Removal and installation of camshafts and valve lifters, checking of timing components (Opel Corsa C)

1. The procedure for removing/checking/installing camshafts is fundamentally similar for all engines. It is described in most detail for the Z10XE(P)/Z12XE/Z14XEP petrol engines. For the rest, the main attention is paid to the features of each specific engine.

2. When removing the bearing caps, follow the established sequence. The cap fasteners must be loosened evenly, in a spiral from the edges inward, in several steps, 1-0.5 turns per approach. On engines whose camshafts are installed on supports cast directly into the cylinder head, special care must be taken when loosening the fasteners and removing the support bearing caps.

If handled carelessly, the camshaft bearings or the bearing cap may be damaged. If even one cap is broken, the entire cylinder head will have to be replaced - during manufacture, the caps are processed together with the head and are not supplied to the spare parts market individually! Installation and tightening of the cap fasteners is performed in the reverse order of their removal.

Engines Z10XE(P)/Z12XE/Z14XEP

Removal

3. Set the piston of the first cylinder to the TDC position and loosen the timing chain by pulling the chain tensioner and fixing it using the KM-955-1 device (see Section 6).

4. After unscrewing the 2 mounting bolts, remove the upper guide (see accompanying illustration) timing chains. Holding the camshafts from turning with an open-end wrench on the hexagonal part of the shaft, unscrew the mounting bolts and remove the camshaft sprockets.





5. Please note - all upper camshaft bearing caps have their own number (see accompanying illustration). 1, 3, 5, 7, 9 - exhaust valve shaft and 2, 4, 6, 8, 10 - intake valve shaft.

Note: For 3-cylinder engines there are no bearings with numbers 9 and 10 respectively.

Loosen the exhaust camshaft bearing cap mounting bolts in the sequence shown, remove the caps and remove the shaft. Remove the intake camshaft in the same manner.



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6. Prepare 16 small transparent plastic bags or clean plastic cups and label them according to the valve numbers. Using the tools, remove the tappets from the head and place them in the appropriate cups.

Note: To prevent oil from leaking from the hydraulic tappets, place the tappets with the working ends facing up.

Examination

7. Wipe the timing belt parts with a clean rag and carefully examine the condition of the bearing journals and camshaft cams. If scoring, scratches or signs of wear are detected on the camshafts, they must be replaced along with the hydraulic tappets. If wear or damage to the support bearings is detected, the cylinder head assembly must be replaced (see paragraph 5).

8. Alternately placing the camshafts in the prisms, use a plunger-type dial gauge to determine the value of their radial runout (by bearing journals). If the measurement results are outside the permissible range, the camshaft must be replaced.

9. Check the condition of the tappets and their mounting seats in the head. If signs of excessive wear of the working surfaces, cracks, scoring and other damage are detected, replace the tappets.

Note: The tappets must also be replaced if the valve mechanism has recently been accompanied by increased noise levels.

Installation

10. Before installation, lubricate the mating surfaces of the camshafts and hydraulic tappets with molybdenum grease (with MoS2 content). Install the intake valve shaft first and tighten the mounting bolts in the reverse order of loosening, then install the exhaust valve shaft.

Attention: When installing the shafts, the piston of the first cylinder must be at TDC.

11. Install the camshaft sprockets and secure them with new bolts, adjust the valve timing and reinstall all removed components (see Section 6).

Engine Z14XE/Z16XE/Z18XE

Removal

12. On models with a timing belt drive, to remove the camshafts, it is first necessary to remove the toothed belt (see Section 8). Before loosening the timing belt, move the engine out of TDC by turning the crankshaft 60° counterclockwise so that none of the pistons are at TDC.

13. Remove the ignition module (see Chapter 5), disconnect all electrical wiring connectors and hoses located on top of the cylinder head cover. Unscrew the 10 mounting bolts and remove the cover.

14. Remove the camshaft gears (see Section 5), then unscrew the 2 upper bolts and remove the rear timing belt cover.

15. Remove the camshafts. Remove the exhaust camshaft first: moving in a spiral from the edges inward (in the sequence shown in the accompanying illustration), evenly loosen the bolts securing the upper shaft covers in several steps, then completely unscrew the bolts.





16. When removing the upper camshaft covers, pay special attention to their numbering (see illustration 10.6) - when assembling, the covers must be installed strictly in their original places. If for some reason the marks (numbers) are missing, they must be applied independently using a marker.

19. Lift the camshaft and remove it from the engine, carefully remove the oil seal.

20. Proceeding in a similar manner, remove the intake camshaft - when installing the shafts must be installed only in their places.

21. Remove the valve lifters from the head and place them in the appropriate cups (see paragraph 6).

22. The procedure for checking the timing components is given above (see paragraphs 7-9).

Installation

23. Before installation, lubricate the mating surfaces of the camshafts with fresh engine oil. Clean the mating surfaces of the guide (front) bearings (see accompanying illustration), apply fresh sealant (green color).

Caution: Do not apply sealant too close to oil passage holes (oil flows)! Installation of the covers must be completed no later than 10 minutes after applying the sealant!

24. Install the intake valve shaft first and tighten the mounting bolts in the reverse order of loosening (see illustration 10.15), then install the exhaust valve shaft. After tightening the fasteners, remove any excess sealant that protrudes from under the covers.

25. Press in new seals using the KM-422 tool (see accompanying illustration) or other suitable tool. Before installation, lubricate the outer surfaces of the seals with silicone grease (white color).



26. Before installing the cylinder head cover, clean all mating surfaces, replace the gaskets on the cover and apply fresh sealant (black color) (see accompanying illustration). Install the cover onto the cylinder head and tighten the mounting bolts to the required torque.





27. Install the camshaft gears (see Section 5). Adjust the valve timing and install the toothed belt (see Section 8).

28. Further installation is carried out in the reverse order of removal.

Z16SE Engine

Removal

29. Unlike other petrol engines, this engine has camshaft support bearings on a separate timing case. If necessary, they can be replaced without changing the cylinder head.

30. Remove the timing belt (see Section 8).

Note: If there is no need to replace the timing belt, the right engine support can be left in place. After releasing the tension, remove the belt from the camshaft gear only.

31. Remove the front section of the exhaust system, remove the remaining exhaust system tract from the holders, move it to the side and secure it in a suspended position with wire (see Chapter 4).

32. Loosen the nut of the lower generator mounting bolt while holding the bolt with the second wrench. Disconnect the wiring from the engine oil pressure sensor switch and lower the car.

33. Disconnect all supply lines and wiring from the throttle body assembly, remove 4 bolts (see accompanying illustration) and remove the assembly from the engine.





34. Unscrew and loosen the corresponding generator mounting bolts (see accompanying illustration) and move the generator back. Remove the generator mounting bracket.



35. Disconnect the electrical wiring from the following engine management system components: EVAP valve, injectors, EGR valve, intake air pressure sensor, ECM, DIS ignition module, coolant temperature sensor, knock sensor.

36. Disconnect the brake booster vacuum lines, disconnect the cabin heater supply line.

37. Relieve the pressure in the fuel supply system (see Chapter 4) and disconnect the fuel line (see accompanying illustration).



38. Disconnect the crankcase ventilation system (PCV) hose. Disconnect the BB wires and remove the DIS module of the ignition system (see Chapter 5).

39. Disconnect the lambda probe wiring connector, unscrew the 5 mounting bolts, remove the lifting eye and remove the exhaust manifold heat shield. Then loosen the 8 nuts, remove the exhaust manifold and remove it from the engine compartment from below.

40. Disconnect the upper cooling system hose from the thermostat housing.

41. Remove the 5 mounting bolts and remove the camshaft housing cover.

42. Remove the camshaft gear (see Section 5). Unscrew 2 bolts and remove the rear timing belt cover.

43. Loosen the head mounting bolts in the reverse order to that shown in the accompanying illustration. Carefully pry the housing under the camshaft with a suitable tool and remove it together with the shaft from the engine.



44. Remove the tappets, hydraulic compensators, and other valve drive elements and place them in appropriate cups (see paragraph 6). Check the condition of the timing components (see paragraphs 7-9).

Installation

45. Before installation, lubricate the mating surfaces of the camshafts and hydraulic compensators, valve tappets with molybdenum grease (with MoS2 content).

46. Remove the remains of the old sealant and apply a layer of new (green color) onto the mating surface of the cylinder head. Install the camshaft housing.

47. Further installation is carried out in the reverse order of removal. The order of tightening the cylinder head mounting bolts is shown in Illustration 10.43.

Z13DT Engine

Removal

48. Disconnect the cable from the negative terminal of the battery (see Chapter 5), raise the car on a lift, remove the multi-rib belt cover (see Section 5) and drain the coolant (see Chapter 3).

49. Lower the vehicle and remove the air cleaner (see Chapter 4).

50. Disconnect the electrical wiring connectors, disconnect the fuel lines and remove the fuel filter (see Chapter 1).

Caution: Do not forget to close the free ends of the fuel lines with suitable plugs! Special sets of disposable plugs are available for sale. Even small particles of dirt or sand getting into the fuel system can cause serious damage to the engine!

51. Remove the expansion tank from the holders. Remove the fuel filter mounting clamp (see Chapter 4).

52. Disconnect the wiring connectors of the 4 injectors, 4 glow plugs, camshaft sensor, crankshaft sensor, manifold absolute pressure (MAP) sensor, EGR valve, fuel rail, fuel rail pressure sensor, starter/generator wiring harness. Remove the 3 bolts, separate the wiring channel box from the engine and move it to the side.

53. Loosen the 8 union nuts and remove the 4 high pressure fuel lines from the injectors (see accompanying illustration). Then loosen 2 more nuts and remove the high pressure fuel supply line of the fuel distribution line. Release the two return fuel lines from the clamps, disconnect the oil line, unscrew the 2 mounting bolts and remove the fuel distribution line.



54. Remove the 4 fasteners and separate the oil line from the injectors.

55. Unscrew 2 nuts and remove the injectors from their mounting sockets together with the mounting brackets (see accompanying illustration).

Note: Each bracket holds 2 injectors. The injectors are removed in pairs: first - second and third - fourth cylinders.

56. Remove the timing chain (see Section 8).

57. Remove 2 bolts and brake booster vacuum pump (see accompanying illustration). Unscrew 3 bolts and remove the fuel injection pump.



58. Loosen the bolts securing the camshafts and the drive shaft sprocket to the mounting housing, holding the shafts from turning using the KM-956-1 and KM-6347 devices installed on the sprocket (see Section 5). Then completely unscrew the mounting bolt and remove the sprocket from the shaft.

59. Remove the 16 bolts around the perimeter of the camshaft mounting housing, then the 2 central mounting bolts of the housing (see accompanying illustration). Pry and carefully remove the housing from the engine head.



60. Remove the bolt and the intake camshaft, remove the pinion shaft. Then remove the exhaust camshaft in the same order. Clean all removed components and their mating surfaces. Check the condition of the timing belt components (see paragraphs 7-9).

Installation

61. Before installation, lubricate the mating surfaces of the camshafts with fresh engine oil. Install the shafts in the housing and secure them with bolts.

62. Set the shafts to the position corresponding to the TDC of the piston of the first cylinder, for which use the EN-46781 devices (see Section 6). Tighten the 3 shaft mounting bolts with enough force to hold them in this position (approximately 20 Nm).

63. Replace the gasket and install the housing on the cylinder head. Insert 2 mounting bolts and center the housing on the cylinder head. Align the side faces of the cylinder head and the camshaft housing, use any suitable tool with a straight edge to align them (see accompanying illustration).



64. Tighten the housing mounting bolts to the required torque (see Specifications) in the sequence indicated in the accompanying illustration.

Note: The long bolt must be installed in the position indicated by number (14).

65. Further installation is carried out in the reverse order of removal. The camshaft mounting bolts are fully tightened after installing the sprocket with a force of (120 Nm). When installing the injectors, do not forget to replace the sealing gaskets. Upon completion of the work, fill the engine cooling and lubrication systems, if necessary, make the appropriate adjustments (see Chapter 1). Check the tightness of the systems during a test drive.

Engine Y17DT(L)/Z17DTH

66. The procedure for removing the shafts for the Z17DTH engine is given below. On Y17DT(L) engines, this procedure has some differences due to the specifics of the power plant layout.

Removal

67. Disconnect the cable from the negative terminal of the battery (see Chapter 5).

68. Remove the air cleaner (see Chapter 4).

69. Disconnect the two electrical connectors from the Engine Control Module (ECM) (see accompanying illustration), unscrew 2 bolts and 2 nuts and remove the module.



70. Remove the 4 mounting bolts and the ECM holder, then remove the 2 more bolts and the holder bracket (see accompanying illustration).



71. Disconnect the injector wiring connectors (see accompanying illustration) and glow plugs, release their wiring harness. Then, one by one, disconnect the wiring from the coolant temperature sensor, throttle body assembly, intake air pressure sensor, camshaft sensor, and solenoids.



72. Disconnect the air intake manifold cooler duct from the throttle body assembly.

73. Remove 3 bolts, loosen the mounting clamp and remove the air intake duct (see illustration 10.71).

74. Disconnect the crankcase ventilation system (PCV) hose and remove it together with the seal.

75. Remove the rear left engine lifting eye, then remove the 2 bolts and remove the engine oil dipstick guide tube.

76. Mark the installation position of both high pressure fuel line holders and remove the holders (see accompanying illustration).



77. Prepare a container for draining the fuel and disconnect the high-pressure fuel lines from the injectors - to loosen the union nuts, you must use special tools Hazet 4560-17 or Opel-KM-6098.

Caution: After removing the pipes, immediately close the openings of the line and injectors with plugs to prevent contamination from entering the injection system!

78. Remove the mounting bolt, loosen the clamp and disconnect the injector return oil line.

79. Disconnect the vacuum line, unscrew the mounting bolt and remove the cable channel (see accompanying illustration).



80. Remove the timing belt (see Section 8). Turn the crankshaft 60° counterclockwise and remove the camshaft timing gear (see Section 5).

Note: The wheel is mounted on the intake camshaft and drives the exhaust camshaft via a gear transmission.

81. Remove the return oil line (see illustration 10.71) from the injectors.

82. Remove the rear right engine lifting eye.

83. Unscrew 2 bolts and remove the fuel line sealing plates of the injectors (see illustration 10.76).

84. Unscrew 2 bolts and remove the injector sealing plates (see illustration 10.71).

85. Disconnect the exhaust gas recirculation (EGR) cooler from the camshaft housing cover.

86. Remove the mounting bolts (see accompanying illustration), separate the camshaft housing cover and remove it together with the seal.



87. Remove the fuel injection nozzles (see Chapter 4).

88. Lock the exhaust camshaft together with the compensating gear from turning (see accompanying illustration), for which remove the support bearing cover closest to the shaft gears and install the KM-6092-10 device.



89. Moving in a spiral from the edges inwards (in the sequence shown in the accompanying illustration), in several steps, 1-0.5 turns per approach, evenly loosen the bolts securing the upper bearing caps of the shafts, then completely unscrew the bolts. Before removing the caps, mark them so that they can be installed in the same place later. Carefully remove the shafts - when removing the exhaust valve shaft, in addition to the KM-6092-10 device, install the KM-6092 device to securely fix the compensation gear on the camshaft gear (see accompanying illustration).



90. Carefully remove the intake camshaft oil seal so as not to damage the seating surfaces.

91. Check the condition of the timing components (see paragraphs 7-9).

Installation

92. If the exhaust shaft was replaced and the compensating gear was removed, to install it in the required position, clamp the exhaust camshaft in a vice. Install the KM-6092 device in the corresponding holes (see illustration 10.89). Turning the compensation gear counterclockwise, align the gear holes and insert the KM-6092-10 device.

93. Lubricate the mating surfaces of the shafts with clean engine oil. Before installing the shafts, engage their gears and install the shafts on the engine so that the mark on the gear of the exhaust shaft is between the marks on the intake shaft (see accompanying illustration), and the marks should be approximately at the level of the upper edge of the camshaft housing. Apply sealant (green color) for sealing the joint of the first cover of the support bearings.



94. Replace the four front covers and hand tighten the bolts and nuts securing them.

Note: The arrows on the bearing caps must point towards the timing drive. Remove the KM-6092-10 tool and install the fifth support bearing cap.

95. Tighten 10 fastening nuts and 5 bolts to the required torque in several stages, making 1-1.5 turns per approach in the numbering order shown in the accompanying illustration.



96. Lubricate the outer surface of the new camshaft seal and install it using the KM-656 tool (see accompanying illustration).



97. Install the camshaft timing gear (see Section 5), adjust the valve timing (see Section 6), install the timing belt (see section 8) and check and adjust the valve clearances (see Section 9). The installation of the remaining removed components is carried out in the reverse order of removal (see the relevant sections and chapters).