Opel Kadett Owner's Manual page 60

2C•10 DOHC (16-valve) engine
Refitting
9 Commence refitting by smearing a new
gasket with grease and placing it on the
pump. Grease the lips of the oil seal and refit
the pump, being careful not to damage the oil
seal as it passes over the crankshaft.
10 Insert the pump securing bolts. Position
the bottom of the pump flush with the sump
mating face of the block and tighten the bolts
to the specified torque.
11 Thinly coat the outer face of the spacer
with sealant to GM spec 15 04 200/8 983 368
(see Chapter 2B, Section 20, paragraph 17).
Push the spacer onto the crankshaft.
12 The remainder of refitting is the reverse of
the removal procedure. Remember to fit a
new camshaft toothed belt.
15 Oil pump - overhaul
Refer to Chapter 2B, Section 14.
16 Oil cooler thermostatic valve
- removal and refitting
Removal
1 The thermostatic valve is mounted in the oil
cooler adapter, just above the oil filter.
2 Place a drain tray under the filter housing.
Remove the circlip from the end of the valve
(see illustration).
3 Recover the plug, spring and thermostatic
element. There will be some oil spillage.
4 Clean and examine the components: renew
any which are obviously worn or damaged.
Refitting
5 Refitting is the reverse of the removal
procedure. Check the engine oil level and top-
up if necessary.
17 Crankshaft front oil seal -
renewal
1 Remove the crankshaft sprocket as
described in the procedure for oil pump
removal. There is no need to remove the cam-
shaft sprockets or belt backplate. Recover the
spacer from behind the sprocket.
2 Drill or punch a small hole in the face of the
oil seal. Screw in a self tapping screw and use
this to lever out the seal. Clean the seal seat.
3 Grease the lips of a new oil seal. Fit the
seal, lips inwards, and seat it using a piece of
tube, some washers and the crankshaft
sprocket bolt.
4 Thinly coat the outer face of the spacer with
sealant to GM spec 15 04 200/8 983 368 (see
Chapter 2B, Section 20, paragraph 17). Push
the spacer onto the crankshaft.
5 The remainder of refitting is the reverse of
the removal procedure. Remember to fit a
new camshaft toothed belt.
16.2 Circlip securing oil cooler
thermostatic valve
18 Pistons and connecting rods
- removal and refitting
Refer to Chapter 2A, Section 15, but note
that the pistons and rods may be separated if
wished, as described in Section 19.
19 Pistons and connecting rods
- dismantling and reassembly
1 With the pistons and connecting rods
removed they may be separated if necessary
as follows.
2 Note the relative orientation of rod and
piston. When fitted, the arrow on the piston
crown points to the camshaft sprocket end of
the engine, and the bosses on the connecting
rod face towards the flywheel.
3 Remove one of the circlips which secure
the gudgeon pin. Push the gudgeon pin out of
the piston and connecting rod using a
wooden or brass rod. No great force should
be necessary.
4 When refitting, fit the connecting rod into
the piston and make sure they are the right
way round. Oil the gudgeon pin and push it
home, then secure it with the circlip.
20 Flywheel - removal and
refitting
Removal
1 Remove the clutch assembly as described
in Chapter 6.
2 Mark the position of the flywheel relative to
the crankshaft. Jam the ring gear teeth and
slacken the flywheel retaining bolts (see
Chapter 2A, Section 16).
3 Remove the bolts and lift off the flywheel.
Do not drop it, it is heavy. Obtain new bolts for
reassembly.
Refitting
4 Refitting is the reverse of the removal
procedure. Tighten the bolts to the specified
torque.
21 Crankshaft rear oil seal -
renewal
Remove the flywheel as described in
Section 20.
Renew the oil seal as described in Chapter
2A, Section 19.
22 Engine/transmission
mountings - removal and
refitting
Refer to Chapter 2A, Section 17.
23 Crankshaft and main bearings
- removal and refitting
Refer to Chapter 2B, Section 20.
24 Engine components -
examination and renovation
1 The cylinder head and oil pump have been
considered earlier in this Chapter. For other
components refer to Chapter 2A, Section 21,
and note the following additional information.
Camshafts
2 With the camshafts removed, examine the
bearing surfaces and lobes for wear, pitting
and scuffing. Measure the bearing journals
with a micrometer. Dimensions are given in
the Specifications.
3 Wear or damage to a camshaft means that
it must be renewed. If there is corresponding
wear in the bearing seats and caps, a
complete new cylinder head will be required.
The bearing caps are line bored in position on
the head and cannot be renewed separately.
4 With the camshafts fitted to the head,
check their endfloat using a dial gauge or
feeler blades. Endfloat outside the limits
specified means that the camshaft(s) and/or
cylinder head must be renewed.
Camshaft toothed belt
5 As mentioned earlier, the belt must be
renewed every time that it is removed, even if
it appears to be in good condition.
Piston/bore grade marks
6 The number or code denoting the piston
and bore grade (see Specifications) is
stamped on the block near the engine
number.
25 Engine - removal and refitting
Removal
1 The engine is removed with the transmission
by lowering the two out of the engine bay. They
can then be separated on the bench.