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
2.3. 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
2.7.1. Removal and installation of a flywheel (engine of 1,4 l)
2.7.2. Replacement of a back epiploon of a bent 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 bent shaft
2.7.5. Removal and installation of a head of the block of cylinders (engine of 1,4-1,6 l)
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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2.7.3. 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 tag on a belt pulley of a bent shaft (the shooter in the drawing).

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

Prepare the MKM-6086 lever for removal of a valvate 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 valvate spring: 1 – support head; 2 – support legs; 3 – persistent part

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

Installation of the lever and support for removal of a valvate 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.
Install the MKM-6086-7 lever.

NOTE
The removable head has to be turned to the party of an admission.

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

Procedure of compression of a valvate spring: 1 – lever; 2 – removable head

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

NOTE
The removable head has to be placed vertically above a valve core.

ATTENTION
Observe correctness of installation.

Remove crackers and heads of the valve, valvate springs.

NOTE
Do not use at the same time 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 valvate springs and heads of the valve.
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 by the end reduced on a cone towards the valve

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

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

Accurately shift valvate springs by means of the lever down (an arrow in the 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 compressed air.

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

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

NOTE
The tag on a belt pulley of a bent shaft has to be combined with a ledge on the gas distribution mechanism case.

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

Installation
Establish spark plugs by means of special KM-194-E adaptation and tighten the moment 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 the chain drive of the mechanism of gas distribution
Weaken cam-shaft pulley bolts.
Hold cam-shafts for hexagons.
Block a natyazhitel of a chain.
Install the special KM-955-1 tool.
Move back a natyazhitel of a chain and block him by means of the special KM-955-1 tool.
Remove a guide, having turned off 2 bolts of fastening.
Remove a guide, having turned off 2 bolts of fastening.
Remove a tension guide, having turned off a fastening bolt.
Remove the gas distribution mechanism drive chain conducting an asterisk and laying of the case of the mechanism of gas distribution.
Disconnect the socket of a plait of wires of the sensor of impulses of a bent shaft.
Remove the KM special tool 952.
Remove the generator of impulses of a bent shaft, having turned off a fastening bolt.
Disconnect the basis of the block of cylinders from the block of cylinders, having turned off 22 bolts of fastening.
Uncover the conrod bearing.

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

NOTE
The surfaces of contact of rods and covers of conrod bearings are selected individually and therefore them it is impossible to rearrange or allow their damages. to avoid damage, do not put rods and covers on the surfaces of contact.

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

Mark covers of conrod bearings.
Mark the sequence of cylinders.
Turn off 8 bolts of fastening and uncover a rod.
Remove a bent shaft.
Disconnect the basis of the block of cylinders.

Removal of a bent shaft: 1 – kolechaty shaft

NOTE
Separate the basis evenly assembly shovel.

Turn off 22 bolts.
Remove a back epiploon of a bent shaft.
Remove a bent shaft and put on wooden whetstones.
Remove clips of bearings of a bent shaft.

NOTE
Observe the correct sequence

Remove inserts of the conrod bearing and mark them, observing at the same time the correct sequence.
Check all elements for wear and replace in case of need.

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

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

Installation
Attach a disk of the sensor of impulses of a bent shaft and tighten 3 bolts of fastening the moment of 15 N · m.
Install inserts of bearings of a bent 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 the drawing).
To establish inserts of conrod bearings in rods and covers of conrod bearings.
Cover them with engine oil.
Accurately install a bent shaft in the block of cylinders.

NOTE
The provision of a bent shaft can be corrected percussion by the rubber hammer on a crank cheek.

Cover with engine oil of a neck of a bent shaft.
Attach the basis of the block of cylinders to the block of cylinders new bolts.
Apply sealant on outer edges of a groove (the size I = 2 mm).

NOTE
You do not put a sealant in a groove.
Execute assembly within 10 min.

ATTENTION
Observe the 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 bent shaft. Before it apply (white) silicone lubricant on a working edge.
Install special KM-235-6 adaptation on a neck of a bent shaft.
Put on a sealing ring special adaptation and press aflush using KM-658-1.
Attach covers of conrod bearings to rods new bolts.

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

NOTE
Pay attention to adjusting situation, inflows (the shooter in the drawing) on covers of conrod bearings have to be turned towards the 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 bent shaft.
Block a bent shaft, having installed the KM special tool 952.
Smoothly turn a bent shaft against the stop of the KM special tool 952.
Install new consolidation of the pump of cooling liquid in the gas distribution mechanism case.
Provide correctness of installation of the directing plugs (an arrow in the drawing)

Installation of covers of conrod 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 gas distribution by short bolts.
Tighten 3 bolts of fastening the moment of 8 N · m.
Apply sealant.

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

NOTE
The case of the mechanism of gas distribution has to be installed within 10 min. after putting silicon sealant (gray).

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

NOTE
The roller of silicone sealant (gray) can be put directly if there are no ledges of elastomer.

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

Installation of the mechanism of gas distribution: 1 – natyazhitel of a chain; 2 – special tool; 3 – guide; 4 – gas distribution mechanism drive chain; 5 – guide; 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 bent shaft: 1 – belt pulley of a bent shaft; 2 – nave of a bent shaft; 3 – special tool

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

NOTE
Provide the leader's tension (the party of release) of a gas distribution mechanism drive chain branch.

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

NOTE
The disk of the sensor of a phase has to rotate by effort of a hand.

Attach the clip tire to the block of cylinders.
Tighten a fastening bolt the moment of 20 N · m.
Attach a guide to the block of cylinders.
Tighten 2 bolts of fastening the moment of 8 N · m.
Attach a guide 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 gas distribution mechanism case.
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 bent shaft.
Note the adjusting provision of a nave of a bent shaft.
The tag has to be turned up.
Hold by means of the special KM-956-1/-2 tool.
Tighten a bolt the moment of 150 Nanometers, tighten on +45 °.

NOTE
Use a new bolt.

Remove the special KM-956-1/-2 tool.
Attach a belt pulley of a bent shaft.
Tighten 6 bolts of fastening the moment of 8 N · m.
Turn a bent shaft approximately on 720 ° in the direction of rotation of the engine for a bolt of a nave of a bent shaft.
The tag on a belt pulley of a bent shaft is established opposite to a ledge on the gas distribution mechanism case.
In this position cams of the cylinder No. 1 settle down before VMT (both cams are turned outside).
Install 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 bent shaft against the stop of KM adaptation 952.

NOTE
Rotate a bent shaft slowly and smoothly.

In this position, the tag on a belt pulley of a bent shaft has to be combined with a ledge on the gas distribution mechanism case.
Install the KM special adaptation 953 on a cam-shaft.

Combination of a tag on a belt pulley of a bent shaft with a ledge on the gas distribution mechanism case: 1 – a ledge on the gas distribution mechanism case; 2 – a tag on a belt pulley; 3 – special tool

NOTE
If KM adaptation 953 cannot be installed, then it is necessary to execute basic adjustment of the moment of ignition.
KM adaptation 953 has to be installed in cam-shaft grooves against the stop.

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

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

NOTE
If KM adaptation 953 cannot be installed, then it is necessary to execute basic adjustment of the moment of ignition.

Tighten 2 bolts of fastening.
Remove KM devices 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 60 N · m.
Remove the remains of laying and clear the condensed surfaces.
Apply sealant.

NOTE
The cover of a head of the block of cylinders has to be established within 10 min. after putting sealant (gray).

Cut off the acting part of laying of the case of the mechanism of gas distribution aflush with a block head gas distribution mechanism cylinders / case.
Put the roller (gray) silicone sealant about 2 mm thick (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 regarding damage consolidation. If consolidation has damages, the bolt has to be replaced by 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.
Install 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 an ignition module cover 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.
Install the generator of alternating current.
Establish 2 bolt connections and tighten the moment 35 N · m.
Attach a plait of wires of the generator of 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 direction of an arrow (fig. 2.179), using KM adaptation 6131, install KM adaptation 6130.
Establish a poliklinovy belt.
Pay attention to the direction of rotation and the provision of a belt.
Squeeze a natyazhitel of a poliklinovy belt KM adaptation 6131.
Weaken a natyazhitel of a poliklinovy belt.
Attach a support of the damping engine block to the mechanism case to the gas distribution / block of cylinders.
Tighten 3 bolts of fastening the moment of 50 N · m.
Establish a flywheel.
Block a flywheel, using 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.
Install 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 the level of engine oil and modify in case of need.
Remove the engine from a building berth.
Attach the mechanical transmission to the engine.
Install the engine.

"on the page back
2.7.2. Replacement of a back epiploon of a bent shaft
on the following page"
2.7.4. Check of an axial free wheeling of a bent shaft