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Vauxhall Workshop Service and Repair Manuals

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Cylinder Block|Specifications > < Cylinder Block, Check for Plane Surface

Corsa D

Crankshaft drive bearing

  Remove

1.   Remove engine
2.   Remove manual transmission from engine LUREF_1.gif
3.   Remove clutch (1)
4.   Detach thrust plate and clutch disk LUREF_1.gif
5.   Remove flywheel (3)
•   Lock with KM-652 (1)
•   Unscrew 6x bolt (2)
Object Number: 13408788 Size: DEFAULT


6.   Attach engine to suitable engine overhaul stand
•   Attach KM-2358 to 3x engine transport shackle
•   Raise using engine crane
•   Attach engine to engine overhaul stand
•   Detach KM-2358 from 3x engine transport shackle
7.   Drain engine oil
•   Place collecting basin underneath.
•   Remove oil drain bolt
•   Remove oil filter housing cover
•   Remove oil filter element
8.   Remove engine bracket right (1)
•   Unscrew 3x bolts
9.   Screw in oil drain bolt
•   Replace sealing ring
•   Tighten bolt 10 Nm
•   Remove collecting pan
Object Number: 2411044 Size: DEFAULT


10.   Detach ribbed V-belt
•   Mark direction of rotation
•   Tension the ribbed V-belt tensioner using KM-6131 (1) in the direction of the arrow
•   Insert KM-955-2 (2)
•   Release ribbed V-belt tensioner
Object Number: 10678417 Size: DEFAULT


11.   Remove ribbed V-belt tensioner
•   Unscrew 2 bolts (arrows)
•   Remove ribbed V-belt tensioner
Object Number: 2410378 Size: DEFAULT


12.   Detach coolant pump ribbed V-belt pulley
•   Unscrew 3x bolts
Note:   Counterhold with open-end wrench
13.   Detach alternator
•   Detach alternator wiring harness (1)
– Unscrew 2x nuts
•   Remove cable ties
•   Detach 2x bolted connections
Object Number: 2410438 Size: DEFAULT


14.   Detach 3x coolant hoses from coolant pump
15.   Unclip engine management wiring harness from cylinder head cover
•   Disconnect 3 wiring harness plugs
– Camshaft sensor, coolant temperature sensor, oil pressure sensor
16.   Detach coolant pump (1) together with thermostat housing
Note:   When removing guide sleeves, please note
•   Place collecting basin underneath.
•   Unscrew 9x bolts
Note:   Note differing bolt lengths (arrows = short bolts)
Object Number: 2410459 Size: DEFAULT


17.   Detach ignition module
•   Detach ignition module cover
– Push to the right
•   Disconnect ignition module wiring harness plug
•   Unscrew 2x bolts
•   Pull out using KM-6009 (1)
Note:   Do not tilt
Object Number: 2410586 Size: DEFAULT


18.   Remove cylinder head cover
•   Detach 2 engine vent hoses
– Undo 2x clamps
•   Unscrew 13x bolts
Object Number: 13408798 Size: DEFAULT

19.   Set engine to TDC of combustion stroke of cylinder 1
•   Unscrew crankshaft closure bolt
– Take out seal ring
•   Rotate crankshaft in direction of engine rotation to the marking (4) on the torsional vibration damper and align with marking (3) on timing case
Important:   It must be possible to insert EN-953 smoothly and without major effort into the camshaft grooves.
•   Lock camshafts with EN-953 (2)
Important:   It must be possible to insert KM-952 smoothly and without major effort into the crankshaft recess.
•   Fix crankshaft with KM-952 (1)

20.   Detach torsional vibration damper (3)
•   Counterhold it with EN-49979 (1) together with KM-956-1 (2)
•   Unscrew bolt (4)
Object Number: 13408794 Size: DEFAULT


21.   Rotate engine on engine overhaul stand through 180°
22.   Remove oil pan
•   Unscrew 16x bolts
Important:   Do not damage oil pan and base place seal surfaces when prising off
•   Detach oil pan by carefully prising out to position (1)
Object Number: 13408799 Size: DEFAULT


23.   Detach oil baffle plate
•   Unscrew 6x bolts
24.   Rotate engine on engine overhaul stand through 180°
Object Number: 2410461 Size: DEFAULT

25.   Remove timing case
•   Unscrew 15x bolts (arrows)
– Note bolt lengths
– Do not damage camshaft sensor (1)
•   Prise out timing case seal ring
Note:   Do not damage sealing surface

Object Number: 2398446 Size: DEFAULT

26.   Detach chain drive
•   Slacken bolts, camshaft sprockets
– Counterhold the camshafts on the hexagon
•   Lock chain tensioner (1)
– Insert KM-955-1 (2)
27.   Turn back chain tensioner (1) and lock with KM-955-1 (2)
28.   Remove sliding rail (3)
•   Unscrew 2x bolts
29.   Remove guide rail (5)
•   Unscrew 2x bolts
30.   Remove guide rail (7)
•   Unscrew bolt
31.   Remove timing chain (4), drive gear (6) and timing case gasket

32.   Rotate engine on engine overhaul stand through 180°
33.   Remove KM-952
34.   Remove crankshaft sensor
Note:   Note seal ring
•   Unscrew bolt
35.   Detach cylinder block base plate
•   Unscrew 18 bolts
36.   Remove con-rod bearing cover
Note:   The shear surfaces of the con-rod and the con-rod bearing cover form a unique fit and must not be swapped or damaged. Do not lay down on the shear surfaces
•   Mark con-rod bearing cap (1)
– Note cylinder sequence
•   Unscrew 6x bolts
•   Remove con-rod bearing cap
Object Number: 2410579 Size: DEFAULT


37.   Detach crankshaft
•   Remove rear crankshaft seal ring
•   Take out crankshaft and place on wooden blocks
38.   Remove crankshaft bearing clips
•   Mark crankshaft bearing shells
Note:   Observe the correct sequence
39.   Remove con-rod bearing shells
•   Identify con-rod bearing shells
Note:   Observe the correct sequence
40.   Check all parts for wear, replace if necessary
41.   Detach crankshaft pulse sensor disk (1)
•   Unscrew 3x bolts
Object Number: 2410580 Size: DEFAULT


  Install

42.   Attach crankshaft pulse pick-up disc
•   Tighten 3x bolt 15 Nm
43.   Insert crankshaft bearing shells in cylinder block and in cylinder block base plate
•   Coat with engine oil
•   Note position of axial bearing (arrow)
Object Number: 2410552 Size: DEFAULT


44.   Insert con-rod bearing shells into con-rods and con-rod bearing caps
•   Coat with engine oil
45.   Insert crankshaft carefully into cylinder block
Note:   The position of the crankshaft can be corrected by hammering gently on the crank webs with a rubber mallet
•   Coat crankshaft journal with engine oil
46.   Attach cylinder block base plate to cylinder block with new bolts
Note:   Complete assembly work within 10 minutes
•   Apply sealant to the outer edge of the groove (dimension I = 2 mm)
Note:   Do not apply sealant in groove
Important:   Observe tightening sequence
•   Tighten 8 M8 bolts inside 25 Nm + 60° + 15°
•   Tighten 10 M6 bolts outside 10 Nm + 60° + 15°
•   Remove superfluous sealant
Object Number: 2414779 Size: DEFAULT


47.   Install crankshaft rear seal ring (1)
•   Position KM-235-6 (2) on crankshaft journal
•   Slide seal ring onto KM-235-6
•   Drive in flush using KM-658-1 (3)
Object Number: 2410460 Size: DEFAULT


48.   Attach con-rod bearing cap to con-rod with new bolts
Note:   Note installation position, bead (arrow) on the con-rod bearing cap points towards the transmission side
•   Tighten 6 bolts 13 Nm + 60° + 15°
Note:   Only use screws of size M6.5
Object Number: 13408806 Size: DEFAULT

49.   Lock crankshaft
•   Unscrew crankshaft closure bolt
– Take out seal ring
Important:   It must be possible to insert KM-952 smoothly and without major effort into the crankshaft recess.
•   Insert KM-952 (1)
– Rotate smoothly on crankshaft dihedral (2) in direction of engine rotation until KM-952 engages

50.   Attach crankshaft sensor
Note:   Use new seal ring
•   Tighten bolt 8 Nm
•   Fix wiring harness plug
Object Number: 2410447 Size: DEFAULT

51.   Replace timing case gasket
•   Apply 2x sealing bead as shown (2 mm)
Note:   After application of the sealant, the chain drive and timing case must be fitted within 10 minutes
•   Place new gasket in position
Note:   Note guide bushings (arrows)
52.   Attach timing chain
•   Insert KM-953 into camshafts
Note:   If necessary, gently adjust camshafts by the hex
•   Apply timing chain (3) together with drive gear (5)
53.   Attach timing chain tension rail (6)
•   Tighten bolt 20 Nm
Note:   Ensure correct seat of timing chain
54.   Attach timing chain guide rail (4)
•   Tighten 2x bolt 8 Nm
Note:   Ensure correct seat of timing chain
55.   Attach timing chain sliding rail (2)
•   Tighten 2x bolt 8 Nm
56.   Relieve tension on chain tensioner
•   Remove KM-955 (1)

Object Number: 13408825 Size: DEFAULT

57.   Attach timing case.
Note:   Note guide bushings and camshaft sensor
•   Screw in all bolts
•   Tighten 13x bolt M6 (1) 8 Nm
•   Tighten 2x M10 bolt (3) 35 Nm
58.   Replace front crankshaft sealing ring (2)
•   Push onto KM-960 (4)
•   Drive in flush using KM-960

Object Number: 13408812 Size: DEFAULT

59.   Fit torsional vibration damper (6)
•   Insert torsional vibration damper in oil pump rotor hex head (2) and crankshaft dihedral (1)
Note:   Marking on the torsional vibration damper must align with the marking on the timing case
•   Check for correct torsional vibration damper seating
– Measure distance between torsional vibration damper and edge of timing case (dimension a = 5,5 mm)
•   Screw in torsional vibration damper bolt (7)
•   Tighten torsional vibration damper bolt 150 Nm
– Counterhold it with EN-49979 (4) together with KM-956-1 (5)

60.   Fix 2x camshaft sprocket
•   Attach EN-49977-200 (3)
Note:   Press EN-49977-200 in direction of arrow so that the teeth (4) engage in the teeth of the intake camshaft sprocket without play
– Tighten 2x fastening bolt (1)
– Tighten adjusting bolt (2)
Note:   Press EN-49977-200 in direction of arrow when tightening
61.   Adjust and fix phase sensor disc
•   Rotate phase sensor disc until EN-49978 (5) can be inserted
Note:   EN-49978 must rest on the surfaces shown (arrows) without play
•   Tighten 2x fastening bolt (6)
62.   Tighten 2x camshaft sprocket 50 Nm + 60°
•   Counterhold with open-end wrench against the hexagon of the camshafts
63.   Remove all special tools: KM-952 , EN-953 , EN-49977-200 , EN-49978
Object Number: 13408826 Size: DEFAULT


64.   Timing, Check
•   Turn crankshaft (720°)
•   Insert KM-952
•   Insert KM-953
•   Attach EN-49978
65.   Repeat adjustment procedure if necessary
66.   Remove locking tool
•   KM-952 , KM-953 , EN-49978
67.   Insert crankshaft sealing plug and tighten 50 Nm
Note:   Use new seal ring
68.   Attach coolant pump together with thermostat housing
•   Insert new gasket
•   Insert 9x bolt 8 Nm
Note:   Note different bolt lengths
69.   Attach 3 coolant hoses to coolant pump
70.   Clip engine management wiring harness into cylinder head cover
•   Connect 3 wiring harness plugs
– Camshaft sensor, coolant temperature sensor, oil pressure sensor
71.   Attach coolant pump belt pulley
•   Insert 3x bolt and tighten 22 Nm
Note:   Counterhold with open-end wrench on flange
72.   Rotate engine on engine overhaul stand through 180°
73.   Attach oil baffle plate
•   Tighten 6x bolt 8 Nm
Object Number: 13408815 Size: DEFAULT

74.   67. Install oil pan
•   Apply sealant (dimension I = 2 mm)
Note:   Oil pan installation must take place within 10 minutes
– Inner oil pan edge
– Timing case groove
– For the bolt hole shown
•   Rotate 2x EN-49980 (1) into the positions shown
Important:   When positioning the oil pan, it is necessary to ensure that the sealing bead is not wiped away.
•   Carefully apply the oil pan
Note:   Pass EN-49980 through corresponding bolt holes
•   Insert 4x bolt, offset diagonally
•   Remove EN-49980
•   Screw in 12 bolts
•   Adjust oil pan with rubber mallet and straightedge
Note:   Straightedge must rest on the oil pan and cylinder block without play
•   Tighten 16x bolt 10 Nm

75.   Rotate engine on engine overhaul stand through 180°
76.   Attach cylinder head cover (1)
•   Replace gasket (2)
•   Apply sealant (dimension I = 2 mm)
Note:   Complete assembly work within 10 minutes
•   Tighten 17x bolts 8 Nm
•   Attach 2x engine vent hose
– Attach 2x clamps
77.   Attach ignition module
•   Tighten 2x bolt 8 Nm
•   Connect ignition module wiring harness
Object Number: 2410387 Size: DEFAULT


78.   Install alternator
•   Insert alternator into bracket
•   Attach 2x screwed connection 35 Nm
•   Attach alternator wiring harness
– Tighten 2x nuts
79.   Attach ribbed V-belt tensioner -
•   Tighten bolt (M8) 20 Nm
•   Tighten bolt (M10) 55 Nm
80.   Insert ribbed V-belt
Note:   Ensure correct running direction and installation position
•   Release ribbed V-belt tensioner
•   Remove KM-955-2
81.   Attach engine bracket right
•   Tighten 2x bolt 60 Nm
82.   Top up engine oil.
•   Observe specified engine oil quantity
83.   Detach engine from engine overhaul stand
•   Attach KM-2358 to 3x engine transport shackle
•   Hitch engine up to workshop crane.
•   Lower engine onto wooden pallet
•   Detach KM-2358 from 3x engine transport shackle
84.   Fit flywheel
•   Clean 6x thread in crankshaft
•   Tighten 6x new bolt 35 Nm +60 °
– Lock with KM-652
85.   Attach clutch and thrust plate LUREF_1.gif
86.   Attach manual transmission to engine LUREF_1.gif
87.   Install engine

Cylinder Block|Specifications > < Cylinder Block, Check for Plane Surface