolts – Tightening torque 20 Nm
130. 130. Install oil dipstick guide tube • Tighten 1 bolt – Tightening torque 8 Nm
131. 131. Attach thermostat housing • Replace gasket • Tighten 4 bolts – Tightening torque 8 Nm • Attach coolant hose. – Fasten clamp
132. 132. Install 4 injection lines • Fit 8 union nuts

Note. Note installation position.

133. 133. Fit 2 injection line spacers • Tighten 2 bolts

Note. Note installation positions

134. 134. Tighten 4 injection lines • Use KM-6098 • Tighten 8 union nuts – Tightening torque 30 Nm
135. 135. Attach intake pipe • Replace gasket • Position upper engine cover bracket • Tighten 4 bolts – Tightening torque 8 Nm

Note. For engines with throttle valve vacuum unit: Connect vacuum hose

136. 136. Attach cylinder block coolant flange • Replace seal ring • Tighten 2 bolts – Tightening torque 20 Nm • Fasten clamp
137. 137. Attach upper bracket for alternator (coolant flange) • Replace gasket • Tighten 3 bolts – Tightening torque 20 Nm
138. 138. Install starter • Tighten bolt – Tightening torque 45 Nm / 33 lbf. ft.
139. 139. Attach turbocharger oil return line • Tighten union nut – Tightening torque 20 Nm
140. 140. Attach exhaust manifold support • Tighten 2 bolts – Tightening torque 25 Nm / 18 lbf. ft.
141. 141. Attach turbocharger oil feed line • Tighten union nut – Tightening torque 20 Nm
142. 142. Attach 2 exhaust manifold heat shield plates • Insert 2 bolts
143. 143. Install turbocharger heat shield • Insert 3 bolts
144. 144. Fasten 3 heat shield plates • Tighten 5 bolts – Tightening torque 8 Nm

Important. The application of silicone sealing compound (grey), installation of timing case cover and tightening to torque must be performed within 10 minutes.

145. 145. Install timing case cover • Tighten 6 bolts – Tightening torque 6 Nm / 4.4 lbf. ft.

Note. Apply an approx. 2 mm (Dimension I) thick bead of silicone sealing compound (grey) to timing case cover.

146. 146. Install compressor main bracket • Tighten 2 bolts – Tightening torque 35 Nm / 26 lbf. ft. • Attach KM-6313-10
147. 147. Install compressor • Tighten 3 bolts – Tightening torque 20 Nm
148. 148. Install mounting block, auxiliary units • 4 bolts – Tightening torque 35 Nm / 26 lbf. ft.
149. 149. Install alternator • Position coolant hose bracket • Tighten 2 bolts and 2 nuts – Tightening torque 35 Nm / 26 lbf. ft.
150. 150. Fit ribbed V-belt tensioner • Tighten 2 bolts – Tightening torque (M8) 20 Nm / 15 lbf. ft. – Tightening torque (M10) 42 Nm / 31 lbf. ft.
151. 151. Place ribbed V-belt in position • Tension ribbed V-belt tensioner at hex lug (1) anti-clockwise (arrow)

Note. Note running direction

152. 152. Install wiring harness for engine management • Connect wiring harness plug. – Oil pressure switch, pressure sensor - intake pipe, pulse pick-up - crankshaft, coolant temperature sensor, sensor - dynamic oil level monitoring, oil temperature sensor, compressor • Connect wiring harness plug for sheathed glow plugs • Connect 2 turbocharger control vacuum lines – Vacuum reservoir, solenoid valve • Starter – Tighten 2 nuts • Alternator – Tighten 2 nuts
153. 153. Attach wiring trough • Tighten 2 bolts
154. 154. Top up engine oil. • Observe specified engine oil quantity

Note. After installing the engine, the engine oil level must be checked and corrected if necessary

155. 155. Detach engine from engine assembly stands ( KM-412 ) • see operation "Manual Transmission from Engine, Detach and Reattach"
156. 156. Install engine • see operation "Engine, Remove and Install"