Contents: Removal ⬇ Installation ⬇
Note: Starting from year 04, KM-6394 must be used instead of KM-6169-1.
Removal
Open the hood.
Disconnect the battery terminals.
Note: On vehicles from year 04 with ESP - after each battery disconnection the steering wheel angle sensor loses its basic setting. It must be recalibrated.
Disconnect the ground wire.
Drain the coolant.
Note: On the "ECO" model variant, remove the engine compartment cover at the bottom.
Place a receiving tray underneath.
Open the drain plug (arrow).
Remove the air filter housing 1.
Disconnect the 2 wiring harness connectors, the hot film air flow meter 3 and the tank vent valve 2.
Release the tank vent valve.
Remove the suction pipe 4.
Unscrew 2 nuts.
Remove the engine crankcase ventilation hose 5.
On Z10XEP engines: Remove the air intake hose.
Release the clamp.
Remove the bolt (arrow).
Remove the throttle body heating hose 1.
Release the clamp.
Remove the hot water supply hose 6 from the coolant pump.
Release the clamp.
Remove the engine management system wiring harness.
Disconnect 3 wire harness connectors, oil pressure switch 3, coolant temperature sensor 4, camshaft sensor 5.
Clear the channel for the wire harness 2.
Set the wiring harness aside.
Remove the radiator hose at the top 1.
Release 2 clamps.
Disconnect the radiator hose at the bottom 2 from the coolant pump.
Release the clamp.
Remove the ignition module.
Remove the ignition module cover.
Move it to the right.
Disconnect the wiring harness connector.
Unscrew the 2 mounting bolts.
Remove using the KM-6009 tool.
Note: Do not tilt the lid.
Remove the cylinder head cover.
Remove the engine crankcase ventilation hose.
Release the clamp.
Remove 13 mounting bolts.
Free the front wheel on the right.
Unscrew the 4 mounting bolts.
Raise the car.
Remove the front wheel on the right.
Unscrew the 4 mounting bolts.
Raise the car.
Remove the poly V-belt cover.
Note: On the "ECO" model variant, remove the engine compartment cover at the bottom 1.
Remove 3 mounting bolts 1.
Remove the clamp (arrow).
Close the threaded plug of the coolant drain port.
Drain the engine oil.
Place another receiving tray underneath.
Unscrew the drain plug.
Note: Bending the flexible tube even by 5-10 angular degrees relative to the intended installation position may result in damage to the flexible hose and subsequent failure.
Clear the exhaust system.
Note: When removing the middle muffler, catalytic converter, exhaust manifold or exhaust manifold with catalytic converter, the part of the exhaust system remaining in the vehicle must be secured against uncontrolled sagging. To do this, the part of the exhaust system with the flexible pipe in it can be secured with suitable means, for example, with wire on the chassis.
Remove the catalytic converter monitoring lambda sensor 1 wiring harness connector.
Release the 2 damping partitions (arrows).
Unscrew the exhaust pipe from the front 2.
Unscrew 3 nuts.
Connect the exhaust pipe from the front to the front axle housing on the left.
Tighten the bolts securing the engine oil drain plug to a torque of 10 Nm.
Replace the sealing ring.
Remove the generator wiring harness 1.
Unscrew 2 nuts.
Remove the cable ties.
Remove the poly V-belt.
Using the KM-6131 tool, tension the poly V-belt tensioner in the direction of the arrow.
Insert the KM-6130 tool.
Remove the poly V-belt tensioner.
Note: Ensure proper support of the poly V-belt tensioner (the arrow points up). If it cannot be ensured, the air should be released from the tensioner of the poly V-belt. To do this, at least 5 strokes should be performed (pull-press), and the loading speed must remain constant and the loading must be performed uniformly. Do not allow damage to the tension element.
Tighten the polyethylene belt tensioner using the KM-6131 tool.
Remove the KM-6130 tool.
Loosen the tension of the poly V-belt tensioner.
Unscrew 2 mounting bolts 1.
Remove the generator.
Unscrew 2 threaded connections 1.
Remove the oil pan.
On the gearbox, unscrew the 3 mounting bolts 1.
On the crankshaft support, unscrew the 14 mounting bolts.
Install the KM-6169-2 tool on the gearbox.
Tighten the 2 mounting bolts to 95 Nm.
Install fixture KM-61691.
KM-6169 fit on the left side of the front axle housing (arrows, figure I).
Note: The guide pin must be located in the hole in the front axle housing.
Install both holders on the right side onto the front axle housing (arrows, figure II).
Note: The guide pin must be located in the hole in the front axle housing (arrow, figure III).
Tighten the 8 mounting bolts.
Install the support on the KM-6169 fixture.
Install the support bracket 2.
Tighten nut 1.
Adjust the supports.
From the gearbox side, tighten the spindles so that the fasteners 3 on the guide journals fit without any gap.
From the engine control side, insert the support journal into the cylinder block hole without any gap (arrow).
Tighten nut 1.
Unscrew the motor holder on the right.
Loosen bolt 1 at the bottom.
Lower the car.
Remove the compressor.
Note: The air conditioning system remains closed.
Disconnect the wire harness connector (arrow).
Remove 3 mounting bolts 1.
Put the compressor aside.
Lower the car.
Remove the motor mount on the right.
Release the engine shock absorber block.
Unscrew 2 mounting bolts 1.
Unscrew the 2 mounting bolts (arrows).
Remove the coolant pump poly V-belt pulley.
Unscrew the 3 mounting bolts.
Remove the poly V-belt tensioner.
Remove the bolt.
Remove the coolant hose.
Unscrew the 3 mounting bolts.
Set the TDC position of the ignition of cylinder 1.
Remove the crankshaft support plug.
Insert the KM-952 tool.
Note: The mark on the crankshaft belt pulley 4 must be in line with the boss 3 on the timing belt housing.
Turn the crankshaft evenly until the KM-952 tool is engaged.
Insert the KM-953 tool.
Note: KM-953 must fit into the groove of the camshafts.
Remove the KM-953 tool.
Raise the car.
Remove the crankshaft poly V-belt pulley 1.
Unscrew the 6 mounting bolts.
Hold the crankshaft hub bolt.
Loosen the crankshaft hub bolt.
Remove the KM-952 tool.
Install device KM-956-1/ KM-956-2 3.
Hold the KM-956-1/KM-956-2 fixtures.
Remove crankshaft hub 2.
Note: Observe the installation position.
Insert the KM-952 tool.
Remove the bolt.
Remove it using tools KM-956-1 / KM-956-2.
Release the timing belt housing from below.
Note: Please take into account the different lengths of the mounting bolts.
Unscrew 2 mounting bolts 3 (M10).
Unscrew the 14 mounting bolts (M6) (arrows).
Lower the car.
Remove the coolant pump.
Note: Pay attention to the guide bushings when removing.
Place another receiving tray underneath.
Unscrew 4 mounting bolts 2.
Note: Please take into account the different lengths of the mounting bolts.
Remove the timing belt housing.
Unscrew the 4 mounting bolts 1.
Remove the chain drive.
Loosen the 2 camshaft gear mounting bolts.
Hold the camshafts by the hex key.
Lock the chain tensioner 1.
Insert the KM-955-1 tool.
Remove the damper bar 3, guide bar 5, tensioner slides 7, and camshaft drive gears.
Remove camshaft drive chain 4 with drive wheel 6.
Remove the timing case seal.
Remove the crankshaft seal ring from the front.
Pry up and remove the sealing ring.
Note: Do not damage the sealing surface.
Installation
Clean the sealing surfaces of the timing case, cylinder block, cylinder head, crankshaft support, oil pan, cylinder head cover, coolant pump, thermostat housing.
If present, remove any sealant from the cylinder head seal area.
Inspect the nodes.
Note: If it is necessary to check and treat the cylinder head, remove all externally mounted parts from the cylinder head: chain drive, timing case, cylinder block, cylinder head, crankshaft support, oil pan, cylinder head cover, coolant pump, thermostat housing.
When replacing parts, consider the different design options. Ensure that the part numbers and catalog are correct.
Replace the crankshaft seal ring front 1.
Lubricate the sealing edges with silicone grease (white).
Slide onto KM-960 fixtures.
Use the KM-960 tool to drive flush.
Replace the timing case seal.
Apply silicone sealant to the joint between the cylinder block and the crankshaft support.
Note: Complete installation work within 10 minutes.
Separate the protruding elastomer of cylinder head seal 1 and replace it with a 2 mm thick strip of silicone sealant.
Note: If there is no protruding elastomer, you can immediately apply a bead of silicone sealant.
Install the camshaft timing chain.
Note: Make sure the guide bushings (arrows) are seated correctly.
Install fixture KM-953.
Replace the bolts.
Move drive wheel 5.
Install the exhaust camshaft gear.
Screw in the bolt.
Install the camshaft timing chain 3.
Insert the intake camshaft gear with the phase sensor disc into the camshaft drive chain.
Screw in the bolt.
Note: The phase sensor disk must be rotated manually.
Install the camshaft timing chain tensioner slide 6.
Tighten the bolt and tighten to a torque of 20 Nm.
[Material was taken from a resource: opelbook.ru]
Note: Make sure the camshaft drive chain is seated correctly.
Install the camshaft timing chain guide groove 4.
Note: Make sure the camshaft drive chain is seated correctly.
Tighten the bolt to 8 Nm.
Install the camshaft timing chain guide bar 2.
Tighten the 2 mounting bolts to 8 Nm.
Remove the KM-955-1 tool.
Install the coolant pump.
Note: Make sure the guide bushings (arrows) are seated correctly
Replace seal 1.
Install using short mounting bolts.
Tighten the 3 mounting bolts to 8 Nm.
Install the timing belt housing.
Note: Follow the tightening sequence.
Tighten the 21 mounting bolts.
Tighten 5 mounting bolts 1 (M6) 8 Nm.
Tighten 14 mounting bolts 2 (M6) 8 Nm.
Tighten 2 mounting bolts 3 (M10) 35 Nm.
Install the coolant hose.
Replace the pipe seal.
Tighten the 3 mounting bolts to 8 Nm.
Raise the car.
Remove the KM-952 tool.
Note: Fixation tools cannot be used for holding.
Install the crankshaft hub.
Note: Observe the installation position of the crankshaft hub - the mark must point upwards.
Replace the bolt.
Tighten the crankshaft hub bolt.
Note: This procedure requires two people to work together.
Hold the hubs using tools KM-956-1/ KM-956-2.
Tighten the bolt to 150 Nm. +45°.
Remove fixtures KM-956-1/ KM-956-2.
Install the crankshaft poly V-belt pulley.
Tighten the 6 mounting bolts to 8 Nm.
Hold the crankshaft hub bolt.
Insert the KM-952 tool.
Lower the car.
Install fixture KM-9541.
Rotate the phase sensor disc 2 until it becomes possible to install the KM-954 device on the timing case.
Secure the camshaft drive gears.
Note: Tighten the intake camshaft drive gear bolt first.
Tighten the 2 mounting bolts to 210 Nm.
Note: Tighten the camshaft drive gears and the phase sensor disc to 10 Nm.
Support the camshafts using hexagon 1.
Remove the fixing tools.
Note: Fixation tools cannot be used for holding.
Tighten the camshaft drive gears.
Note: This procedure requires two people to work together.
Tighten the bolts to a torque of 50 Nm +60°.
Note: Tighten the intake camshaft drive gear bolt first.
Hold the camshafts by the hex key.
Rotate the crankshaft (720°).
Install devices KM-952, KM-953, KM-954.
Remove the fixing tools KM-952, KM-953, KM-954.
Raise the car.
Install the crankshaft support plug.
Replace the sealing ring.
Tighten the bolt to 50 Nm.
On the "ECO" model, install the engine cover at the bottom.
Lower the car.
Clean the sealing surfaces of the cylinder head and cylinder head cover.
Install cylinder head cover 1.
Replace seal 2 and O-ring.
Apply sealant (distance 1–2 mm).
Note: Installation work must be completed within 10 minutes.
Tighten the 13 mounting bolts to 8 Nm.
Install 2 engine crankcase ventilation hoses.
Install the ignition module.
Unscrew 2 pcs. KM-6009.
Tighten the 2 mounting bolts to 8 Nm.
Install the engine management system wiring harness.
Route the wiring harness.
Secure the wiring harness channel.
Connect the 4 wire harness connectors.
Connect the battery terminals.
Program volatile memory.
Close the hood.
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