How to Replace the Crankshaft Opel Vivaro A

The steps for removing and installing the cylinder head with the engine out of the vehicle are required.

Remove

1. 1. Remove crankshaft from engine – see “Crankshaft, Remove and Install”
2. 2. Support old crankshaft in soft-jawed vice
3. 3. Remove pulse generator wheel (1) from crankshaft • Remove 3x screw (2)

Install

4. 4. Support new crankshaft in soft-jawed vice
5. 5. Install new needle bearing (3) to crankshaft • Use Installer KM-26516
6. 6. Install pulse generator wheel (1) to crankshaft • Install 3x screw (2)

Important. Observe the correct orientation of the crankshaft bearing shells.

7. 7. Install 10x new crankshaft bearing shell • Install 5x new crankshaft bearing shell to cylinder block – Push in • Install 5x new crankshaft bearing shell to 5x main bearing cap – Push in

Important. Observe the correct orientation of the thrust washers.

8. 8. Install 2x new thrust washer (1) to cylinder block • Apply clean engine oil to 2x thrust washer • Lower in with oil grooves towards crankshaft

9. 9. Install 8x new bearing shell to 4x con-rod and 4x bearing cap • Push in
10. 10. Remove crankshaft from soft-jawed vice
11. 11. Install crankshaft to cylinder block • Apply clean engine oil to journals • Install 5x main bearing cap – Apply clean engine oil to 5x bearing shell – Install 10x new bolt (1) 20 Nm + 70° ± 6°

12. 12. Check lateral clearance of crankshaft • See “Technical Data” • Check crankshaft for free rotation

Note. If lateral clearance is incorrect replace 2x thrust washer.

13. 13. Rotate crankshaft using Front Pulley Counterhold EN-48334 with Handle KM-956-1 to position No. 2 piston and No. 3 piston at TDC

Important. Ensure indentation on bearing cap aligns with indentation on con-rod.

14. 14. Install 2x bearing cap for No. 2 and No. 3 piston • Install 2x bearing cap (1) to 2x con-rod (3) – Apply clean engine oil to 2x bearing shell – Install 4x bolt (2); do not tighten at this stage

15. 15. Rotate crankshaft using Front Pulley Counterhold EN-48334 with Handle KM-956-1 to position No. 1 piston and No. 4 piston at TDC
16. 16. Repeat procedure to install 2x bearing cap for No. 1 and No. 4 piston
17. 17. Secure 4x bearing cap to 4x con-rod • Secure 8x bolt 25 Nm + 55° ± 6°
18. 18. Rotate cylinder block 180° on Engine Overhaul Stand KM-412
19. 19. Remove cylinder head from engine – see “Gasket, Cylinder Head, Replace”
20. 20. Perform piston protrusion check – see “Piston Protrusion, Check” and “Piston Selection”
21. 21. Continue assembly of engine – see “Gasket, Cylinder Head, Replace” and “Crankshaft, Remove and Install”