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
2.3. 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
2.7.1. Removal and flywheel installation (engine of 1,4 l)
2.7.2. Replacement of a back epiploon of a cranked shaft
2.7.3. Replacement of consolidations of cores of valves (the established head of the block of cylinders)
2.7.4. Check of an axial free wheeling of a cranked shaft
2.7.5. Removal and installation of a head of the block of cylinders (engine of 1,4-1,6 l)
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
 












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2.7.3. Replacement of consolidations of cores of valves (the established head of the block of cylinders)

Removal
Remove cam-shafts.
Remove spark plugs by means of the special KM-194-E tool.
Lift the car.
Remove the right mudguard of the engine.
Make an adjusting label on a belt pulley of a cranked shaft (the shooter in drawing).

NOTE
Displace on 180 ° concerning a label, cylinder No. 1 VMT.

Prepare the MKM-6086 lever for removal of a klapanny spring.
Adjust support the special MKM-6086-6 tool.
Adjust heads of support on the center concerning legs of a support and tighten.

Preparation of the special tool for removal of a klapanny spring: 1–support head; 2–support legs; 3–persistent part

Extend a MKM-6086-7 lever shoulder with the MKM-6086-8 hinge and a demountable head of MKM-6086-10.
Establish a MKM-6086-200 block set.
Establish a persistent part of MKM-6086-200-10.
Attach the lever for a klapanny spring of MKM-6086.
Attach MKM-6086-6 support.
Insert a block shaft into support.

Installation of the lever and support for removal of a klapanny spring: 1–support; 2–lever

NOTE
Combine a block shaft with the center of an opening of a spark plug

Tighten 4 bolts of fastening.
Establish the MKM-6086-7 lever.

NOTE
The demountable head should be turned to the admission party.

Fix an adjusting shaft and tighten 2 bolts of fastening.
Establish the adapter of the compressed air.
Screw in a spark plug carving, the cylinder No. 1.

Procedure of compression of a klapanny spring: 1–lever; 2–demountable head

Submit the compressed air to the cylinder No. 1.
Remove 2 springs of the inlet valve of the cylinder No. 1.
Accurately put forward klapanny springs down the lever.

NOTE
The demountable head should be placed vertically above a valve core.

ATTENTION
Observe correctness of installation.

Remove crackers and valve heads, klapanny springs.

NOTE
Do not use thus magnetic tools.

Replace consolidations of a core of the valve.
Place new consolidation of a core of the valve on a valve core.
Put on against the stop by means of KM 958.
Establish springs of the inlet valve, the cylinder No. 1.
Establish klapanny springs and valve heads.
Establish valve crackers in a block head.
Shift the plastic tightening plug in the direction of fastening of a shoulder of the lever.

Installation of crackers of the valve in a head of the adjusting block: 1–valve cracker; 2–plastic tightening plug

ATTENTION
Establish crackers the end reduced on a cone towards the valve

Shift the plastic tightening plug in the valve direction (an arrow in drawing.
Attach an adjusting head to the lever.

ATTENTION
The head should be located vertically above a valve core. Crackers should enter on a seat with click.

Accurately shift klapanny springs down by means of the lever (the shooter in drawing).

ATTENTION
Do not do the 2nd attempt, without having convinced that both crackers are established in a block head. Check reliability of landing of crackers. Be convinced of supply of the compressed air.

Installation of crackers of the valve and klapanny springs: 1–head; 2–crackers

Move the lever and remove it.
Do the above described procedure for all cylinders.
Block feeding line of the compressed air
Remove blocking of a cranked shaft.
Establish the cylinder No. 3 piston in situation VMT.
Extend a chain of a drive of the mechanism of a gazoraspredeleniye up.
Evenly turn a cranked shaft (180 °).

NOTE
The label on a belt pulley of a cranked shaft should be combined with a ledge on the case of the mechanism of a gazoraspredeleniye.

Block a cranked shaft by means of the KM special tool 952.
Rearrange the adapter of supply of the compressed air.
Block feeding line of the compressed air.
Unscrew the adapter from a spark plug carving, the cylinder No. 4.
Screw in a spark plug carving, the cylinder No. 2.
Submit the compressed air to the cylinder No. 2.
Replace consolidations of a core of the valve, the cylinder No. 2.
Rearrange the adapter of supply of the compressed air.
Block feeding line of the compressed air.
Unscrew the adapter from a spark plug carving, the cylinder No. 2.
Screw in a spark plug carving, the cylinder No. 3.
Submit the compressed air to the cylinder No. 3.
Replace consolidations of a core of the valve, the cylinder No. 3.
Block feeding line of the compressed air.
To disconnect the lever of a klapanny spring.
Remove the adapter of the compressed air.
Release a cranked shaft.
Establish the gear shifting lever in neutral situation.
Switch off lay brake system.
Lift the car.
Block a cranked shaft.
Extend a chain of a drive of the mechanism of a gazoraspredeleniye up.
Evenly turn a cranked shaft against the stop the KM special adaptations 952.
Establish the KM special tool 952.
Lower the car

Installation
Establish spark plugs by means of the special KM-194-E adaptation and tighten the moment of 25 N · m.
Visually check elements – cam-shafts, a cover of bearings of a cam-shaft, a head of the block of cylinders, pushers of valves, hydraulic pushers of valves.
Establish hydraulic pushers and pushers of valves.

Removal of a chain drive of the mechanism of a gazoraspredeleniye
Weaken bolts of a pulley of a cam-shaft.
Hold cam-shafts for shestigrannik.
Block a natyazhitel of a chain.
Establish the special KM-955-1 tool.
Move back a natyazhitel of a chain and block it by means of the special KM-955-1 tool.
Remove directing, having unscrewed 2 bolts of fastening.
Remove directing, having unscrewed 2 bolts of fastening.
Remove directing tension, having unscrewed a fastening bolt.
Remove a chain of a drive of the mechanism of the gazoraspredeleniye, conducting asterisk and laying of the case of the mechanism of a gazoraspredeleniye.
Disconnect the socket of a plait of wires of the sensor of impulses of a cranked shaft.
Remove the KM special tool 952.
Remove the generator of impulses of a cranked shaft, having unscrewed a fastening bolt.
Disconnect the basis of the block of cylinders from the block of cylinders, having unscrewed 22 bolts of fastening.
Uncover the shatunny bearing.

Removal of a chain drive of the mechanism of a gazoraspredeleniye: 1–natyazhitel of a chain; 2–special tool; 3–the directing; 4–chain of a drive of the mechanism of a gazoraspredeleniye; 5–the directing; 6–asterisk; 7–directing tension

NOTE
Surfaces of contact of rods and covers of shatunny bearings steal up individually and therefore them it is impossible to rearrange or allow their damages. to avoid damage, do not put rods and covers on contact surfaces.

Removal of a cover of a rod: 1–basis of the block of cylinders; 2–special tool; 3–covers of shatunny bearings

Mark covers of shatunny bearings.
Mark sequence of cylinders.
Unscrew 8 bolts of fastening and uncover a rod.
Remove a cranked shaft.
Disconnect the basis of the block of cylinders.

Removal of a cranked shaft: 1–kolechaty shaft

NOTE
Separate the basis evenly assembly shovel.

Unscrew 22 bolts.
Remove a back epiploon of a cranked shaft.
Remove a cranked shaft and put on wooden whetstones.
Remove clips of bearings of a cranked shaft.

NOTE
Observe the correct sequence

Remove loose leaves of the shatunny bearing and mark them, observing thus the correct sequence.
Check all elements on wear and replace in case of need.

Check of a cranked shaft
Check ovality of a cranked shaft. Check an axial free wheeling of a cranked shaft.
Disconnect a disk of the sensor of impulses of a cranked shaft, having unscrewed 3 bolts of fastening.

Disk of the sensor of impulses of a cranked shaft: 1–disk

Installation
Attach a disk of the sensor of impulses of a cranked shaft and tighten 3 bolts of fastening the moment of 15 N · m.
Establish loose leaves of bearings of a cranked shaft in the block of cylinders and in the basis of the block of cylinders.
Cover them with engine oil.
Note position of persistent bearings (the shooter in drawing).
To establish loose leaves of shatunny bearings in rods and covers of shatunny bearings.
Cover them with engine oil.
Accurately establish a cranked shaft in the block of cylinders.

NOTE
The provision of a cranked shaft can be corrected a postukivaniye a rubber hammer on a crank cheek.

Cover with engine oil of a neck of a cranked shaft.
Attach the basis of the block of cylinders to the block of cylinders new bolts.
Put hermetic on external regions of a groove (the size I = 2 mm).

NOTE
Do not put a sealant in a groove.
Execute assembly within 10 minutes.

ATTENTION
Observe sequence of an inhaling.

Tighten 10 bolts of M8 (internal) the moment of 25 N · m, tighten on +60 °.
Tighten 12 bolts of M6 (external) the moment of 10 N · m, tighten on +60 °.
Remove the sealant remains.
Establish a back epiploon of a cranked shaft. Before it put on a working edge (white) silicone greasing.
Establish the special KM-235-6 adaptation on a neck of a cranked shaft.
Put on a sealing ring the special adaptation and press aflush using KM-658-1.
Attach covers of shatunny bearings to rods new bolts.

Press fitting of a back epiploon of a cranked shaft: 1–epiploon; 2–special adaptation; 3–the special adaptation for a press fitting

NOTE
Pay attention to adjusting situation, inflow (the shooter in drawing) on covers of shatunny bearings should be turned towards a transmission.

Tighten 8 bolts of fastening the moment of 13 N · m, tighten on +60 ° +15 °.

NOTE
Always use bolts of M 6,5.

Connect a plait of wires of the sensor of impulses of a cranked shaft.
Block a cranked shaft, having established the KM special tool 952.
Smoothly turn a cranked shaft against the stop the KM special tool 952.
Establish new consolidation of the pump of cooling liquid in the case of the mechanism of a gazoraspredeleniye.
Provide correctness of installation of directing plugs (an arrow in drawing)

Installation of covers of shatunny bearings: 1–covers

Installation of the pump of cooling liquid: 1–fastening bolts

Attach the pump of cooling liquid to the case of the mechanism of a gazoraspredeleniye short bolts.
Tighten 3 bolts of fastening the moment of 8 N · m.
Put hermetic.

Scheme of laying of hermetic: 1–laying of a head of the block of cylinders; 2–roller of silicone hermetic

NOTE
The case of the mechanism of a gazoraspredeleniye should be established during 10 mines after drawing of silicon hermetic (gray).

Turn the engine on the KM special adaptation 412 on 90 °.
Cut off acting parts of an elastomer from laying of a head of the block of cylinders and replace them with the roller of silicon hermetic (gray) in the thickness of 2 mm.

NOTE
The roller of silicone hermetic (gray) can be put directly if ledges of an elastomer are not present.

Installation of the mechanism of a gazoraspredeleniye
Establish new laying of the case of the mechanism of a gazoraspredeleniye.
Provide correctness of installation of directing plugs (an arrow in drawing).
Establish a chain of a drive of the mechanism of a gazoraspredeleniye.

Installation of the mechanism of a gazoraspredeleniye: 1–natyazhitel of a chain; 2–special tool; 3–the directing; 4–chain of a drive of the mechanism of a gazoraspredeleniye; 5–the directing; 6–leading gear wheel; 7–clip tire

NOTE
At installation use new bolts of a pulley of a cam-shaft.

Accession of a nave of a cranked shaft: 1–belt pulley of a cranked shaft; 2–nave of a cranked shaft; 3–special tool

Provide correctness of installation of directing plugs (an arrow in drawing).
Establish a leading gear wheel.
Establish an asterisk of a cam-shaft of a drive of final valves.
Wrap a fastening bolt.
Establish a chain of a drive of the mechanism of a gazoraspredeleniye.

NOTE
Provide a tension of the leader (the release party) branches of a chain of a drive of the mechanism of a gazoraspredeleniye.

Establish a pulley of a cam-shaft of a drive of inlet valves in a chain of a drive of the mechanism of a gazoraspredeleniye with a disk of the sensor of a phase and wrap a fastening bolt.

NOTE
The disk of the sensor of a phase should rotate effort of a hand.

Attach the clip tire to the block of cylinders.
Tighten a bolt of fastening the moment of 20 N · m.
Attach directing to the block of cylinders.
Tighten 2 bolts of fastening the moment of 8 N · m.
Attach directing to a head of the block of cylinders.
Tighten 2 bolts of fastening the moment of 8 N · m.
Weaken a natyazhitel of a chain.
Remove the special KM-955-1 tool.
Attach the case of the mechanism of a gazoraspredeleniye.
Tighten 22 bolts of fastening.
Tighten 6 bolts the moment of 8 N · m.
Tighten 14 bolts the moment of 8 N · m.
Tighten 2 bolts the moment of 35 N · m.
Remove the KM special tools 952 and KM 953

NOTE
Special tools should not be used for deduction.

Attach a nave of a cranked shaft.
Note the adjusting provision of a nave of a cranked shaft.
The label should be turned up.
Hold by means of the special tool KM-956-1/-2.
Tighten a bolt the moment of 150 Nanometers, tighten on +45 °.

NOTE
Use a new bolt.

Remove the special tool KM-956-1/-2.
Attach a belt pulley of a cranked shaft.
Tighten 6 bolts of fastening the moment of 8 N · m.
Turn a cranked shaft approximately on 720 ° in the direction of rotation of the engine for a bolt of a nave of a cranked shaft.
The label on a belt pulley of a cranked shaft is established opposite to a ledge on the case of the mechanism of a gazoraspredeleniye.
In this position cams of the cylinder No. 1 settle down before VMT (both cams are turned outside).
Establish the KM special tool 952. (3)
At the same time continue to rotate a shaft in the direction of rotation of the engine for a bolt of a nave of a cranked shaft against the stop KM adaptations 952.

NOTE
Cranked shaft rotate slowly and smoothly.

In this position, the label on a belt pulley of a cranked shaft should be combined with a ledge on the case of the mechanism of a gazoraspredeleniye.
Establish the KM special adaptation 953 on a cam-shaft.

Label combination on a belt pulley of a cranked shaft with a ledge on the case of the mechanism of a gazoraspredeleniye: 1–a ledge on the case of the mechanism of a gazoraspredeleniye; 2–a label on a belt pulley; 3–special tool

NOTE
If the KM adaptation 953 cannot be established, it is necessary to execute base adjustment of the moment of ignition.
The KM adaptation 953 should be established in cam-shaft grooves against the stop.

Establish the KM special adaptation 954 (1) on a disk of the sensor of a phase (2) and attach to the case of the mechanism of a gazoraspredeleniye.

KM special adaptation 954 installation on a disk of the sensor of a phase: 1–special adaptation; 2–disk of the sensor of a phase

NOTE
If the KM adaptation 953 cannot be established, it is necessary to execute base adjustment of the moment of ignition.

Tighten 2 bolts of fastening.
Remove KM adaptations 954, KM 953 and KM 952.
Establish a bolt in an opening of the basis of the block of cylinders with a new sealing ring and tighten the moment of 60 N · m.
Remove the remains of laying and clear condensed surfaces.
Put hermetic.

NOTE
The cover of a head of the block of cylinders should be established during 10 mines after drawing of hermetic (gray).

Cut off an acting part of laying of the case of the mechanism of a gazoraspredeleniye aflush with a block head cylinders / case of the mechanism of a gazoraspredeleniye.
Put the roller (gray) silicone hermetic in thickness about 2 mm (measurement of I).
Establish a cover of a head of the block of cylinders.
Establish new consolidation in a cover of a head of the block of cylinders.

ATTENTION
It is necessary to examine bolts about damage consolidation. If consolidation has damages, the bolt should be replaced with the new.

Attach a cover of a head of the block of cylinders to a head of the block of cylinders
Tighten 13 bolts of fastening the moment of 8 N · m.
Establish the ignition module.
Connect the ignition module to spark plugs.
Tighten 2 bolts of fastening the moment of 8 N · m.
Connect the socket of a plait of wires of the module of ignition.
Attach a cover of the module of ignition to a cover of a head of the block of cylinders.
Attach a ventilating hose of the engine to a cover of a head of the block of cylinders.
Attach a pulley to the pump of cooling liquid.

Installation of a cover of a head of the block of cylinders: 1–cover; 2–consolidation

Tighten 3 bolts of fastening the moment of 20 N · m.
Connect sockets of plaits of wires of the sensor of temperature of cooling liquid, the sensor of a cam-shaft and the sensor of pressure of oil.
Fix plaits of wires on a cover of a head of the block of cylinders.
Attach hoses of cooling liquid to the pump of cooling liquid and dress 2 collars.
Attach the thermostat case with the top hose of cooling liquid to the pump of cooling liquid.
Establish a new sealing ring.
Tighten 3 bolts of fastening the moment of 8 N · m.
Establish the generator of an alternating current.
Establish 2 boltovy connections and tighten the moment of 35 N · m.
Attach a plait of wires of the generator of an alternating current.
Attach a natyazhitel of a poliklinovy belt.
Tighten M8 bolt the moment of 20 N · m.
Tighten M10 bolt the moment of 55 N · m.
Turn a natyazhitel of a poliklinovy belt in the arrow direction (fig. 2.179), using the KM adaptation 6131, establish the KM adaptation 6130.
Establish a poliklinovy belt.
Pay attention to the direction of rotation and the provision of a belt.
Compress a natyazhitel of a poliklinovy belt the KM adaptation 6131.
Weaken a natyazhitel of a poliklinovy belt.
Attach a support of the dempfiruyushchy block of the engine to the mechanism case gazoraspredeleniya/to the block of cylinders.
Tighten 3 bolts of fastening the moment of 50 N · m.
Establish a flywheel.
Block a flywheel, using the KM adaptation 652.
Clear a carving on cranked to a shaft.
Use new bolts.
Tighten 6 bolts of fastening the moment of 35 N · m, tighten on + 30 °.
Attach coupling.
Attach a plate of a maslootrazhatel to the basis of the block of cylinders.
Tighten 8 bolts of fastening the moment of 8 N · m.
Establish the oil pallet.
Establish new consolidation of the oil pallet.
Tighten 16 bolts of fastening the moment of 10 N · m.
Add engine oil.
Check level of engine oil and modify in case of need.
Remove the engine from a building berth.
Attach a mechanical transmission to the engine.
Establish the engine.

«on page back
2.7.2. Replacement of a back epiploon of a cranked shaft
on the following page»
2.7.4. Check of an axial free wheeling of a cranked shaft