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Cylinder Head|Valves > < Replace front camshaft sealing ring (Z 14 XE, Z 16 YNG with air conditioning, RHD)

Corsa C

Remove and install both camshafts (Z 14 XE, Z 16 YNG with AC, RHD)

1.   Open bonnet
Important:   On vehicles as of model year 04 with ESP - the steering angle sensor loses its basic adjustment each time the battery is disconnected. It must be recalibrated.
2.   Disconnect battery
•   Detach ground cable
3.   Remove engine cover.
•   Unscrew oil filler pipe cap
•   Remove 2 bolts
•   Screw on oil filler pipe cap
4.   Remove air cleaner housing (1)
•   Disconnect wiring harness plug
– Intake air temperature sensor (4), tank vent valve (2)
•   Unclip tank vent valve
•   Detach intake hose
•   Detach engine vent hose (5)
•   Remove bolt (3)
•   Remove air intake pipe
Object Number: 2410698 Size: DEFAULT


5.   Loosen right front wheel.
6.   Raise vehicle
7.   Remove right front wheel.
•   Remove 4 bolts
8.   Raise vehicle
9.   Remove ribbed V-belt cover
•   Remove 3 bolts (1)
•   Remove clip (arrow).
Object Number: 2410600 Size: DEFAULT


10.   Remove ribbed V-belt
•   Tension ribbed V-belt tensioner in direction of arrow
– Using KM-913-A (2) (SW 15)
•   Use KM-6130 (1)
•   Mark running direction.
Object Number: 2410700 Size: DEFAULT


11.   Remove ribbed V-belt tensioner
•   Tension ribbed V-belt tensioner.
•   Remove KM-6130 (2)
•   Release ribbed V-belt tensioner
•   Remove bolt (1)
Object Number: 2410697 Size: DEFAULT


12.   Detach crankshaft ribbed V-belt pulley
•   Lever out front closure plug
– From oil pan
•   Use KM-911
•   Remove bolt
•   Remove KM-911
Object Number: 2410695 Size: DEFAULT


13.   Release lower part of toothed belt cover
•   Remove bolt (arrow)
•   Unclip from rear toothed belt cover
Object Number: 2411206 Size: DEFAULT


14.   Lower vehicle
15.   Remove upper part of toothed belt cover
•   Remove 3 bolts (arrows)
•   Unclip from rear toothed belt cover
Object Number: 2410726 Size: DEFAULT


16.   Remove camshaft sensor (1)
•   Unclip from bracket
•   Disconnect wiring harness plug
•   Remove 2 bolts (2)
Object Number: 2410703 Size: DEFAULT


17.   Remove lower part of toothed belt cover
•   Unclip from rear toothed belt cover
18.   Set 1st cylinder to TDC of combustion stroke
•   Install crankshaft V-belt pulley bolt
•   Set crankshaft to mark.
– Turn crankshaft evenly
Note:   Marks on drive gear toothed belt and rear toothed belt cover must align (III).
•   Fix camshaft sprockets in position.
Note:   Marks must be opposite one another and aligned with the top edge of the cylinder head (I)
– Use KM-852 (II)
19.   Remove toothed belt
•   Release toothed belt tension roller (IV)
– Loosen bolt
– Turn adjusting eccentric in direction of arrow (clockwise) until pointer (1) of the toothed belt tension roller is located just before left stop.
•   Remove toothed belt.
Object Number: 2415419 Size: DEFAULT


20.   Remove ignition module
•   Disconnect wiring harness plug
•   Remove 4 bolts
Important:   Do not tilt
•   Extract using KM-6009 (1)
21.   Detach preheater hose for throttle valve module (2)
•   From thermostat housing
22.   Disconnect wiring harness plug for coolant temperature sensor (3)
•   Unclip from rear toothed belt cover
Object Number: 2410699 Size: DEFAULT


23.   Remove cylinder head cover
•   Detach engine vent hose
– 2 off
•   Disconnect wiring harness plug for mixture regulating heated oxygen sensor
– Unclip cable
•   Remove 10 bolts
•   Remove seal
Object Number: 2410701 Size: DEFAULT


24.   Remove KM-852
25.   Remove exhaust camshaft sprocket
•   Remove bolt
– Counterhold camshaft at hexagonal section
26.   Remove intake camshaft sprocket
•   Remove bolt
– Counterhold camshaft at hexagonal section
Object Number: 2410704 Size: DEFAULT


27.   Release rear toothed belt cover
•   Remove 2 upper bolts
28.   Remove exhaust camshaft
•   Remove camshaft bearing cap
Important:   Note identification
– Remove 10 bolts
– Release camshaft bearing cap working in inward spiral from outside in steps of 1/2 to 1 turn
Note:   Camshaft must be evenly released from the bearing seats
– Remove camshaft seal ring
Object Number: 2400681 Size: DEFAULT


29.   Remove intake camshaft
•   Remove camshaft bearing cap
Important:   Note identification.
– Remove 10 bolts
– Release camshaft bearing cap working in inward spiral from outside in steps of 1/2 to 1 turn
Note:   Camshaft must be evenly released from the bearing seats.
– Remove camshaft seal ring
30.   Inspect components
•   Camshafts, camshaft bearing caps, cylinder head, ribbed V-belt, ribbed V-belt tensioner, ribbed V-belt pulleys, toothed belt drive
31.   Position crankshaft
Note:   Set crankshaft to 60° before no.1 cylinder TDC of combustion stroke
Object Number: 2398324 Size: DEFAULT


32.   Install intake camshaft
•   Coat sliding surfaces with engine oil
•   Apply sealant
Important:   Do not apply sealant in vicinity of oil channels. Complete installation work within 10 minutes.
– In camshaft seal ring area (arrows)
Important:   Observe identification and allocation.
•   Insert camshaft, camshaft bearing cap
•   Install camshaft bearing cap
– Tighten camshaft bearing caps in steps working from inside outwards ( 8 Nm )
•   Remove excess sealant
33.   Install exhaust camshaft
•   Coat sliding surfaces with engine oil
•   Apply sealant
Important:   Do not apply sealant in vicinity of oil channels. Complete installation work within 10 minutes.
– In camshaft seal ring area (arrows)
Important:   Observe identification and allocation.
•   Insert camshaft, camshaft bearing cap
•   Install camshaft bearing cap
– Tighten camshaft bearing caps in steps working from inside outwards ( 8 Nm )
•   Remove excess sealant
Object Number: 2398329 Size: DEFAULT


34.   Install exhaust camshaft seal ring
•   Coat seal lip with grease
•   Place seal ring on camshaft journal
•   Install camshaft seal ring
– With KM-422 (1), bolt and camshaft sprocket washer
Object Number: 2398332 Size: DEFAULT


35.   Install intake camshaft seal ring
•   Coat seal lip with grease
•   Place seal ring on camshaft journal
•   Install camshaft seal ring
– With KM-422 , bolt and camshaft sprocket washer
36.   Fasten rear toothed belt cover
•   Tighten bolts 6 Nm
37.   Install intake camshaft sprocket
•   Replace bolt
Note:   Second person required
•   Tighten bolt 50 Nm + 60° + 15°
– Counterhold camshafts at hexagonal section
38.   Install exhaust camshaft sprocket
•   Replace bolt
Note:   Second person required
•   Tighten bolt 50 Nm + 60° + 15°
– Counterhold camshafts at hexagonal section
39.   Fix camshaft sprockets in position.
Note:   Marks must be opposite one another and aligned with the top edge of the cylinder head.
•   Use KM-852
– Turn the camshafts at hexagonal section
40.   Install cylinder head cover
•   Replace gasket
Important:   Complete installation work within 10 minutes
•   Apply sealant to sealing surfaces(1)
•   Tighten bolts 8 Nm
•   Attach engine vent hose
– 2 off
•   Connect cable harness plug of oxygen sensor, mixture regulation, heated
– Clip in cable
Object Number: 2410713 Size: DEFAULT


41.   Connect wiring harness plug for coolant temperature sensor
•   Clip to rear toothed belt cover
42.   Attach preheater hose for throttle valve module
43.   Install ignition module
•   Unscrew KM-6009
•   Tighten bolts 8 Nm
•   Connect wiring harness plug.
44.   Check that 1st cylinder is at TDC
•   Set crankshaft to mark.
– Turn crankshaft evenly
Note:   Marks on drive gear toothed belt and rear toothed belt cover must align.
45.   Put toothed belt in place
•   Position toothed belt
Note:   Tensioned side must be taut (I).
Object Number: 2398314 Size: DEFAULT


46.   Tension toothed belt
•   Tension toothed belt tension roller
– Turn adjusting eccentric in direction of arrow (anticlockwise) until pointer of the toothed belt tension roller is located just before left stop
•   Fasten toothed belt tension roller bolt (1)
Object Number: 2410723 Size: DEFAULT


47.   Remove KM-852
48.   Timing, Check
•   Turn crankshaft (720°)
– At crankshaft ribbed V-belt pulley bolt
Note:   In direction of engine rotation.
•   Set crankshaft to mark.
Note:   Marks on drive gear toothed belt and rear toothed belt cover must align (III).
•   Use KM-852 (II)
Note:   Marks must be opposite one another and aligned with the top edge of the cylinder head (I)
Object Number: 2415403 Size: DEFAULT


49.   Remove KM-852
50.   Adjust toothed belt tension
•   Release toothed belt tension roller
– Loosen bolt
•   Turn adjustment eccentric in the direction of the arrow (clockwise) until pointer (1) is aligned with the notch mark at the toothed belt tension roller (2).
– Adjust used toothed belts to the marking USED
– Adjust new toothed belts to the marking NEW
•   Tighten toothed belt tension roller bolt 20 Nm
Object Number: 2410712 Size: DEFAULT


51.   Check toothed belt tension
•   Turn crankshaft (720°)
Note:   Pointers on the toothed belt tension roller and notch mark must align.
– Adjust used toothed belts to the marking USED
– Adjust new toothed belts to the marking NEW
52.   Install lower part of toothed belt cover
•   Clip to rear toothed belt cover
•   Tighten bolt 4 Nm
53.   Clean threads
•   Cylinder head
– 2 off
54.   Attach camshaft sensor
•   Insert bolts with locking compound (red)
•   Tighten bolts 8 Nm
•   Connect wiring harness plug.
55.   Install upper part of toothed belt cover
•   Clip to rear toothed belt cover
•   Tighten bolts 4 Nm
56.   Raise vehicle
57.   Install ribbed V-belt tensioner
•   Tighten bolt 35 Nm
•   Tension ribbed V-belt tensioner.
– using KM-913-A
•   Use KM-6130
58.   Attach crankshaft ribbed V-belt pulley
•   Replace bolt
•   Use KM-911
•   Tighten bolt 95 Nm + 30° + 15°
•   Remove KM-911
•   Insert front sealing plug
59.   Install ribbed V-belt
Note:   Note running direction and installation position
•   Release ribbed V-belt tensioner
– using KM-913-A
•   Remove KM-6130
60.   Install ribbed V-belt cover
•   Screw in bolts
•   Install clip
61.   Lower vehicle
62.   Mount right front wheel.
•   Screw in bolts
63.   Lower vehicle
64.   Fasten right front wheel.
•   Tighten bolts 110 Nm
65.   Install air cleaner housing
•   Install air intake pipe
•   Tighten bolt
•   Install suction hose
•   Attach engine vent hose
•   Connect wiring harness plug.
– 2 off
66.   Install engine cover.
•   Unscrew oil filler pipe cap
•   Tighten bolts 8 Nm
•   Screw on oil filler pipe cap
67.   Connect battery
68.   Calibrate steering angle sensor
•   Switch on ignition
Note:   Rotate the steering wheel one time from its right-hand to its left-hand stop.
69.   Program volatile memories
70.   Close bonnet

Cylinder Head|Valves > < Replace front camshaft sealing ring (Z 14 XE, Z 16 YNG with air conditioning, RHD)