Engine assembly procedure (Opel Corsa B)

Before you begin assembling the engine, make sure you have all the necessary parts, materials and tools, which include the following:

• Standard set of locksmith tools;
• Torque wrench with 1/2-inch drive;
• Piston ring tool;
• Piston Ring Crimping Tool;
• Short sections of fuel hose for fitting onto connecting rod bearing cap studs;
• Plastigage Measuring Kit;
• Blade type feeler gauge set;
• Fine tooth file;
• Fresh engine oil;
• Assembly engine or molybdenum-containing grease;
• Gasket sealant;
• Sealant for fixing threaded connections.

At this stage, all components to be installed must be absolutely clean and dry. For convenience, lay out the parts on a clean surface in the order of installation.

To save time and minimize the number of problems that may arise, assemble the engine in the following order:

Petrol engines

• Piston rings;
• Crankshaft and main bearings;
• Connecting rod and piston assemblies;
• Oil pump with oil intake pipe (see Part SOHC Gasoline Engine Repair Procedures Without Removing Them From The Vehicle or Repair procedures for DOHC gasoline engines without removing them from the vehicle);
• Main Bearing Balancing Assembly/Bridge (depending on the configuration, if provided);
• Oil pan (including oil deflector plate, if provided) (see Part SOHC Gasoline Engine Repair Procedures Without Removing Them From The Vehicle or Repair procedures for DOHC gasoline engines without removing them from the vehicle);
• Flywheel/drive disc (see Part SOHC Gasoline Engine Repair Procedures Without Removing Them From The Vehicle);
• Cylinder head with camshaft and valve train components (see Part SOHC Gasoline Engine Repair Procedures Without Removing Them From The Vehicle or Repair procedures for DOHC gasoline engines without removing them from the vehicle);
• The camshaft housing and its cover (see Part SOHC Gasoline Engine Repair Procedures Without Removing Them From The Vehicle or Repair procedures for DOHC gasoline engines without removing them from the vehicle);
• Water pump (see Chapter Engine cooling, interior heating and air conditioning systems);
• Rear timing cover (see Parts SOHC Gasoline Engine Repair Procedures Without Removing Them From The Vehicle or Repair procedures for DOHC gasoline engines without removing them from the vehicle);
• Timing drive components (see Part SOHC Gasoline Engine Repair Procedures Without Removing Them From The Vehicle or Repair procedures for DOHC gasoline engines without removing them from the vehicle);
• Front timing belt covers (see Part SOHC Gasoline Engine Repair Procedures Without Removing Them From The Vehicle or Repair procedures for DOHC gasoline engines without removing them from the vehicle);
• Intake manifold and exhaust manifold (see Chapter Fuel, exhaust and emission control systems);
• Mounted units;
• Engine Protective Cover (with appropriate equipment).

Diesel engines

• Piston rings;
• Crankshaft and main bearings;
• Connecting rod and piston assemblies;
• Mounted units;
• Oil pump with oil intake pipe (see Part Procedures for repairing diesel engines without removing them from the vehicle);
• Oil pan (including oil deflector plate, if provided) (see Part Procedures for repairing diesel engines without removing them from the vehicle);
• Flywheel/drive disc (see Part SOHC Gasoline Engine Repair Procedures Without Removing Them From The Vehicle);
• Cylinder head with camshaft and valve train components (see Part Procedures for repairing diesel engines without removing them from the vehicle);
• Water pump (see Chapter Engine cooling, interior heating and air conditioning systems);
• Timing drive components (see Part Procedures for repairing diesel engines without removing them from the vehicle);
• The camshaft housing and its cover (see Part Procedures for repairing diesel engines without removing them from the vehicle);
• Timing drive components with rear cover (see Part Procedures for repairing diesel engines without removing them from the vehicle);
• Front timing belt covers (see Part Procedures for repairing diesel engines without removing them from the vehicle);
• Intake manifold and exhaust manifold (see Chapter Fuel, exhaust and emission control systems).

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