Vauxhall Workshop Service and Repair Manuals

Removing and installing both camshafts

Important:   When working on the fuel system it is essential to pay attention to cleanliness as even the smallest dirt particles can lead to faults in engine operation or in the fuel system. Open fuel connections must be sealed with appropriate plugs from the Opel Parts Catalogue (catalogue number: 45 06 154 / part number: 9201697). Sealing plugs are only intended to be used once.

  Remove

6.   Drain coolant •   Open drain bolt on radiator (1) •   Collect coolant •   Close drain bolt

9.   Remove engine cover (2) •   Detach oil filler port closure cap (1) •   Pull off engine cover Note:   Rubber retainers (3) must remain on engine cover •   Attach oil filler port closure cap

10.   Remove air intake manifold (1) •   Detach wiring harness – Release 3x clip •   Undo 2 clamps •   Unscrew 2x bolts

11.   Remove charge air pipe (1) •   Unscrew 6x bolts

12.   Detach wiring harness for injectors •   Disconnect 4x wiring harness plugs for injector (2) •   Unscrew 2x bolts (3) •   Disconnect 4x wiring harness plug for glow plug (1) with KM-717 •   Push wiring harness to one side

Important:   After detaching the pressure lines, seal off injector and pressure chamber openings with protective caps 1) 14.   Remove high pressure lines (1), pressure chamber to injectors •   Unscrew 8x union nut with KM-812 or KM-6098 •   Take out pressure lines •   Seal 4x pressure chamber opening with protective cap •   Seal 4x injector opening with protective cap

15.   Detach fuel return line (1) •   Detach 4x fuel return line from injector – Press 4x retaining clamps in direction of arrow •   Detach fuel return line from pressure chamber •   Unscrew 2x bolts Note:   Note different bolt lengths •   Unscrew nut

16.   Remove rear right engine transport shackle (1) •   Unscrew 2x bolts

17.   Remove rear left engine transport shackle (1) •   Detach wiring harness – Unclip clip •   Unscrew bolt

18.   Remove bracket, oil dipstick guide tube (1) •   Unclip vacuum line – Unclip 2x clips •   Remove oil dipstick guide tube – Release clamp •   Detach bracket, oil dipstick guide tube, from camshaft housing – Unscrew 2x bolts

19.   Remove 4x seals, connection for injectors (1) •   Unscrew 8x bolts

20.   Remove 4x seal, injectors (1) •   Unscrew 8x bolts

21.   Remove camshaft housing cover (1) •   Unscrew 11x bolts Note:   Note different bolt lengths

22.   Remove 4x injector (1) Note:   Mark injectors •   Remove 4x bracket, injector (2) – Unscrew 4x bolts Note:   If a heat protection sleeve (5) also has to be removed when removing an injector, the gaskets (3) must be replaced and the heat protection sleeve must be hammered into the cylinder head with KM-6357 (4)

25.   Insert KM-6173 (3) •   Align support bearing (1) •   Raise support bearing until journal (2) sits flush in mount (4) •   Fasten KM-6173 – Screw in 2x bolts

26.   Attach KM-6001-A (1) Note:   Attaching KM-6001-A guarantees perfect alignment of the drive unit with the front axle body •   Slacken 4x bolts (arrows) in adjusting rails •   Insert KM-6001-A – Insert journals (2) and (5) in guide holes in front axle body •   Tighten 4x bolts in adjusting rails •   Adjust support bearings, front (4) and rear (3) – Raise support bearings up to the stop on the guide journals Note:   The guide journals must be seated free from play in the support bearings

28.   Remove air cleaner housing (5) with air intake hose •   Disconnect wiring harness plug (2) from hot film mass air flow meter •   Detach air intake hose from air intake pipe – Release clamp (1) •   Detach air cleaner housing from wheel housing – Unscrew bolt (4) •   Detach water drain hose (3) from air cleaner housing – Release clamp

29.   Remove ribbed V-belt •   Mark direction of rotation •   Apply tension to ribbed V-belt tensioner via bolt (1) in the direction of the arrow •   Fix ribbed V-belt tensioner to bore (2) •   Remove ribbed-V-belt

30.   Detach wiring trough (4) from front toothed belt cover (top) •   Unscrew bolt (2) •   Detach wiring harness (3) – Disconnect camshaft sensor wiring harness plug – Release 2x clip •   Detach vacuum line (1) – Release 2x clip •   Unclip wiring trough in direction of arrow – Undo clip

31.   Detach front toothed belt cover (top) (4) •   Detach vacuum line (3) – Unclip 3x clip •   Unscrew 8x bolts Note:   Note different bolt lengths •   Remove camshaft sensor bracket (1) – Unscrew bolt (2)

32.   Remove engine damping block support •   Detach from engine damping block bracket – Unscrew 3x bolts (2) •   Detach from cylinder block – Unscrew 3x bolts (3) •   Remove engine damping block adapter (1)

33.   Remove coolant pump drive gear (1) •   Unscrew 3 bolts

34.   Detach torsional vibration damper (1) •   Unscrew 4x bolts Note:   Counterhold at bolt (2)

35.   Remove front toothed belt cover (lower) (1) •   Unscrew 3x bolts (2)

36.   Move crankshaft in direction of engine rotation to "Cylinder no.1 combustion stroke TDC" Note:   Marking on toothed belt drive gear must align with projection on oil pump cover (arrows) •   Fix with TDC fixing bolt (M6) (1) camshaft drive gear •   Fix with TDC fixing bolt (M8) (2) high pressure pump gear

37.   Remove toothed belt •   Mark direction of rotation •   Slacken the toothed belt tension roller – Loosen bolt (1) •   Apply preliminary tension to toothed belt tension roller with hexagon (2) in direction of arrow •   Fix toothed belt tension roller in pre-tensioned position – Tighten bolt

38.   Turn crankshaft 60° against the direction of engine rotation

39.   Remove camshaft sprocket •   Remove TDC fixing bolt (1) •   Unscrew bolt Note:   Counterhold with KM-6347 (2) in conjunction with KM-956-1 (3)

40.   Lock exhaust camshaft gear wheels •   Remove camshaft bearing cap (3) •   Lock balancer gear wheel, exhaust camshaft (2), with exhaust camshaft gear wheel (4) with KM-6092-10 (1) so that it cannot twist

41.   Remove both camshafts Note:   Note marking before dismantling camshaft bearing cap •   Release the camshaft bearing cap in the order illustrated in a spiral in stages of 1/2 to 1 turn Note:   When replacing the exhaust camshaft, the balancer gear wheel (2) must be pre-tensioned with KM-6092 (1) and connected to the gear wheel of the exhaust camshaft (3) with fixing pin KM-6092-10 (4)

42.   Remove camshaft seal ring (1)

  Install

44.   Insert both camshafts Important:   When installing the camshafts, care must be taken to ensure that the marking (1) exhaust camshaft gear wheel is positioned between the two markings (2) gear wheel intake camshaft and the markings are approximately level with the upper edge of the camshaft housing •   Insert camshafts into camshaft housing •   Apply surface sealant (green) to sealing surfaces (3) of the 1st camshaft bearing cap

45.   Install both camshafts Note:   Coat bearing positions with engine oil •   Attach camshaft bearing cap 1 - 4 to camshaft housing Note:   Arrows on bearing cap point towards engine timing side •   Remove KM-6092-10 from gearwheel exhaust camshaft and attach camshaft bearing cap 5 •   Tighten the camshaft bearing cap in the order illustrated (1) - (15) in stages of 1/2 to 1 turn – Tighten 10x nut (M8) 21.6 Nm – Tighten 5x bolt (M10) 26.5 Nm

46.   Insert camshaft seal ring •   Drive in flush using KM-656 (1)

47.   Install camshaft sprocket Note:   Camshaft journal (2) must engage in the bore (1) in the camshaft sprocket •   Tighten bolt 63.7 Nm Note:   Counterhold with KM-6347 in conjunction with KM-956-1 •   Screw in TDC fixing bolt

48.   Install toothed belt Note:   TDC fixing bolts must be installed in the high pressure drive gear and camshaft drive gear and markings (6) and (7) must align •   Position toothed belt – Toothed belt must be tensioned in the direction of the arrow from the toothed belt drive gear (5) via the oil pump drive gear (4) and high pressure pump drive gear (2) to the camshaft sprocket (1) – Observe direction of rotation •   Slacken the toothed belt tension roller (3) •   Remove 2x TDC fixing bolt •   Turn crankshaft 60° against the direction of engine rotation •   Tighten toothed belt tension roller 38.2 Nm

49.   Timing, Check •   Turn crankshaft 6 revolutions in direction of engine rotation to the adjustment position •   The following factors must be present at the adjustment position Note:   If one of these factors is not present, the timing must be adjusted 1. TDC fixing bolt M6 (1) must be able to be inserted in the camshaft drive gear 2. TDC fixing bolt M8 (2) must be able to be inserted in the high pressure pump drive gear 3. Marking (4) on the toothed belt drive gear must align with the marking (3) on the oil pump housing cover •   Remove 2x TDC fixing bolt

50.   Turn the crankshaft until the cam pair (1) and (2) faces upwards. 51.   Check valve lash with feeler gauge Note:   Valve lash must be checked at room temperature when the engine is cold. •   Test values: Intake valve/exhaust valve (0.35 - 0.45 mm) 52.   Adjust valve play •   Turn the bucket tappet until the tappet groove faces outwards Important:   Care should be taken that the valves do not strike the piston head •   Press down cup tappet with KM-6090 Note:   Note different tool designs for intake and exhaust valve – Marking - IN = intake side – Marking - EX = exhaust side •   Remove shim

53.   Example for determination of shim thickness: 1. Thickness of installed shim   3.15 mm 2. Measurement between cams and cup tappets + 0.45 mm     = 3.60 mm 3. Nominal valve play - 0.40 mm 4. Thickness of new shim = 3.20 mm 54.   Insert shim •   Coat new shim (7) with engine oil and insert in cup tappet with code facing down 55.   Check and adjust remaining valves •   Turn crankshaft 180° in the direction of rotation of the engine – Check and adjust valve pair (6) and (2) •   Turn crankshaft 180° in the direction of rotation of the engine – Check and adjust valve pair (5) and (3) •   Turn crankshaft 180° in the direction of rotation of the engine – Check and adjust valve pair (4) and (1) Note:   Valve lash must be checked again on all adjusted valves

Important:   Journal (1) of toothed belt drive gear must engage in the bore (2) of the torsional vibration damper 57.   Install torsional vibration damper •   Tighten 4x bolt 19.6 Nm Note:   Counterhold against bolt, toothed belt drive gear

62.   Insert ribbed V-belt Note:   Note running direction of ribbed V-belt •   Position ribbed V-belt – I. Ribbed V-belt without air conditioning – II. Ribbed V-belt with air conditioning •   Apply tension to ribbed V-belt tensioner via bolt (1) in the direction of the arrow •   Take out fixing •   Release ribbed V-belt tensioner

69.   Replace injector gaskets •   Rubber gasket (1) •   Copper gasket (2)

70.   Install 4x injector •   Install 4x brackets – Align injectors with EN-48560 (1)

72.   Fasten 4x injectors •   Tighten 4x bolt in three stages – 1. Tighten bolt 40 Nm – 2. Loosen bolt – 3. Tighten bolt 32 Nm

76.   Apply sealing compound Important:   Oil return bore (2) may not be covered with adhesive sealing compound •   Apply adhesive sealing compound (white) to sealing surfaces (1) and (3)

77.   Install camshaft housing cover •   Replace gasket •   Tighten 9x bolt in the stated order (1...9) 9.8 Nm

78.   Install 4x new seal, injectors (2) •   Align seal for injectors Note:   Sealing lip of seal must be in full contact with the injector with no gaps (arrow) •   Coat 8x bolt head contact surface (1) with special grease (white) •   Tighten injector seal in 2 stages Note:   During the tightening process, press injector seal against the camshaft housing cover with your hand 1. Tighten 2x bolt 10 Nm 2. Tighten 2x bolt 19 Nm

79.   Install 4x new seal, connection for injectors Note:   Marking "UP" must point upwards •   Tighten 8x bolts