Repair of Opel Corsa C, from 2000 to 2005 of release.
1. Operation and car maintenance
2. Engine
2.1. Petrol engines Z10XE, Z10XEP, Z12XE, Z12XEP DOHC-I
2.2. Mechanical part of petrol engines Z10XE, Z10XEP, Z12XE, Z12XEP DOHC-I
2.2.1. Regulation of phases of a gazoraspredeleniye by impact on a camshaft of Z10XEP, Z12XE, Z14XEP (since the end 2004 till 2005 of release)
2.2.2. Adjustment of phases of a gazoraspredeleniye (Z10XE, Z10XEP, without the conditioner)
2.2.3. Replacement of a poliklinovy belt (Z10XE, Z10XEP, with the conditioner)
2.2.4. Head of the block of cylinders
2.2.5. Removal and GRM case installation (Z10XE, Z10XEP)
2.2.6. Engine repair (Z10XE, Z10XEP, without the conditioner)
2.2.7. Block of cylinders, krivoshipno-shatunny mechanism and piston group
2.3. Cooling system
2.4. Greasing system
2.5. Injection system
2.6. Petrol engines – the general procedures of check
2.7. Mechanical part of the engine
2.8. Verifying and repair operations of components of a mechanical part of the engine
2.9. Cooling system
2.10. System of injection of fuel of petrol engines
2.11. Greasing system
3. Transmission
4. Running gear
5. Steering mechanism
6. Brake system
7. Onboard electric equipment
8. Body
9. Electric equipment schemes
 












2-2-6-remont-dvigatelya-z10xe-z10xep-bez-kondicionera.html

2.2.6. Engine repair (Z10XE, Z10XEP, without the conditioner)

Removal
Remove a transmission from the engine.
Remove directing tube щупа an oil meter.
Turn out a bolt.
Dismantle heated up a lambda sensor of regulation of structure of a fuel mix.
Disconnect the socket of a plait of wires.
Release a plait of wires.
Carefully turn out a lambda sensor by means of the KM-6129 adaptation.
Dismantle a guard of a final collector.
Turn off 2 bolts of fastening.
Dismantle a final collector.
Turn off 7 nuts of fastening.
Take out consolidation.
Lift the engine.
Establish on the engine on the KM-412-18 adaptation.
Tighten 4 bolts of fastening.
Fix the engine on the KM-412 2 adaptation.
Tighten 8 carving connections.
Establish the KM-2358 adaptation.
Merge engine oil.
Substitute the reception pallet.
Turn out a carving stopper of a drain opening.
Uncover cases of the oil filter.
Take out the loose leaf of the oil filter.
Dismantle coupling.
Remove a flywheel.
Establish the KM-652 adaptation.
Turn off 6 bolts of fastening.
Dismantle the KM-652 adaptation.
Remove the holder of the engine on the right 1.
Turn off 3 bolts of fastening.
Wrap a carving stopper of a masloslivny opening.
Replace a sealing ring.
Tighten a bolt the moment of 10 N · m.
Remove the reception pallet for oil.
Remove a poliklinovy belt.

NOTE
Mark the rotation direction.

Pull the tension device of a poliklinovy belt in the arrow direction.
Insert the KM-955-2 adaptation.
Remove from a pulley poliklinovy ременя a cranked shaft.
Remove a pulley poliklinovy ременя the pump of cooling liquid.
Turn off 3 bolts of fastening.
Dismantle a pulley poliklinovy ременя a cranked shaft.
Turn off 6 bolts of fastening.
Hold a bolt of a nave of a cranked shaft.
Remove the tension device of a poliklinovy belt.
Turn off 2 bolts of fastening.
Dismantle plaits of wires of the engine.
Turn off a plait of wires of the generator.
Turn off 2 nuts.
Отболт ите plait of wires of a starter.
Turn off 2 nuts 1.
Remove cable collars.
Dismantle the generator.
Turn off 2 carving connections.
Dismantle a starter.
Turn off 2 bolts of fastening (shooters).
Dismantle a plait of wires of a control system of the engine.
On the Z 10 XEP engine: dismantle a casing of a pipe of the fuel distributor.
Turn off 2 bolts of fastening.
Disconnect 12 sockets of a plait of wires of a control system of the engine.
The relay of pressure of oil 6, the sensor of temperature of cooling liquid 8, the sensor of a camshaft 9, the module of a butterfly valve 2, the controler of engine management 12, the valve of system of a retsirkulyatsiya of OG 4, the module of ignition 3, the sensor of a detonation 10, the sensor of a cranked shaft 11, fuel nozzles 1.
Turn off a wire of weight of the controler of engine management 13.
Release the channel for a plait of wires 7.
Release a plait of wires – 4 holders 14.
Disconnect 3 hoses from the pump of cooling liquid.
Hose of cooling liquid disconnect from a flange of cooling liquid of a retsirkulyatsiya of exhaust gases.
Release a collar.
Dismantle the pump of cooling liquid 1.

NOTE
At removal pay attention to directing plugs.

Substitute the reception pallet.
Turn off 9 bolts of fastening.

NOTE
Consider different length of bolts of fastening (an arrow – short bolts).

Dismantle the ignition module.
Uncover the ignition module, having shifted it to the right.
Turn off 2 bolts of fastening.
Take out a cover by means of the KM-6009 1 adaptation.
Uncover heads of the block of cylinders.
Remove a hose of ventilation of a case of the engine.
Release a collar.
Turn off 17 bolts of fastening.
Release a bolt of a nave of a cranked shaft 1.

NOTE
For this work participation of two people is required.

Establish and hold KM-956-1/KM-956-2 adaptations.
Hold KM-956-1/KM-956-2.
Adjust camshafts.
Cranked shaft by means of the KM-956-1/KM-956-2 adaptation evenly turn in the direction of rotation of the engine until the KM-953 1 adaptation against the stop will not come into a camshaft groove.
Remove a nave of a cranked shaft.

NOTE
Observe the assembly provision of a nave.

Turn out a bolt.
Take out a nave by means of KM-956-1/KM-956-2 adaptations.
Remove the oil pallet.
The engine turn on 180 °.
Turn off 14 bolts of fastening.
Remove consolidation of the oil pallet.
Remove the GRM case.
The engine turn on 90 °.
Turn out 15 bolts of fastening (shooters).
Consider length of bolts of fastening.
Do not damage the sensor of a camshaft 1.
To Poddnta also take a sealing ring of the GRM case.

NOTE
Do not damage a sealing surface.

Dismantle a chain drive.
Release bolts of driving gears of a camshaft.
Camshafts hold for a shestigrannik.
Stop the tension device of a chain 1.
Insert the KM-955-1 adaptation.
Dismantle the level of an uspokoitel 3 directing a level 5, a sled for a tension 7 and driving gear wheels of camshafts.
Take out a driving chain of a cam-shaft 4 with a driving wheel 6. Take GRM case consolidation.
Dismantle a head of the block of cylinders.
The engine turn on 90 °.
Dismantle the KM-953 adaptation.
Turn off 10 bolts of fastening.

NOTE
Release hairpins of a head of cylinders in that order:
– release hairpins of a head of cylinders (90 °);
– release hairpins of a head of cylinders (180 °);
– take out hairpins of a head of cylinders.

Head of the block of cylinders enclose in wooden blocks.
Take out consolidation of a head of the block of cylinders.
Dismantle the case of the oil filter.
Turn off 3 bolts of fastening.
Dismantle the detonation sensor.
Turn out a bolt.
Remove a maslootrazhatel.
Turn the engine on 180 °.
Turn off 6 bolts of fastening.
Dismantle the sensor of provision of a cranked shaft.
Turn out a bolt.
Dismantle the block of cylinders.
Establish the KM-2358 adaptation.
The engine suspend on the crane.
Remove the KM-412-18 adaptation.
Establish the block of cylinders.
Establish on the engine the KM-412-18 adaptation. Tighten 4 bolts of fastening.
Dismantle the KM-2358 adaptation.
6 directing sleeves by means of the KM-427 adaptation press in the block of cylinders.
Dismantle soaking-up oil pipeline 1.
Turn off 4 bolts of fastening.
Remove a sealing ring 2.
Clean sealing surfaces of the block of cylinders and a head of cylinders, a cover of a head of cylinders, the case of the oil filter, a support of a cranked shaft, the GRM case, the oil pallet, the pump of cooling liquid and a final collector.

Engine installation
Examine knots of the power unit.

NOTE
If it is necessary check and process a head of cylinders, remove from a head of cylinders everything established outside of a detail: the block of cylinders, a head of cylinders, a cover of a head of cylinders, the case of the oil filter, a support of a cranked shaft, a chain drive, the GRM case, the oil pallet, the pump of cooling liquid, a final collector.

By means of a lekalny ruler and kaliberny щупа check flatness of a head of the block of cylinders.
Stop a cranked shaft.
Remove a carving stopper 1.
Insert on its place the KM-952 2 adaptation.
Cranked shaft evenly turn until the adaptation will not be grasped.
Establish a maslootrazhatel.
Tighten 6 bolts of fastening the moment of 8 N · m.
Establish the case of the oil filter.
Turn the engine on 180 °.
Replace consolidation.
Tighten 3 bolts of fastening the moment of an inhaling of 20 N · m.
Replace the loose leaf of the oil filter.
Establish a cover of the case of the oil filter.
Replace a sealing ring.
Tighten bolts of fastening of a cover the moment of 10 N · m.
Adjust camshafts.
Insert the KM-953 adaptation.
Camshafts turn for a shestigrannik.
Take out the KM-953 adaptation.
Establish a head of the block of cylinders.
Replace consolidation.

NOTE
Marking of "OPEN/TOP" should indicate up.
Replace bolts of fastening of a head of the block of cylinders.

By means of a lekalny ruler level a head of cylinders in relation to the block of cylinders.
Tighten 10 bolts of fastening the moment of 25 N · m + 60 ° + 60 ° + 60 °.

NOTE
Observe sequence of an inhaling of bolts.

Establish a driving chain of a cam-shaft.
Establish the KM-953 adaptation.
Replace GRM case consolidation.

NOTE
Watch correctness of landing (arrow).

Replace bolts.
Driving wheel 5 shift.
Get a gear wheel of a final camshaft. Screw a bolt.
Establish a driving chain of a cam-shaft 3.
Insert into a driving chain of a cam-shaft a gear wheel of an inlet camshaft with a disk of the phase sensor, screw a bolt.

NOTE
The disk of the phase sensor should turn manually.

Establish a sled for a tension of a driving chain of a cam-shaft 6.
Tighten a bolt the moment of an inhaling of 20 N · m.

NOTE
Watch correctness of landing of a driving chain of a cam-shaft.

Establish directing fillet of a driving chain of a cam-shaft 4.
Tighten 2 bolts of fastening with the moment of 8 N · m.

NOTE
Watch correctness of landing of a driving chain of a cam-shaft.

Establish a level of an uspokoitel of a driving chain of a cam-shaft 2.
Tighten 2 bolts of fastening with the moment of 8 N · m.
Weaken a tension of the tension device of a chain.
Take out the KM-9551 adaptation.
At replacement of details consider various options of a design. Watch correctness of numbers of details.
Establish the pump of cooling liquid.

NOTE
Watch correctness of landing of directing plugs (arrow).

Consolidation 1 replace.
Fix the pump by means of short bolts of fastening 2.
Tighten 3 bolts of fastening of 8 N · m.
Dismantle a branch pipe of cooling liquid, открутитв 3 bolts of fastening.
Establish the GRM case.
Screw bolts.

NOTE
Observe sequence of an inhaling

Tighten 5 bolts of fastening (М6) the moment of 18 N · m.
Tighten 14 bolts of fastening (М6) the moment of 28 N · m.
Tighten 2 bolts крепленияов (M10) 3 the moment of 35 N · m.
Establish a branch pipe of cooling liquid.
Check, clear sealing surfaces.
Replace a sealing ring.
Tighten 3 bolts of fastening the moment of 8 N · m.
Replace a sealing ring of a cranked shaft in front 1.
Sealing edges grease with silicone greasing (white).
Establish the KM-960 2 adaptation and press a sealing ring of a cranked shaft.
Take out adaptations KM-952, KM-953.

NOTE
Fixing tools cannot be used for keeping.

Establish a nave of a cranked shaft.
Observe the assembly provision of a nave of a cranked shaft 2, the mark should indicate up.
Bolt of a nave replace.
Hold a nave by means of KM-956-1/KM-956-2 adaptations.
Tighten a bolt the moment of 150 N · m +45 °.
Remove KM-956-1/KM-956-2 adaptations.
Establish a pulley poliklinovy ременя a cranked shaft 1.
Tighten 6 bolts of fastening the moment of 8 N · m.
Hold a bolt of a nave of a cranked shaft.
Insert the KM-952 adaptation.
The KM-953 adaptation insert into a flute of camshafts.
Establish the KM-954 1 adaptation.
Turn a disk of the phase sensor 2, there will be no yet a possibility to establish the KM-954 adaptation on the GRM case.
Fix driving gear wheels of camshafts.

NOTE
Driving gear wheels of camshafts and disk of the phase sensor tighten with the moment of 10 N · m.

Tighten 2 bolts of fastening the moment of 210 N · m.

NOTE
In the beginning tighten a bolt of a driving gear wheel of an inlet camshaft.

Camshafts support for a shestigrannik 1.
Take out fixing tools KM-952, KM-953, KM-954.
Tighten driving gear wheels of camshafts.
Tighten 2 bolts of fastening the moment of 50 N · m + 60 °.

NOTE
In the beginning tighten a bolt of a driving gear wheel of an inlet camshaft.
Camshafts hold for a shestigrannik.

Check installation of phases of a gazoraspredeleniye.
Establish the oil pallet.
Tighten 14 bolts of fastening the moment of 10 N · m.
Establish a carving stopper of a support of a cranked shaft.
Replace a sealing ring.
Tighten a bolt of fastening the moment of 50 N · m.
Establish the detonation sensor.
Tighten a bolt of fastening the moment of an inhaling of 20 N · m.
Establish the sensor of provision of a cranked shaft.
Replace a sealing ring.
Tighten a bolt of fastening the moment of 8 N · m.
Establish a cover of a head of the block of cylinders 1.
Turn the engine on 180 °.
Replace consolidation 2, a sealing ring.
Put hermetic (distance of 1-2 mm).

NOTE
Installation works finish within 10 minutes.

Tighten 17 bolts of fastening the moment of 8 N · m.
Establish a hose of ventilation of a case of the engine.
Fix a collar.
Establish the ignition module.
Tighten 2 bolts of fastening with the moment of 8 N · m.
Establish hoses of cooling liquid.
On the pump of cooling liquid and on the valve of a retsirkulyatsiya of OG fix collars.
Establish a plait of wires of a control system of the engine.
Lay a plait of wires.
Connect 13 sockets of a plait of wires.
Attach a wire of weight of the controler of management of the engine.
Tighten a fastening nut.
Fix the channel for a plait of wires.
Fix a plait of wires.
On the Z 10 XEP engine: establish a casing of a pipe of the fuel distributor.
Tighten 2 bolts of fastening.
Establish a starter.
Turn the engine on 90 °.
Tighten 2 bolts of fastening the moment of 25 N · m.
Establish the generator.
Tighten 2 carving connections by the moment of 35 N · m.
Establish a plait of wires of the engine.
Turn the engine on 90 °.
Fix plaits of wires of the generator and a starter and tighten 4 nuts of fastening.
Establish the tension device of a poliklinovy belt.
Turn the engine on 180 °.
Bolt (М8) tighten the moment of an inhaling of 20 N · m.
Bolt (М10) tighten the moment of an inhaling of 55 N · m.
Establish a pulley poliklinovy ременя the pump of cooling liquid.
Tighten 6 bolts of fastening the moment of an inhaling of 20 N · m.
Establish a poliklinovy belt.

NOTE
Observe the direction of rotation and assembly situation.

Weaken a tension of the tension device of a poliklinovy belt.
Take out the KM-955-2 adaptation.
Establish the holder of the engine on the right.
Tighten 2 bolts of fastening the moment of 60 N · m.
Establish a flywheel.
Clear 6 carving connections in cranked to a shaft.
Replace fastening bolts.
Tighten 6 bolts of fastening the moment of 35 N · m +60 °.
Block a flywheel by means of the KM-652 adaptation.
Establish coupling.
Fill in engine oil.
Check and, if necessary, modify level of engine oil.
Disconnect the engine from the KM-412 adaptation.
Turn off 8 carving connections.
Dismantle the KM-412-18 adaptation.
Turn off 4 bolts of fastening.
Establish a final collector.
Replace consolidation.
Replace nuts.
Tighten 7 nuts of fastening the moment of an inhaling of 20 N · m.
Establish a guard of a final collector.
Tighten 2 bolts of fastening the moment of 8 N · m.
Establish heated up a lambda sensor of regulation of structure of a fuel mix.
Put on a carving assembly paste (white).
Tighten a lambda sensor the moment of 40 N · m.
Connect the socket of a plait of wires.
Fix a plait of wires.
Establish directing tube щупа an oil meter.
Replace 2 sealing rings.
Tighten a bolt the moment of 8 N · m.
Establish a transmission on the engine.

«on page back
2.2.5. Removal and GRM case installation (Z10XE, Z10XEP)
on the following page»
2.2.7. Block of cylinders, krivoshipno-shatunny mechanism and piston group