Repair of Opel Corsa C, from 2000 to 2005 release.
1. Operation and maintenance of the car
2. Engine
2.1. Petrol Z10XE, Z10XEP, Z12XE, Z12XEP DOHC-I engines
2.2. Mechanical part of petrol Z10XE, Z10XEP, Z12XE, Z12XEP DOHC-I engines
2.2.1. Regulation of phases of gas distribution by impact on the Z10XEP, Z12XE, Z14XEP camshaft (since the end of 2004 till 2005 release)
2.2.2. Adjustment of phases of gas distribution (Z10XE, Z10XEP, without 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 installation of the GRM case (Z10XE, Z10XEP)
2.2.6. Repair of the engine (Z10XE, Z10XEP, without conditioner)
2.2.7. Block of cylinders, krivoshipno-conrod mechanism and piston group
2.3. Cooling system
2.4. Lubrication system
2.5. System of injection
2.6. Petrol engines – the general procedures of check
2.7. Mechanical part of the engine
2.8. Test 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. Lubrication system
3. Transmission
4. Running gear
5. Steering mechanism
6. Brake system
7. Onboard electric equipment
8. Body
9. Schemes of electric equipment
 















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

2.2.6. Repair of the engine (Z10XE, Z10XEP, without conditioner)

Removal
Remove the transmission from the engine.
Pick up the directing oil meter probe phone.
Turn out a bolt.
Dismantle heated a lambda sensor of regulation of composition of fuel mix.
Disconnect the socket of a plait of wires.
Release a plait of wires.
Carefully turn out a lambda sensor by means of 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.
Install on the engine on KM-412-18 adaptation.
Tighten 4 bolts of fastening.
Fix the engine on KM-412 2 adaptation.
Tighten 8 threaded connections.
Install KM-2358 adaptation.
Merge engine oil.
Substitute the reception pallet.
Turn out a carving stopper of a drain opening.
Uncover the case of an oil filter.
Take out an insert of an oil filter.
Dismantle coupling.
Remove a flywheel.
Install KM-652 adaptation.
Turn off 6 bolts of fastening.
Dismantle KM-652 adaptation.
Remove the holder of the engine 1 on the right.
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.
Take off a poliklinovy belt.

NOTE
Mark the direction of rotation.

Pull the tension device of a poliklinovy belt in the direction of an arrow.
Insert the KM-955-2 device.
Remove from a pulley poliklinovy ременя a bent shaft.
Remove a pulley poliklinovy ременя the pump of cooling liquid.
Turn off 3 bolts of fastening.
Dismantle a pulley poliklinovy ременя a bent shaft.
Turn off 6 bolts of fastening.
Hold a bolt of a nave of a bent 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 you iteit a plait of wires of a starter.
Turn off 2 nuts 1.
Remove cable collars.
Dismantle the generator.
Turn off 2 threaded connections.
Dismantle a starter.
Turn off 2 bolts of fastening (arrow).
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.
Oil 6 pressure relay, sensor of temperature of cooling liquid 8, sensor of the camshaft 9, module of a butterfly valve 2, controller of engine management 12, valve of system of recirculation of OG 4, module of ignition 3, sensor of a detonation 10, sensor of a bent shaft 11, fuel nozzles 1.
Turn off a wire of mass of the controller of engine management 13.
Free the canal for a plait of wires 7.
Release a plait of wires – 4 holders 14.
Disconnect 3 hoses from the pump of cooling liquid.
Disconnect a hose of cooling liquid from a flange of cooling liquid of recirculation of exhaust gases.
Release a collar.
Dismantle the pump of cooling liquid 1.

NOTE
At removal pay attention to the directing plugs.

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

NOTE
Consider the 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 KM-6009 1 adaptation.
Uncover a head 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 bent shaft 1.

NOTE
This work will require participation of two people.

Establish and hold KM-956-1/KM-956-2 devices.
Hold KM-956-1/KM-956-2.
Adjust camshafts.
Evenly turn a bent shaft by means of KM-956-1/KM-956-2 adaptation in the direction of rotation of the engine until KM-953 1 adaptation against the stop does not come into a camshaft groove.
Remove a nave of a bent 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 devices.
Remove the oil pallet.
Turn the engine on 180 °.
Turn off 14 bolts of fastening.
Remove consolidation of the oil pallet.
Remove the GRM case.
Turn the engine on 90 °.
Turn out 15 bolts of fastening (arrow).
Consider length of bolts of fastening.
Do not damage the sensor of the camshaft 1.
Poddnte also take a sealing ring of the GRM case.

NOTE
Do not damage a sealing surface.

Dismantle the chain drive.
Release bolts of driving gears of the camshaft.
Hold camshafts for a hexagon.
Stop the tension device of a chain 1.
Insert the KM-955-1 device.
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 consolidation of the GRM case.
Dismantle a head of the block of cylinders.
Turn the engine on 90 °.
Dismantle 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.

Enclose a head of the block of cylinders in wooden blocks.
Take out consolidation of a head of the block of cylinders.
Dismantle the case of an 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 bent shaft.
Turn out a bolt.
Dismantle the block of cylinders.
Install KM-2358 adaptation.
Suspend the engine on the crane.
Remove KM-412-18 adaptation.
Install the block of cylinders.
Install KM-412-18 adaptation on the engine. Tighten 4 bolts of fastening.
Dismantle KM-2358 adaptation.
Press 6 guides of sleeves by means of KM-427 adaptation in the block of cylinders.
Dismantle the soaking-up oil pipeline 1.
Turn off 4 bolts of fastening.
Remove a sealing ring 2.
Clean the sealing surfaces of the block of cylinders and a head of cylinders, covers of a head of cylinders, cases of an oil filter, a support of a bent shaft, the GRM case, the oil pallet, the pump of cooling liquid and a final collector.

Installation of the engine
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 the details established outside: block of cylinders, head of cylinders, cover of a head of cylinders, case of an oil filter, support of a bent shaft, chain drive, GRM case, oil pallet, pump of cooling liquid, final collector.

By means of a lekalny ruler and the caliber probe check flatness of a head of the block of cylinders.
Stop a bent shaft.
Remove a carving stopper 1.
Insert the KM-952 2 device on its place.
Evenly turn a bent shaft until adaptation is not captured.
Establish a maslootrazhatel.
Tighten 6 bolts of fastening the moment of 8 N · m.
Install the case of an oil filter.
Turn the engine on 180 °.
Replace consolidation.
Tighten 3 bolts of fastening the moment of an inhaling of 20 N · m.
Replace an insert of an oil filter.
Establish a cover of the case of an 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 device.
Turn camshafts for a hexagon.
Take out KM-953 adaptation.
Establish a head of the block of cylinders.
Replace consolidation.

NOTE
Marking of "OPEN/TOP" has to specify 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 the sequence of an inhaling of bolts.

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

NOTE
You watch correctness of landing (arrow).

Replace bolts.
5 shift a driving wheel.
Spread a gear wheel of the 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 the inlet camshaft with a disk of the phase sensor, screw a bolt.

NOTE
The disk of the phase sensor has to 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
You watch correctness of landing of a driving chain of a cam-shaft.

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

NOTE
You 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 KM-9551 adaptation.
When replacing details consider various options of a design. You watch correctness of numbers of details.
Install the pump of cooling liquid.

NOTE
You watch correctness of landing of the directing plugs (arrow).

1 replace consolidation.
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.
Install the GRM case.
Screw bolts.

NOTE
Observe the sequence of an inhaling

Tighten 5 bolts of fastening (M6) the moment of 18 N · m.
Tighten 14 bolts of fastening (M6) the moment of 28 N · m.
Tighten 2 bolts of krepleniya (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 bent shaft in front 1.
Grease sealing edges with silicone lubricant (white).
Install KM-960 2 adaptation and press a sealing ring of a bent shaft.
Take out KM-952, KM-953 devices.

NOTE
The fixing tools cannot be used for keeping.

Establish a nave of a bent shaft.
Observe the assembly provision of a nave of a bent shaft 2, the mark has to specify up.
Replace a bolt of a nave.
Hold a nave by means of KM-956-1/KM-956-2 devices.
Tighten a bolt the moment of 150 N · m +45 °.
Remove KM-956-1/KM-956-2 devices.
Establish a pulley poliklinovy ременя a bent shaft 1.
Tighten 6 bolts of fastening the moment of 8 N · m.
Hold a bolt of a nave of a bent shaft.
Insert the KM-952 device.
Insert the KM-953 device in a flute of camshafts.
Install KM-954 1 adaptation.
Turn a disk of the phase sensor 2, there will be yet no opportunity to install 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 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 the inlet camshaft.

Support camshafts for a hexagon 1.
Take out the fixing KM-952, KM-953, KM-954 tools.
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 the inlet camshaft.
Hold camshafts for a hexagon.

Check installation of phases of gas distribution.
Install the oil pallet.
Tighten 14 bolts of fastening the moment of 10 N · m.
Establish a carving stopper of a support of a bent shaft.
Replace a sealing ring.
Tighten a fastening bolt the moment of 50 N · m.
Install the detonation sensor.
Tighten a fastening bolt the moment of an inhaling of 20 N · m.
Install the sensor of provision of a bent shaft.
Replace a sealing ring.
Tighten a fastening bolt 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.
Apply sealant (distance of 1-2 mm).

NOTE
Finish installation works within 10 min.

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.
Install 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 recirculation 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 mass of the controller 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.
Install the generator.
Tighten 2 threaded connections 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.
Install the tension device of a poliklinovy belt.
Turn the engine on 180 °.
Bolt (M8) tighten the moment of an inhaling of 20 N · m.
Bolt (M10) 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 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 threaded 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 KM-652 adaptation.
Establish coupling.
Fill in engine oil.
Check and, if necessary, modify the level of engine oil.
Disconnect the engine from KM-412 adaptation.
Turn off 8 threaded connections.
Dismantle 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 a lambda sensor of regulation of composition of fuel mix.
Apply on a carving assembly paste (white).
Tighten a lambda sensor the moment 40 N · m.
Connect the socket of a plait of wires.
Fix a plait of wires.
Establish the directing oil meter probe tube.
Replace 2 sealing rings.
Tighten a bolt the moment of 8 N · m.
Install the transmission on the engine.

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