Engine Maintenance Using a Section Engine Opel Omega B

Remove

1. 1. Remove engine • see operation "Engine, Remove and Install"
2. 2. Detach manual transmission or automatic transmission from engine • see operation "Manual Transmission from Engine, Detach and Reattach" or "Automatic Transmission from Engine, Detach and Reattach"
3. 3. Remove flywheel • see operation "Flywheel, Remove and Install"
4. 4. Remove oil dipstick guide tube (1) • Remove oil dipstick • from oil filter housing – 1 Fastening bolt • Draw oil out of oil pan

5. 5. Detach wiring harness (1) • 6 Wiring harness plugs, injectors • 4 Fastening bolts

6. 6. Detach intake manifold (1) • 5 Acoustic covers • 1 Wiring harness plug – From solenoid valve switch-over valves • 2 Vacuum hoses – From solenoid valve switch-over valves • 1 Wiring harness plug – From charge pressure sensor • 1 Vacuum hose – From exhaust gas recirculation valve • Detach metal tube, exhaust recirculation – 1 Fastening clamp • 7 Fastening nuts • 12 Fastening bolts

7. 7. Detach cable duct • 18 Wiring harness plugs – Mark wiring harness plug • 2 fastening bolts

Note. Note cable layout

8. 8. Detach cable strand • From starter • 2 Fastening nuts • Remove wiring harness

Note. Note cable layout

9. 9. Detach vacuum lines • Mark vacuum lines

Note. Note cable layout

10. 10. Detach fuel lines • Detach oil leak line from injectors – Press retaining split pin in direction of arrow • Unclip oil leak line from cylinder head cover • Detach fuel return line (1) – From high pressure pump – 1 Fastening clamp – Remove with oil leak line (2) • Detach fuel supply line (3) – From high pressure pump – 1 Fastening clamp

11. 11. Coolant flange (1) • from engine block – 3 Fastening bolts

12. 12. Detach coolant pipes • Coolant pipe (2) – 1 Fastening bolt – 1 Fastening clamp • Coolant pipe (1) – 2 fastening bolts

13. 13. Detach oil filter housing (heat exchanger) (1) • 3 Fastening bolts

14. 14. Detach exhaust recirculation system (1) • From exhaust manifold – 2 fastening bolts • From timing case – 3 Fastening bolts

15. 15. Detach vacuum pump (2) • 2 fastening bolts
16. 16. Detach charge air pipe bracket • 1 Fastening bolt

17. 17. Detach engine transport shackle (1) • 2 Fastening bolts

18. 18. Detach ribbed V-belt, compressor • Mark direction of travel • Tension tensioning roller (1) in the direction of the arrow (clockwise) • Remove ribbed V-belt, compressor

19. 19. Detach alternator ribbed V-belt • Mark direction of travel • Tension tensioning roller (1) in the direction of the arrow (anti-clockwise) • Remove alternator ribbed V-belt

20. 20. Detach power steering pump • see operation "Power Steering Pump, Remove and Install (Y 25 DT)"
21. 21. Remove alternator (2) • Detach upper guide roller (1) • Detach guide roller bracket (3) – 2 fastening bolts • Remove alternator

22. 22. Detach ribbed V-belt tensioning device, alternator • Detach tensioning roller (1) with tensioning lever • 1 Fastening nut • Detach ribbed V-belt tensioning device, alternator (2) • 2 fastening bolts

23. 23. Detach coolant pump • 4 Fastening bolts (1)

24. 24. Detach ribbed V-belt tensioning device, compressor • Detach tensioning roller with tensioning lever • 1 Fastening bolt (2) • Detach ribbed V-belt tensioning device, compressor (1) • 2 fastening bolts

25. 25. Attach KM-6268 • Unscrew and remove fastening bolts – From support, compressor for air conditioning – 2 pieces • Attach counterhold (1) from KM-6268 – To support, compressor for air conditioning • Attach bracket (3) from KM-6268 – To torsional vibration damper (2) – Secure with detent (4)

26. 26. Remove torsional vibration damper • Release 4 fastening bolts (1) • Detach bracket from KM-6268 – From torsional vibration damper • Remove torsional vibration damper – Unscrew and remove 4 fastening bolts

27. 27. Detach counterhold, torsional vibration damper • Unscrew and remove 2 fastening bolts
28. 28. Detach support, compressor for air conditioning • see operation "Support – AC Compressor, Remove and Install".
29. 29. Detach pulse pick-up crankshaft (1) • 1 Fastening bolt

30. 30. Detach pressure lines • From pressure reservoir to injectors – 6 pieces – with KM-812

Important. After removing the pressure lines, seal off the openings of the injectors and the pressure reservoir with protective caps from KM-6273 (2) or KM-6273 KM-6274 (1)!

31. 31. Detach pressure line • From high pressure pump to the pressure reservoir – with KM-812

Important. After removing the pressure lines, seal the apertures of the high pressure pump and the pressure reservoir with protective caps from KM-6274 (1) or KM-6274 KM-6273 (2)

32. 32. Remove fastening nut for high-pressure pump sprocket • Remove closure bolt with KM-6275 (1). • Remove fastening nut for high-pressure pump sprocket – Counterhold on crankshaft with KM-6269

33. 33. Attach KM-6275 • Install guide sleeve (1) from KM-6270 in timing case. • Screw in KM-6270 (2) without remover bolt (3) in sprocket wheel of high pressure pump • Screw in remover bolt in KM-6270 until it is in contact

Important. KM-6270 (4) is used to fix the sprocket wheel of the high pressure pump and may not be removed.

34. 34. Remove high pressure pump • Remove fastening nuts (2) for high-pressure pump • Tighten remover bolt (1) until high-pressure pump (3) is released • Remove high-pressure pump

35. 35. Remove injectors • Unscrew and remove 12 fastening nuts • Remove injectors with injector holders • Renew seal ring (3)

Note. Remove any injectors which are stuck with KM-6272 (1) in conjunction with KM-6272 KM-J-7004 (2)

Note. Ensure that the seal ring has not been left in the injector shaft

36. 36. Remove cylinder head cover • Remove outer fastening bolts in order specified (1 – 18) • Remove inner fastening bolts in order specified (19 - 30)

37. 37. Position engine at 1st cylinder ignition TDC • Engage KM-6269 KM-813 in the bore of the drive disc or flywheel

Note. The cams (arrows) of the 1st cylinder must point upwards

38. 38. Remove guide rail of timing chain (1) • 2 fastening bolts
39. 39. Release chain tensioner • Remove closure bolt with KM-6275 from timing case • Loosen fastening bolt (2)

Note. Oil pressure oil the hydraulic chain tensioner is reduced

40. 40. Attach KM-6267 • Attach hold-down positioner (1) from KM-6267 to cylinder head • Fix peg gauge (3) from KM-6267 KM-6267

Important. If the sprockets are removed without the hydraulic chain tensioner being locked, the chain tension piston slips out and can only be re-assembled with considerable effort and time

41. 41. Lock chain tensioner • Turn exhaust camshaft slowly clockwise using Torx bolt (5) until chain tensioner is compressed • While the chain tensioner is compressed, insert Retaining Pin KM-823 (4) in bore of chain tensioner – this locks the chain tensioner

42. 42. Remove camshaft sprockets • Release 2 Torx bolts • Detach exhaust camshaft sprocket • Detach intake camshaft sprocket • Detach peg gauge and hold-down positioner from KM-6267
43. 43. Detach guide rail (2) • Unscrew fastening bolt (3) • Remove guide rail in the direction of the arrow
44. 44. Detach tensioning rail (1) • Unscrew fastening bolt (4) • Remove tensioning rail in the direction of the arrow

45. 45. Remove KM-813 (1)
46. 46. Turn engine 45° in the opposite direction to the direction of rotation of the engine

Note. Engine must be turned from the TDC-position to prevent the valves striking the piston

47. 47. Detach camshaft bearing caps • Release fastening bolts (arrows) uniformly in 1/2 turn steps from the outside inwards • Detach camshaft bearing caps and lay aside in order – note mark (2)

48. 48. Remove camshafts • Note mark on camshafts – E = Intake camshaft – A = Exhaust camshaft • The bearing caps of the intake camshaft are marked with (E1 – E7) which is legible from the exhaust side • The bearing caps of the exhaust camshaft are marked with (A1 – A7) which is legible from the exhaust side

49. 49. Remove cam followers (1) • Detach cam followers and lay aside in order • Check rollers (2) for ease of movement

Note. Old cam followers may only be reused on the same cam of the camshafts

50. 50. Remove hydraulic valve lifters (1) • Remove from cylinder head and lay aside in order

51. 51. Detach cylinder head • Remove fastening bolts (arrows) • Release cylinder head bolts in order specified (1 – 14) in 1/2 turn steps and remove • Lay cylinder head on wooden blocks

52. 52. Take out cylinder head gasket
53. 53. Turn engine • with KM-412-A • Turn 180°
54. 54. Detach oil pan • Detach fastening bolts for oil pan from cylinder block, time chain and transmission – 25 fastening bolts
55. 55. Detach timing case (1) • 12 Fastening bolts (arrows)
56. 56. Remove camshaft timing chain • Mark running direction

57. 57. Apply tension to hydraulic chain tensioner • Press tensioning rail (8) in direction of arrow and insert Retaining Pin KM-823 (1) in bore of chain tensioner

Note. This locks the chain tensioner

58. 58. Detach tensioning rail • Remove from bearing pin (7)
59. 59. Detach guide rail • Remove fastening bolt (5) • Unclip guide rail (6) in the direction of the arrow
60. 60. Detach sprocket wheel, high pressure pump • Remove fastening nut (2) for high-pressure pump sprocket • Install KM-6270 (3) in high-pressure pump sprocket and release high-pressure pump sprocket from high-pressure pump shaft with remover bolt
61. 61. Remove high pressure pump timing chain • Mark running direction of high pressure pump timing chain • Remove high pressure pump sprocket with high pressure pump timing chain

62. 62. Detach hydraulic chain tensioner (1) • 3 fastening bolts (2) – Remove gasket

63. 63. Remove timing chain gasket (1) • Clean sealing surfaces

64. 64. Detach bracket for rear crankshaft seal ring • Unscrew and remove 6 fastening bolts (arrows)

Note. Note differing bolt lengths

65. 65. Remove seal ring (1) • Edge out of rear end cover with suitable tool

Note. Ensure that the sealing surface is not damaged

66. 66. Remove oil pump (1) • 4 fastening bolts
67. 67. Detach oil baffle plate (2) • 10 fastening bolts

68. 68. Turn engine • with KM-412-A
69. 69. Remove engine block • Attach engine to workshop crane • Detach from KM-412-A

Install

70. 70. Attach engine block • Attach replacement engine to workshop crane • Transfer KM-412-30 • Attach engine to KM-412-A
71. 71. Clean sealing surfaces
72. 72. Clean parts
73. 73. Attach reinforcing plate • Note installation direction • Screw in 10 fastening bolts – Tightening torque 22 Nm
74. 74. Install oil pump • 4 Fastening bolts – Tightening torque 23 Nm
75. 75. Turn engine • with KM-412-A
76. 76. Install new seal ring in bracket for crankshaft seal ring • Install new seal ring in rear bracket for rear crankshaft seal ring • Remove support bushing (1) out of new seal ring and connect to crankshaft (2) • Drive seal ring with KM-817 KM-235-1 (4) into rear end cover as far as the stop

77. 77. Install new bracket for crankshaft seal ring • Coat support bushing (2) and crankshaft (1) with silicone grease (white) • Attach new gasket (3) • Attach rear end cover (4) to cylinder block – – tightening torque (M6) 9.9 Nm – – tightening torque (M8) 24 Nm

78. 78. Attach new timing case gasket
79. 79. Attach hydraulic chain tensioner • Tightening torque 9.9 Nm
80. 80. Attach high pressure pump timing chain • Insert with sprockets

Note. Note running direction

81. 81. Attach guide rail • To cylinder block – Tightening torque 24 Nm
82. 82. Attach tensioning rail • Insert in bearing pin
83. 83. Remove KM-823 • Tension with chain tensioner tensioning rail and pull Retaining Pin KM-823 out of bore for chain tensioner
84. 84. Attach timing case • Renew seal – Tightening torque 15 Nm
85. 85. Turn engine • with KM-412-A
86. 86. Apply sealing compound • Apply a bead of adhesive sealing compound (black) to the separation points (1) and position new gasket on cylinder block

87. 87. Attach oil pan • 25 fastening bolts – – tightening torque (M6) 10 Nm – – tightening torque (M8) 21.5 Nm
88. 88. Turn engine • with KM-412-A
89. 89. Determine piston projection • Position Measurement Bridge KM-301 (1) on the cleaned cylinder block sealing surface • Insert Dial Gauge MKM-571-B (4) into the measurement bridge under pretension and adjust dial to zero • Measure the projection at the points (2) and (3), to do this position measurement bridge with dial gauge over the cleaned piston head on the cylinder block and determine the highest point by turning the crankshaft • The piston projection measurement must be carried out on all 6 pistons

90. 90. Place cylinder head gasket in position • The largest piston projection is used for the selection of the cylinder head gasket with corresponding hole count (1) – Piston projection of 0.92 - 1.03 = 2 holes – Piston projection > 1.03 mm = 3 holes • Fit new cylinder head gasket

Note. The joint between timing case cover and engine block is sealed with adhesive sealing strips (2) as standard – the use of adhesive sealing compound is not necessary

Important. Engine must be 45° before 1st cylinder ingition TDC

91. 91. Attach cylinder head • Place cylinder head in position and tighten in sequence specified (14 – 1) using new bolts – – 80 Nm / 59 lbf. ft. – Ease 180° – 50 Nm / 37 lbf. ft. – +90° – +90° • Screw in fastening bolts (arrows) – Tightening torque 22 Nm

Note. Observe the correct tightening sequence

92. 92. Install cam followers and hydraulic valve lifters • Insert 24 hydraulic valve lifters in the cylinder head • Insert 24 cam followers • Oil bearing points and bearing caps of the camshaft

Note. Note allocation

Note. Old cam followers may only be reused on the same cam of the camshaft

93. 93. Insert camshafts • Oil running surfaces of camshaft bearing and camshafts • Oil running surfaces of camshaft bearing cap and place camshaft bearing cap in position

Note. Note coding for exhaust camshaft and intake camshaft

Note. Note coding

94. 94. Attach camshafts • Attach camshaft bearing cap – Install fastening bolts for camshaft bearing caps hand-tight – Tighten camshaft bearing caps uniformly in 1/2 turn steps from inside to outside – Tightening torque 10 Nm

Important. In order to ensure non-destructive installation of the camshafts, the tightening sequence described below must always be followed

95. 95. Attach KM-6267 • Turn using hex of camshafts so that the cams of the 1st cylinder face one another • Attach hold-down positioner from KM-6267 to cylinder head • Place peg gauge from KM-6267 on intake camshaft and align intake camshaft until peg gauge lies on cylinder head with no gaps • Fix peg gauge from KM-6267
96. 96. Insert sprocket, intake camshaft • Position timing chain on intake camshaft sprocket and slide intake camshaft sprocket on intake camshaft • Install new Torx bolt on intake camshaft sprocket to the stop and then release by 1/2 turn
97. 97. Insert exhaust camshaft sprocket • Position timing chain on exhaust camshaft sprocket and slide exhaust camshaft sprocket onto exhaust camshaft • Insert new Torx bolt (1), exhaust camshaft sprocket
98. 98. Attach guide rail • Attach guide rail with new gasket to cylinder head – Tightening torque 9.9 Nm
99. 99. Remove KM-823 • Tighten Torx bolt, exhaust camshaft sprocket - counterhold on hex of exhaust camshaft – Tightening torque 15 Nm • Turn exhaust camshaft slowly clockwise using Torx bolt of exhaust camshaft sprocket until chain tensioner is compressed • Whilst the chain tensioner is compressed, pull Retaining Pin KM-823 out of bore • Release Torx bolt for exhaust camshaft sprocket by 1/2 turn – Counterhold against camshaft hex
100. 100. Tighten chain tensioner • 1 Fastening bolt – Tightening torque 16 Nm
101. 101. Screw in closure bolt • Attach new gasket to closure bolt • Install closure bolt with KM-6275 in timing case – Tightening torque 30 Nm
102. 102. Turn engine to ignition TDC • with KM-6269 Engage KM-813 in the bore of the drive disc or flywheel

Note. Ensure that for vehicles with automatic transmission, the test drift does not latch into the depressions in the fastening bolts of the converter

103. 103. Tighten Torx bolt (3), intake camshaft sprocket • Counterhold on hex of intake camshaft – Tightening torque 20 Nm + 35°
104. 104. Transfer KM-6267 • Position peg gauge (2) from KM-6267 onto exhaust camshaft (1) and align exhaust camshaft until peg gauge rests on cylinder head without any gap • Fix peg gauge from KM-6267 KM-6267
105. 105. Tighten Torx bolt (4), exhaust camshaft sprocket • Counterhold on hex of exhaust camshaft – Tightening torque 20 Nm + 35°

106. 106. Turn crankshaft 720° in the direction of rotation of the engine • Take peg gauge from KM-6267 off exhaust camshaft • Pull KM-813 out of bore in drive disc / flywheel • Engage KM-6269 KM-813 in the bore of the drive disc or flywheel

Note. Ensure that for vehicles with automatic transmission, the test drift does not latch into the depressions in the fastening bolts of the converter

107. 107. Timing, Check • Peg gauge from KM-6267 KM-6267 must line on cylinder head with no gaps

Note. The adjustment procedure must be repeated if the peg gauge from KM-6267 KM-6267 KM-6267 does not lie on the cylinder head with no gaps.

108. 108. Detach hold-down positioner from KM-6267
109. 109. Pull KM-813 out of bore in drive disc / flywheel
110. 110. Install high-pressure pump • Renew seal • 3 Fastening nuts – Tightening torque 12 Nm
111. 111. Remove KM-6270 • From timing case
112. 112. Install fastening nut, high pressure pump sprocket • Counterhold on torsional vibration damper with KM-6269 – Tightening torque 65 Nm
113. 113. Attach closure bolt, high pressure pump • Attach new gasket to closure bolt • Install closure bolt with KM-6275 in timing case – Tightening torque 30 Nm
114. 114. Apply sealing compound (black) for cylinder head cover • Apply a bead of adhesive sealing compound (black) to separation points (arrows)

115. 115. Attach cylinder head cover • Position cylinder head cover with new gasket on cylinder head. • Tighten inner fastening bolts in the stated order (30 - 19) – Tightening torque 10 Nm • Tighten outer fastening bolts in the stated order (18 - 1) – Tightening torque 10 Nm

116. 116. Clean injector channels • with KM-6271
117. 117. Attach injectors • Insert with new gasket in cylinder head • Attach injector holders – Tightening torque 9 Nm
118. 118. Attach air pressure reservoir • To cylinder head – Tightening torque 24 Nm
119. 119. Attach pressure line, high pressure pump - pressure reservoir • with KM-812 – Tightening torque 20 Nm
120. 120. Attach pressure lines, injectors - pressure reservoir • with KM-812 – Tightening torque 20 Nm
121. 121. Attach alternator support • Screw in fastening bolts – Tightening torque 24 Nm
122. 122. Attach pulse pick-up, crankshaft • Clean thread • Replace fastening bolt – Use red bolt-locking compound – Tightening torque 9.9 Nm
123. 123. Attach bracket for air conditioning compressor • Screw in fastening bolts – Tightening torque 24 Nm
124. 124. Attach air conditioning compressor • Screw in fastening bolts – Tightening torque 24 Nm
125. 125. Insert gasket, front of crankshaft • Position KM-6252 (1) on crankshaft and coat with silicone grease (white) • Slide new crankshaft seal ring at front over KM-6252 until crankshaft seal ring at front bears against timing case • Remove KM-6252

126. 126. Install front crankshaft seal ring • Attach KM-6251 (1) to crankshaft • Place KM-6249 KM-6251 in position • Press seal ring, front of crankshaft, flush into timing case with central nut (2) from KM-6251 • Remove KM-6249 KM-6251

127. 127. Attach counterhold from KM-6268 • Attach to support, air conditioning compressor
128. 128. Attach torsional vibration damper • Attach to crankshaft with new bolts • Position bracket from KM-6268 on torsional vibration damper and secure with detent. • Tighten torsional vibration damper – Tightening torque 40 Nm + 60° + 60°
129. 129. Remove KM-6268 • Detach from torsional vibration damper and AC compressor support • Install fastening bolts, support for air conditioning compressor – Tightening torque 24 Nm
130. 130. Attach air conditioning compressor • Screw in fastening bolts – Tightening torque 24 Nm
131. 131. Attach ribbed V-belt tensioning device, compressor • 2 fastening bolts • Attach tensioning roller with tensioning lever – 1 Fastening bolt
132. 132. Attach coolant pump • Attach to cylinder block with new gasket – Tightening torque 15 Nm
133. 133. Attach ribbed V-belt tensioning device, alternator • 2 fastening bolts – Tightening torque 14.8 Nm • Attach tensioning roller with tensioning lever • 1 Fastening nut – Tightening torque 9.9 Nm
134. 134. Attach alternator • Attach alternator with guide roller – Tightening torque 24 Nm
135. 135. Attach upper guide roller • Screw in fastening bolt – Tightening torque 24 Nm
136. 136. Attach power steering pump • see operation "Power Steering Pump, Remove and Install (Y 25 DT)"
137. 137. Install alternator ribbed V-belt

Note. Note running direction

138. 138. Attach ribbed V-belt, compressor • Note marking
139. 139. Attach charge air pipe bracket • To cylinder head • 1 Fastening bolt – Tightening torque 24 Nm
140. 140. Attach vacuum pump • Clean thread • Insert fastening bolts with red bolt-locking compound – Tightening torque 22 Nm
141. 141. Attach exhaust recirculation system • To timing case – Tightening torque 18.8 Nm • To exhaust manifold – Tightening torque 24 Nm
142. 142. Attach oil filter housing/heat exchanger • Renew seal • Screw in fastening bolts – Tightening torque 22 Nm
143. 143. Attach coolant pipes • 2 pieces • Attach all the coolant hoses
144. 144. Attach coolant flange to cylinder head • Renew seal • Screw in fastening bolts – Tightening torque 9.9 Nm
145. 145. Attach fuel supply line • 1 Fastening clamp
146. 146. Attach fuel return line • Insert fuel line with oil leak line • Attach fuel return line to high pressure pump – 1 Fastening clamp • Attach oil leak line to injectors • Clip oil leak line to cylinder head cover
147. 147. Attach vacuum hoses • Insert vacuum lines • Vacuum hose solenoid valve charge pressure regulator • Vacuum hose, vacuum pump • Clip vacuum pressure hoses to fuel line
148. 148. Attach cable strand • To starter • Insert wiring harness • 2 Fastening nuts

Note. Note cable layout

149. 149. Attach cable duct • Attach 18 wiring harness plugs • Fit 2 bolts • Attach 4 vacuum pressure lines

Note. Note cable layout

150. 150. Attach intake manifold • Fit 7 nuts M6 – Tightening torque 10 Nm • Fit 12 bolts M7 – Tightening torque 15 Nm • Attach metal tube to intake manifold • Attach wiring harness plug to charge pressure sensor • Attach 2 vacuum hoses to solenoid valve/switch-over valves, exhaust recirculation • Attach 1 wiring harness plug to solenoid valve/switch-over valves, exhaust recirculation • Attach acoustic cover
151. 151. Attach wiring harness plug • 4 Fastening bolts • 6 Wiring harness plugs, injectors
152. 152. Install guide tube for dipstick • Insert in oil pan with new gasket • Attach oil dipstick guide tube to oil filter housing – Tightening torque 9.9 Nm
153. 153. Attach flywheel • see operation "Flywheel, Remove and Install"
154. 154. Attach manual or automatic transmission to engine • see operation "Manual Transmission from Engine, Detach and Reattach" or "Automatic Transmission from Engine, Detach and Reattach"

Note. Note:

155. 155. Install engine • see operation "Engine, Remove and Install"