Opel Corsa B 1993–2000 Service and Repair Manual: Engine dismantling and reassembly - general information

1. If the engine has been removed from the car for major overhaul, or if individual components have been removed for repair or renewal, observe the following general hints on dismantling and reassembly.

2. Drain the oil into a suitable container and then thoroughly clean the exterior of the engine using a degreasing solvent or paraffin.

Clean away as much of the external dirt and grease as possible before dismantling.

3. As parts are removed, clean them in a paraffin bath. However, do not immerse parts with internal oilways in paraffin as it is difficult to remove, usually requiring a high pressure hose. Clean oilways with nylon pipe cleaners.

4. Avoid working with the engine or any of the components directly on a concrete floor, as grit presents a real source of trouble.

5. Wherever possible, work should be carried out with the engine or individual components on a strong bench. If the work must be done on the floor, cover it with a board or sheets of newspaper.

6. Have plenty of clean, lint-free rags available and also some containers or trays to hold small items. This will help during reassembly and also prevent possible losses.

7. Always obtain a complete set of gaskets if the engine is being completely dismantled, or all those necessary for the individual component or assembly being worked on.

Keep the old gaskets with a view to using them as a pattern to make a replacement if a new one is not available.

8. If possible refit nuts, bolts and washers in their locations after removal; this helps to protect the threads and avoids confusion or loss.

9. During reassembly thoroughly lubricate all the components, where this is applicable, with engine oil, but avoid contaminating the gaskets and joint mating faces.

10. Where applicable, the following Sections describe the removal, refitting and adjustment of components with the engine in the car. If the engine has been removed from the car, the procedures described are the same except for the disconnection of hoses, cables and linkages, and the removal of components necessary for access, which will already have been done.

Ancillary components - removal and refitting

If the engine has been removed from the car for complete dismantling, the following externally mounted ancillary components should be removed. When the engine has been reassembled these components can be refitted before the engine is installed in the car, as setting up and adjustment is often easier with the engine removed. The removal and refitting sequence need not necessarily follow the order given:

1. Alternator
2. Distributor and spark plugs
3. Inlet and exhaust manifolds and carburettor
4. Fuel pump
5. Water pump and thermostat
6. Clutch assembly