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Cylinder Head|Valves > < Camshaft Housing Cover, Remove and Install (Z 17 DTH, with Air Conditioning, LHD)

Corsa C

Camshaft Housing, Replace (Z 17 DTH, without AC, LHD)

  Remove

1.   Remove camshaft housing cover LUREF_1.gif
2.   Remove 4 injectors
Note:   Mark 4x injectors (1)
Important:   If the heat insulation sleeve (5) is also pulled out together with the injector during removal, new gaskets (3) must be installed and the heat insulation sleeve driven into the cylinder head using KM-6357 (4)
•   Remove 4 injector brackets (2)
– Unscrew 4 bolts
•   Remove 4x copper ring
Object Number: 2413401 Size: DEFAULT


3.   Check injector bracket
Note:   If an old injector bracket was installed, it must be replaced with a new one
  1. New injector bracket
  2. Old injector bracket
Object Number: 7360932 Size: DEFAULT


4.   Remove air cleaner housing (1)
•   Disconnect wiring harness plug of hot film mass air flow meter (3)
– Release in direction of arrow
•   Remove air intake hose (4)
– Loosen clamp (5)
•   Remove bolt (2)
•   Disconnect wiring harness
Object Number: 2406483 Size: DEFAULT


5.   Raise vehicle
6.   Remove ribbed V-belt cover
•   Unscrew 3 bolts (1)
•   Remove clip (arrow)
Object Number: 2410600 Size: DEFAULT


Object Number: 2408346 Size: DEFAULT

7.   Attach KM-6394
•   Position KM-6394 (1) at the front on the front axle body
Note:   Both locating pins (arrows) must be seated in the holes in the front axle body
•   Push front bracket (2) in the direction of the arrow
•   Place rear bracket (4), right hand side, on front axle body
•   Attach rear bracket (3), left hand side
– Screw in 2x bolt
•   Tighten 6 bolts

Object Number: 2411021 Size: DEFAULT

8.   Install support
•   On KM-6394
– Adjust bracket (2) for support
•   Screw on nut (1)
9.   Adjust 3x support
•   Transmission side
Note:   Turn spindles until mounts (3) are positioned at guide journals free of play
•   Engine timing side
– Insert journal of the support in the bore of the cylinder block free of play (arrow)
– Tighten nuts (1)

10.   Lower vehicle
11.   Remove right engine damping block (1)
•   Unscrew 4 bolts
Object Number: 2408139 Size: DEFAULT


12.   Detach right engine bracket (1)
•   Unscrew 3 bolts
Note:   Lower bolt cannot be removed
•   With right engine bracket adapter
Object Number: 2411072 Size: DEFAULT


Object Number: 2408126 Size: DEFAULT

13.   Detach wiring trough of engine management wiring harness
•   Unclip vacuum line (4)
•   Remove bolt (3)
•   Unclip wiring trough (5)
•   Disconnect 2 wiring harness plugs
– Camshaft sensor (2)
– Charge pressure sensor (1)
•   Unclip wiring harness

14.   Remove camshaft sensor bracket
•   Remove bolt
15.   Remove upper toothed belt cover
Important:   Take care not to damage the increment counter on the camshaft sprocket when removing the upper toothed belt cover
•   Unscrew 8 bolts
Note:   Pay attention to different bolt lengths
Object Number: 2404431 Size: DEFAULT


16.   Raise vehicle
17.   Loosen coolant pump ribbed V-belt pulley (1)
•   Undo 3 bolts
Object Number: 2406521 Size: DEFAULT


18.   Remove ribbed V-belt
•   Tension ribbed V-belt tensioner in direction of arrow
•   Use KM-913-A
Note:   Mark running direction.
Object Number: 2411073 Size: DEFAULT


19.   Detach coolant pump ribbed V-belt pulley
•   Unscrew 3 bolts
20.   Remove torsional vibration damper (1)
•   Unscrew 4 bolts
Object Number: 2411100 Size: DEFAULT


21.   Detach lower part of toothed belt cover
•   Unscrew 3 bolts
Object Number: 2411099 Size: DEFAULT


22.   Remove right engine bracket with right engine bracket adapter
23.   Lower vehicle
24.   Set 1st cylinder to TDC
•   Turn crankshaft evenly until TDC fixing bolt (1) can be screwed in
Note:   Mark (3) on toothed belt drive gear must align with mark (2) on oil pump cover
Object Number: 2412641 Size: DEFAULT


25.   Raise vehicle
26.   Loosen toothed belt tension roller (1)
•   Loosen bolt of toothed belt tension roller (2)
•   Rotate toothed belt tension roller anticlockwise approx. 90°
•   Tighten bolt of toothed belt tension roller
Object Number: 2406524 Size: DEFAULT


27.   Remove toothed belt
Note:   Mark running direction.
28.   Remove toothed belt guide roller
•   Remove bolt
29.   Lower vehicle
30.   Rotate crankshaft 60° against direction of engine rotation
Object Number: 2412643 Size: DEFAULT


31.   Detach camshaft pulley
•   Unscrew TDC fixing bolt (1)
•   Use KM-6347 (3) in combination with KM-956-1 (2)
•   Remove bolt
Object Number: 2412644 Size: DEFAULT


32.   Detach connection hose (1) from intercooler for intake pipe
•   Release clamp
Object Number: 2408332 Size: DEFAULT


Object Number: 2408333 Size: DEFAULT

33.   Detach EGR cooler (1)
•   Release 2 clamps (arrows)
•   Unscrew 6 bolts
•   Remove 2 gaskets

34.   Front left engine transport shackle
•   Remove bolt
35.   Remove throttle valve module bracket
•   Unscrew 2 bolts
36.   Detached rear toothed belt cover from camshaft housing
•   Unscrew 3 bolts (1)
Object Number: 2408143 Size: DEFAULT


Object Number: 2416020 Size: DEFAULT

37.   Remove camshaft housing
•   Loosen 17 bolts 1/2 turn in sequence illustrated and unscrew
•   Remove gasket.

38.   Remove 16 cup tappets (1)
Note:   Note order and installation position
Object Number: 2413403 Size: DEFAULT


39.   Lock exhaust camshaft compensating sprocket
•   Remove camshaft bearing cap (3)
– Unscrew 2 nuts
•   Use KM-6092-10 (1)
Note:   Insert into exhaust camshaft sprocket (4) and exhaust camshaft compensating sprocket (2) as far as it will go. Exhaust camshaft sprocket and exhaust camshaft compensating sprocket must be locked so they cannot turn
Object Number: 2413402 Size: DEFAULT


40.   Remove 2x camshaft
Note:   Note markings on camshaft bearing caps
•   Unscrew 8 nuts
•   Remove front camshaft seal ring
41.   Clean sealing surfaces
42.   Inspect components

  Install

Important:   When installing the camshafts, care must be taken that the marking (1) on the exhaust camshaft sprocket is between the two markings (2) for the intake camshaft sprocket and that the markings are approximately on the same level as the upper edge of the camshaft housing.
43.   Install 2x camshaft
•   Insert camshaft in camshaft housing
•   Apply surface sealant (green) to the sealing surfaces (3) of the 1st camshaft bearing cap
Object Number: 2416017 Size: DEFAULT


Object Number: 2416018 Size: DEFAULT

44.   Install 5 camshaft bearing caps
Note:   Coat bearing positions with engine oil
•   Fit camshaft bearing caps (1 - 4)
•   Screw in 8 nuts
•   Remove KM-6092-10
•   Fit camshaft bearing cap (5)
– Screw in 2 nuts
•   Tighten camshaft bearing caps
– 10 nuts (M8) 21.6 Nm
Note:   Tighten camshaft bearing caps in stages of 1/2 to 1 turn in the order shown

45.   Install front camshaft seal ring
•   Use KM-656 (1)
– Drive in until flush
Object Number: 2412649 Size: DEFAULT


46.   Insert 16x cup tappet
Note:   Observe allocation.
Object Number: 2416021 Size: DEFAULT

47.   Install camshaft housing
•   Replace gasket
Note:   Note tightening sequence (1 - 17)
– Tighten 12 bolts 21.6 Nm
– Tighten 5 bolts 26.5 Nm

48.   Attach rear toothed belt cover
•   Tighten 3 bolts 9.8 Nm
49.   Install bracket for throttle valve module
•   Tighten 2 bolts
50.   Install front left engine transport shackle
•   Tighten bolt 24.5 Nm
51.   Attach EGR cooler
•   Replace 2 gaskets
•   On camshaft housing
– Tighten 2 bolts 24 Nm
•   To connection, exhaust return pipe, exhaust manifold
– Tighten 4 bolts 28.5 Nm
•   Secure 2x clamp
52.   Attach connection hose of intercooler to intake pipe
•   Fasten clamp 5 Nm
Warning:   The different camshaft sprockets (with different part numbers) have different torques for the camshaft sprocket bolt.
53.   Attach camshaft sprocket with part number 97320335
•   Camshaft journal (2) must engage in the bore in the camshaft sprocket (1)
•   Use KM-6347 in combination with KM-956-1
•   Tighten bolt 64 Nm
•   Install TDC-fixing bolt
54.   Attach camshaft sprocket with part number 98021306
•   Camshaft journal (2) must engage in the bore in the camshaft sprocket (1)
•   Use KM-6347 in combination with KM-956-1
•   Tighten bolt 111 Nm
•   Install TDC-fixing bolt
Object Number: 2412650 Size: DEFAULT


55.   Raise vehicle
56.   Rotate crankshaft to 1st cylinder TDC
•   Mark on toothed belt drive gear (3) must align with cast lug (2) on oil pump cover
Object Number: 2412641 Size: DEFAULT


57.   Install toothed belt
Note:   TDC locking bolt must be installed in the camshaft sprocket and marking (6) and (7) must align.
•   Position toothed belt
– Toothed belt must be tensioned in the direction of the arrow from the toothed belt drive gear (5) via the oil pump drive gear (4), via the high pressure pump drive gear (2) to the camshaft sprocket (1)
– Note running direction
•   Loosen toothed belt tension roller (3)
•   Remove TDC locking bolt
•   Rotate crankshaft 60° against direction of engine rotation
•   Tighten toothed belt tension roller 38Nm
Object Number: 2412651 Size: DEFAULT


58.   Timing, Check
•   Turn crankshaft approx. 780° in direction of engine rotation
•   Mark on toothed belt drive gear (3) must align with cast lug (2) on oil pump cover
•   Screw in TDC fixing bolt (1)
Note:   If the TDC fixing bolt cannot be screwed in, basic adjustment must be repeated
•   Unscrew TDC fixing bolt
Object Number: 2412641 Size: DEFAULT


59.   Raise vehicle
60.   Install right engine bracket
•   Fit right engine bracket with adapter
•   Insert and tighten lower bolt
61.   Attach lower part of toothed belt cover
•   Tighten 3 bolts 9.8 Nm
62.   Install torsional vibration damper
•   Tighten 4 bolts 19.6 Nm
63.   Attach coolant pump ribbed V-belt pulley
•   Screw in 3 bolts
64.   Install ribbed V-belt
Note:   Observe running direction and installation position
•   Relieve tension of ribbed V-belt tensioner (1) in the direction of the arrow
•   Use KM-913
– I Ribbed V-belt without AC
– II Ribbed V-belt with AC
Object Number: 2415977 Size: DEFAULT


65.   Fasten coolant pump ribbed V-belt pulley
•   Tighten 3 bolts 16.3 Nm
66.   Lower vehicle
67.   Install camshaft sensor bracket
•   Tighten bolt 9.8 Nm
68.   Install upper toothed belt cover
•   Tighten 8 bolts 9.8 Nm
Note:   Note different bolt lengths
•   Clip in vacuum hose
69.   Attach wiring trough of engine management wiring harness
•   Route wiring harness
•   Clip-in wiring trough
•   Clip in vacuum hose
•   Tighten bolt 6 Nm
•   Connect 2 wiring harness plugs
70.   Fasten right engine bracket
•   Screw in 3 bolts
•   Tighten 2 upper bolts 40 Nm
71.   Install right engine damping block
•   To side member
– Tighten 2 bolts 40 Nm
•   On engine bracket
– Tighten 2 bolts 60 Nm + 30° + 15°
72.   Raise vehicle
73.   Fasten right engine bracket
•   Tighten lower bolt 40 Nm
74.   Detach support
75.   Detach KM-6394
76.   Attach ribbed V-belt cover
•   Tighten 3 bolts
•   Install clip
77.   Lower vehicle
78.   Install air cleaner housing
•   Fasten cable harness
•   Tighten bolt
•   Fasten air intake hose.
– Fasten clamp 5 Nm
•   Connect wiring harness plug of hot film mass air flow meter
79.   Turn crankshaft
•   Turn crankshaft until cam pairs (1) and (2) point upwards
Object Number: 2415968 Size: DEFAULT


80.   Check valve clearance
•   Using feeler gauge
Note:   The valve play is checked on a cold engine – room temperature.
– Test values: Intake valves/Exhaust valves (0.35 – 0.45 mm)
81.   Adjust valve clearance
•   Turn cup tappet until tappet groove points outwards
Important:   Make sure that the valves are not set when the piston is in "TDC". The valves could strike the piston head
•   Press down cup tappets
Note:   Note different tool versions for intake and exhaust valves
– Use KM-6090
– Mark – IN = Intake side
– Mark – EX = Exhaust side
•   Remove adjustment shim
Object Number: 2415968 Size: DEFAULT


82.   Example for determination of shim thickness:

1. Thickness of installed shim

3.15 mm

2. Measurement between cam and cup tappets

+ 0.45 mm
 

= 3.60 mm

3. Nominal valve clearance

- 0.40 mm
83.   Insert adjustment shim
•   Coat new shim (7) with engine oil and insert in cup tappet with identification mark facing downwards
84.   Turn crankshaft
•   In direction of engine rotation by 180°
– Check and adjust valve pair (6) and (2)
•   In direction of engine rotation by 180°
– Check and adjust valve pair (5) and (3)
•   In direction of engine rotation by 180°
– Check and adjust valve pair (4) and (1)
Note:   The clearance of all adjusted valves must be re-checked
Object Number: 2415969 Size: DEFAULT


85.   Detach accumulator
•   Unscrew 2x bolts 1 - 1 1/2 turns
86.   Replace 8 injector seals
•   4 O-rings (1)
•   4 copper seal rings (2)
Object Number: 2416067 Size: DEFAULT


87.   Install 4 injectors
•   Install 4x brackets
– Align injectors with EN-48560 (1)
Object Number: 2413404 Size: DEFAULT


88.   Fasten 4x accumulator high pressure lines to injectors
•   Hand-tighten 8x union nuts
89.   Fasten 4x injectors
•   Tighten 4 bolts in three stages
– 1. Tighten bolt 40 Nm
– 2. Loosen bolt
– 3. Tighten bolt 32 Nm
Object Number: 2413404 Size: DEFAULT


90.   Fasten accumulator
•   Tighten 2x bolts 25 Nm
91.   Remove 4x accumulator high pressure lines at injectors
•   Unscrew 8 union nuts
•   Seal off connections of accumulator using suitable sealing plugs
•   Seal off connections of injectors with protective caps
92.   Install camshaft housing cover LUREF_1.gif
Note:   See operation "Camshaft Housing Cover, Remove".

Cylinder Head|Valves > < Camshaft Housing Cover, Remove and Install (Z 17 DTH, with Air Conditioning, LHD)