Opel Corsa B, Combo, Tigra

Since 1993-2000 of release

Repair and car operation



Opel Corsa B, Combo, Tigra
+ Cars Opel Corsa B, Tigra and Combo
+ Controls and operation receptions
+ Options and car routine maintenance
- Engines
   The general information
   Check компрессионного pressure in cylinders and parametres of impellent oil
   Diagnostics of a condition of the engine with vacuum gauge application
   + Procedures of repair of petrol engines SOHC without their extraction from the car
   - Procedures of repair of petrol engines DOHC without their extraction from the car
      Removal and cover installation газораспределительного the mechanism
      Removal and installation of a belt of drive ГРМ (engines 1.4 and 1.6)
      Removal and installation of cogwheels cranked and camshafts and intermediate rollers (engines 1.4 and 1.6)
      Removal and installation of camshafts
      Removal and installation of a head of cylinders
      Removal and pallet installation картера
      Removal, service and installation of the oil pump
      Replacement of epiploons of camshafts
      Removal, check of a condition and installation of a flywheel/privodnogo of a disk
      Replacement of epiploons of a cranked shaft
      Removal and installation of a pulley of a cranked shaft
   + Procedures of repair of diesel engines without their extraction from the car
   + The general and engine major repairs
+ Systems of cooling of the engine, salon and air conditioning heating
+ Power supply systems, release and decrease in toxicity of the fulfilled gases
+ Systems of an electric equipment of the engine
+ Manual 5-step box of a gear change
+ Automatic 4-step transmission
+ Coupling and power shafts
+ Brake system
+ Suspension bracket and steering
+ Body
+ Onboard electric equipment



Removal and installation of a head of cylinders

Start work performance only after full cooling of the engine!

Removal

Engines of 1.4 and 1.6 l

 PERFORMANCE ORDER

  1. Uncover ГРМ (see Has undressed Removal and cover installation газораспределительного the mechanism).
  2. Separate a socket of a ljambda-probe and remove it from the holder on a transmission.
  3. Turn out bolts of fastening and disconnect a reception pipe at a final collector and at a connecting flange to каталитическому to the converter.
  4. Remove a starter (see the Head of System of an electric equipment of the engine).
  5. Give two bolts of fastening of the pulse gauge near to a camshaft cogwheel.
  6. Turn out bolts of fastening of cogwheels of camshafts for what keep shaft from проворачивания a wrench for inflow of the first cylinder.

Keeping of camshafts at a reversing of bolts of fastening of cogwheels

  1. Turn out the top bolts of fastening of a back cover of a gear belt.

The top bolts of fastening of a back cover of a gear belt

  1. Turn out bolts of fastening and remove both intermediate rollers of a gear belt from a head of cylinders.
  2. Ослабьте all bolts of fastening of a head of cylinders in an order designated on an accompanying illustration.

Order отдавания fixture of a head of cylinders

Easing of bolts of fastening of a head of cylinders is authorised to be made only on the cooled down engine.

  1. Remove a head of cylinders with the inlet pipeline and a final collector.

Engines of 1.0 and 1.2 l

Further removal and installation of a head of cylinders of three-cylinder engine DOHC of 1.0 l is described. For engine DOHC of 1.2 l with four cylinders it is necessary to operate similarly. Special instructions are resulted in corresponding places.


 PERFORMANCE ORDER

  1. Pit pressure of fuel (see the Head of the Power supply system, release and decrease in toxicity of the fulfilled gases).
  2. Disconnect a negative wire from the battery.
  3. Remove the air filter with gauge MAF, a sleeve of an air inlet and a ventilation hose картера (PCV).
  4. Merge impellent oil (see the Head of Adjustment and car routine maintenance).
  5. Merge cooling liquid (see the Head of Adjustment and car routine maintenance).
  6. Disconnect the top and bottom hoses from a radiator.
  7. Separate a socket of electroconducting of the gauge of pressure of oil, gauges ECT and CMP.
  8. Turn out gauge CMP from case GRM.
  9. Disconnect hoses from the water pump.
  10. Separate a socket of the step-by-step e/motor and a potentiometer throttle заслонки.
  11. Remove a cable throttle заслонки and the holder.
  12. Disconnect from the case throttle заслонки all hoses of system of cooling, a vacuum hose and hose PCV.
  13. Separate a multicontact socket of the panel of devices (bottom).

Not later than for 20 with before disconnect the battery.

  1. Remove the control valve of the evaporator with the holder.
  2. Press fuel hoses clips and disconnect them from the holder.
  3. Disconnect a vacuum hose of the amplifier of brakes about a final collector.
  4. Remove the back holder of electroconducting from the inlet pipeline.
  5. Turn out the top bolt of a support of the inlet pipeline, the bottom bolt of a support ослабьте.
  6. Remove the bottom holder of electroconducting from the inlet pipeline.
  7. Disconnect the contact tyre of injectors, pull upwards and take aside.
  8. Give bolts of fastening of a pulley of the water pump.
  9. Remove a belt of a drive of auxiliary units.
  10. Remove a pulley of the water pump.
  11. Turn out the bottom drain stopper from the water pump and collect a following liquid in suitable capacity.
  12. Disconnect hoses from a broad tank of system of cooling.
  13. Remove the tank from a partition of an impellent compartment.
  14. Uncover heads of cylinders.
  15. Turn out 3 bolts of fastening and uncover thermostat cases.
  16. Establish the piston of the first cylinder in position ВМТ (the Section of Procedure of repair of petrol engines DOHC without their extraction from the car see).

The position of a cranked shaft corresponding to position, close to ВМТ, is necessary that it was possible to insert a lock finger of a cranked shaft easily.

  1. In the specified position camshaft cams, managing directors газораспределением in the first cylinder (section 1-1) look outside under the same corner.

Orientation of cams at installation of the piston of the first cylinder in position ВМТ

  1. Turn out a stopper (1) under a lock finger of a cranked shaft.

Stopper (1) under a lock finger of a cranked shaft

  1. Insert a lock finger of a cranked shaft (1) (КМ-952) into an aperture of a plate of the block of cylinders both in regular intervals and slowly turn a cranked shaft for the central bolt in a direction of rotation of the engine so that the lock finger has entered into a groove of a cranked shaft. Thus the cranked shaft is in position ВМТ of the piston of the first cylinder.

Adaptations for fixing of cranked (1) and distributive (2) shaft

  1. Fix a camshaft special adaptation KM-953 (2) in position ВМТ (address to an illustration).

If the tool (КМ-954) for fixing of a washer of gauge CMP is not present, mark чертилкой position of a cogwheel of a camshaft of inlet valves in relation to case GRM and position of a washer of the gauge of phases in relation to a camshaft cogwheel.

  1. Turn out directing tube щупа measurements of level of oil and take out it upward.
  2. Separate a ljambda-probe socket.
  3. At a corresponding complete set separate compressor K/V socket.
  4. Turn out bolts of fastening and disconnect каталитический the converter from a final collector. Take out a sealing lining.
  5. At a corresponding complete set turn out bolts of fastening and disconnect compressor K/V from case GRM.

Do not open a contour of cooling К/В. The coolant being in it can lead обморожению.

  1. Turn out bolts of fastening and remove lock laths of the engine over a final collector.
  2. Turn out bolts of fastening and remove the top thermofilter of a final collector.
  3. Uncover the oil filter (1).

Cover and the case of the oil filter

Close каталитический the converter that on it oil did not drip at removal of the case of the oil filter.

  1. Remove the case of the oil filter (2) from the block of cylinders (marksman) (address to an illustration). Enclose to more rags for gathering of following oil.
  2. Separate a socket of valve AGR (1) and the gauge of temperature (3).

Socket of gauge AGR (1), the gauge of temperature (3) and the union of a contour of cooling (2)

  1. Disconnect a hose of system of cooling (2) from valve AGR case (address to an illustration).
  2. Turn out a stopper from an aperture натяжителя chains (arrow).

Stopper натяжителя chains of drive ГРМ and a fixing core (2)

  1. Wring out натяжитель chains a screw-driver back and fix a suitable core (2) (address to an illustration). For this purpose it is possible to use adaptation KM-955.
  2. Remove the prorate (1).

The prorate (1) and a lock finger натяжителя chains (2)

  1. Ослабьте fastening of asterisks of camshafts. For this purpose keep camshafts a wrench for шестигранник around management cams газораспределением the first cylinder.

The lock tool for camshafts is not intended for deduction of shaft.

  1. Remove asterisks with a washer of gauge CMP from camshafts and throw off from them a chain.
  2. Suspend a chain on case GRM so that it could not fall in the case.
  3. Turn out bolts of fastening of the case of drive ГРМ.

Bolts of fastening of the case of drive ГРМ

  1. Remove the tool for fixing of camshafts.
  2. Give bolts of fastening of a head of cylinders to sequences with 1 on 10 at first on a turn quarter, then on a half-turn and then turn out them completely.

Order отдавания bolts of fastening of a head of cylinders

  1. On the engine of 1.2 l DOHC give bolts of fastening of a head of cylinders to sequences with 1 on 12 as it is described above. Thus begin with the top left bolt (a bolt (2)) (on an illustration) and then give other bolts, moving on a spiral counter-clockwise.
  2. Wring out a head of cylinders towards a transmission and remove a head from the block of cylinders.

For натяжителя it is necessary to direct a lock pin to a chain through an aperture in case GRM.

  1. Lay a head of cylinders on two wooden supports not to damage valves.
  2. Remove a sealing lining of a head of cylinders (1).

Sealing lining of a head of cylinders

  1. Unbend a lining of the case of the mechanism of distribution in points of a separation (arrow) and cut working edges of a lining in the centre (address to an illustration). Watch that did not remain any of working edges of a sealing lining of a head of cylinders.
  2. Remove all linings and the rests of linings.

Preparation for installation

See Has undressed Removal and installation of a head of cylinders.

Installation

Engines of 1.4 and 1.6 l

 PERFORMANCE ORDER

  1. Clear шабером an interfaced surface of the block of cylinders of the hermetic rests. Watch that the dirt has not got to block apertures. Close apertures pure rags.

Carving apertures of bolts of fastening of a head of cylinders should be cleared of oil and a cooling liquid. Blow apertures the compressed air or remove a liquid by means of a screw-driver with the rags reeled up on it. Otherwise at вворачивании new bolts in the block cracks can be formed, and values of effort of a tightening will be deformed.

  1. Check up a curvature of an interfaced surface of the block of cylinders (the Part the General and major repairs of the engine of the present Chapter see).
  2. Put a new sealing lining without hermetic on a fat-free interfaced surface of the block of cylinders a surface. The lining should be laid so that any of apertures thus was not closed. The inscription «OBEN/TOP» on a lining should be turned upwards and towards a gear belt of the engine.
  3. Clear an interfaced surface of a head of cylinders.
  4. Check up a curvature of an interfaced surface of a head of cylinders (the Part the General and major repairs of the engine of the present Chapter see).
  5. Establish a head of cylinders and in regular intervals tighten to прилегания new bolts of fastening in an order designated on an accompanying illustration.

Order of a tightening of bolts of fastening of a head of cylinders

Necessarily apply new bolts of fastening.

  1. Bolts should be tightened in five receptions: at first tighten them with effort of 25 Nanometers, then - tighten them on a corner 90 hailstones three times., and in summary, tighten bolts on a corner 45 hailstones.
  2. Tighten bolts of fastening of a back top cover of a gear belt with effort of 6 Nanometers.
  3. Establish cogwheels of camshafts, keeping a shaft from проворачивания for inflow by a wrench. Tighten a new bolt of fastening of a camshaft with effort of 65 Nanometers.

Necessarily apply new bolts of fastening.

  1. Establish a cover of a head of cylinders and tighten bolts of its fastening cross-wise with effort of 8 Nanometers.
  2. Establish a starter (see the Head of System of an electric equipment of the engine).
  3. Fix a reception pipe of system of release on a collector with effort of 25 Nanometers and on a connecting flange каталитического the converter with effort of 18 Nanometers.
  4. Establish a gear belt (see Has undressed Removal and installation of a belt of drive ГРМ (engines 1.4 and 1.6).
  5. Establish a forward cover of a gear belt.
  6. Tighten with effort of 4 Nanometers fixture of cover ВВ of wires.
  7. The further installation is made in an order, the return to an order of dismantle of components.
  8. Fill cooling system (the Section the General information see), and also check up and, if necessary, modify oil level in the engine. If the head of cylinders acted in film owing to damage of a sealing lining, replace oil and the filter since in oil there can be a cooling liquid.

Engines of 1.0 and 1.2 l

 PERFORMANCE ORDER

  1. Clear interfaced surfaces of the block of cylinders and case GRM of the hermetic rests. Watch that the dirt has not got to apertures of the block of cylinders.

Carving apertures of bolts of fastening of a head of cylinders should be cleared of oil and a cooling liquid. Blow apertures the compressed air or remove a liquid by means of a screw-driver with the rags reeled up on it. Otherwise at вворачивании new bolts in the block cracks can be formed, and values of effort of a tightening will be deformed.

  1. Clear an interfaced surface of a head of cylinders.
  2. Check up a curvature of a head of cylinders (the Part the General and major repairs of the engine of the present Chapter see).

To grind a head of cylinders it is not authorised.

  1. Cut off ledges of new sealing linings of a head of cylinders (the size I) on the party of the case of drive ГРМ.

Places of a cut and a label of top of a sealing lining of a head of cylinders

  1. Establish asterisks of camshafts with the chain put on them in case GRM.
  2. Put platens (1) silicone hermetics in the thickness of 2 mm on corners of the case of a drive of the GRM/BLOCK of cylinders.

Drawing of hermetic (1) on a joint of a cover of drive ГРМ with a head of cylinders and bolts of fastening of the case of drive ГРМ

Apply only hermetic OPEL, ЕТ № 90 543 772. After drawing of hermetic the head of cylinders and case GRM should be established and tightened bolts within 10 minutes

  1. Establish a new sealing lining of a head of cylinders so that it has not been blocked any of apertures. The inscription «OBEN/TOP» on a lining should be turned upwards. Press a lining around silicone hermetic.
  2. Insert both top bolts (2) fastenings of the case of drive ГРМ at the left and on the right (address to an illustration).
  3. Hang above a sealing lining apertures at the left and on the right on bolts, and press it below, around the put silicone hermetic.
  4. Put other two platens in corners of case GRM and a lining of a head of cylinders.
  5. Insert clamps of camshafts. If the clamp does not approach, slowly turn shaft for шестигранник.
  6. Establish a head of cylinders on the block. Thus watch that the lock finger for натяжителя chains took place through an aperture in the case of drive ГРМ and натяжителя chains by a tension lath.
  7. Press a head of cylinders to the case of drive ГРМ.
  8. Screw 3 bottom bolts of fastening of a head of cylinders to the case of drive ГРМ and tighten them with effort of 8 Nanometers.

The bottom bolts of fastening of a head of cylinders to the case of drive ГРМ

  1. Once again easy blows of a plastic hammer correct position of a head of cylinders in case GRM direction.
  2. Remove a clamp of camshafts.
  3. Insert new bolts of fastening of a head of cylinders and tighten them to прилегания to a head of cylinders. Then tighten bolts of fastening of a head of cylinders for four receptions in sequence with 1 on 10: at first - with effort of 25 Nanometers, and then - tighten them on a corner 60 hailstones three times.

Order of a tightening of bolts of fastening of a head of cylinders

  1. On engine DOHC of 1.2 l tighten bolts of fastening of a head of cylinders in sequence with 1 on 12 also for four receptions. Thus a tightening begin with the central bolt in top to a number of bolts and continue, moving to a direction clockwise. Thus the bolt at the left above (a bolt (8) (on an illustration) is tightened by the last.
  2. Again give 3 bottom bolts of fastening of a head of cylinders to the case of drive ГРМ.
  3. Tighten at first bolts of fastening (1) water pumps to a head of cylinders with effort of 8 Nanometers, and then bolts (2) cases of drive ГРМ to a head of cylinders with effort of 8 Nanometers.

Bolts of fastening of the water pump (1) and cases of drive ГРМ (2) to a head of cylinders

  1. Establish a clamp of camshafts. If the clamp does not approach, slowly turn camshafts for шестигранник.
  2. Establish asterisks with a chain on camshafts.

If the conductor of a rotor of gauge CMP is not present, establish an asterisk so that a label put at removal, has coincided with case GRM.

  1. Press gauge CMP rotor to an asterisk of an inlet camshaft and slightly fix an asterisk a new bolt. Tighten a bolt so that gauge CMP rotor still could rotate.
  2. Tighten also slightly a bolt of fastening of an asterisk of a final camshaft.
  3. Insert the top prorate and fix it with effort of 8 Nanometers.
  4. Take out a clamp натяжителя chains.
  5. Establish the conductor (1) rotors of gauge CMP (КМ-954) and fix it on case GRM. If necessary turn gauge CMP rotor so that it was possible to establish the conductor.

The conductor of a rotor of gauge CMP

If the conductor of a rotor of gauge CMP is not present, turn a rotor so that a label put before removal, has coincided with a label on a camshaft asterisk. Simultaneously the label on a camshaft asterisk should coincide with case GRM. In this position tighten a bolt of fastening of an asterisk of a camshaft. Thus watch that gauge CMP rotor did not rotate rather to a camshaft asterisk.

  1. Tighten bolts of fastening of asterisks of camshafts with effort of 50 Nanometers and tighten bolts on a corner 60 hailstones. Thus keep a camshaft from проворачивания a wrench for шестигранник.

Оправки for fixing it is not authorised to apply as the tool to deduction.

  1. Remove all lock оправки and check up phases газораспределения. For this purpose turn a cranked shaft on 2 turns in a direction of rotation of the engine and stop in position ВМТ of the piston of the first cylinder. If in this position lock оправки are inserted simultaneously and without problems, adjustment of phases of distribution is executed truly.
  2. Tighten a stopper of an aperture for натяжителя chains with effort of 20 Nanometers.
  3. Establish gauge CMP with a new sealing ring on case GRM.
  4. Tighten a stopper of an aperture for a stopper of a cranked shaft with effort of 60 Nanometers.
  5. Put on a hose of system of cooling case AGR and fix its collar.
  6. Connect sockets of valve AGR and the temperature gauge.
  7. Establish on the block of cylinders the case of the oil filter with a new sealing ring and tighten its fixture with effort of 20 Nanometers. Fix on the case a cover with a new sealing ring.
  8. Establish the top thermofilter of a final collector and tighten its fixture with effort of 8 Nanometers.
  9. Establish lock laths of the engine and tighten their fixture with effort of 20 Nanometers.
  10. At a corresponding complete set establish compressor K/V on case GRM and the block of cylinders and tighten its fixture with effort of 20 Nanometers.
  11. Fix by hand каталитический the converter with new consolidation on a final collector, without tightening fastening bolts.
  12. Screw by hand, without tightening, bolts of fastening of the holder каталитического the converter.
  13. Establish каталитический the converter and tighten its fixture with effort of 35 Nanometers, and fixture of the holder - with effort of 15 Nanometers.
  14. At a corresponding complete set connect compressor K/V socket on the holder.
  15. Establish directing pipe щупа level of impellent oil with a new lining and tighten its fixture to a final collector with effort of 8 Nanometers.
  16. The further installation is made in sequence, return sequence of dismantle of components. Tighten fixture with demanded effort.
  17. In installation end fill cooling system, and also check up and, if necessary, modify oil level in the engine. If the engine acted in film owing to damage of a sealing lining of a head of cylinders, replace oil and the oil filter since in impellent oil there can be a cooling liquid.