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Vauxhall Workshop Service and Repair Manuals

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Cylinder Head Cover, Remove and Install > < Attaching Parts - Cylinder Head, Remove and Install

Astra H

Valve Lash - Petrol Engine, Check and Adjust

  Remove

1.   Open bonnet
2.   Disconnect battery
•   Detach earth connection from earth terminal
– Slacken nut
3.   Remove air cleaner housing
  • A 16 XER, Z 16 XER
  • A 18 XER, Z 18 XER
4.   Remove front toothed belt cover (top) LUREF_1.gif
5.   Remove cylinder head cover
6.   Raise vehicle by its full height
7.   Remove ribbed V-belt tensioner LUREF_1.gif
8.   Set engine to TDC
•   Turn crankshaft in the direction of engine rotation by the bolt of the torsional vibration damper to cylinder 1 TDC of combustion stroke
•   Marking on torsional vibration damper must align with the marking on the lower part of the toothed belt cover (1)
Object Number: 2412844 Size: DEFAULT


9.   Cams at the intake side of cylinder no.2 (1) and the exhaust side of cylinder no.3 (2) are on top and tilted slightly towards the inside to the same extent
Object Number: 26582148 Size: DEFAULT


10.   Check valve lash
•   Prescribed valve lash
– Intake valves 0.21 - 0.29 mm (nominal value 0.25 mm )
– Exhaust valves 0.27 - 0.35 mm (nominal value 0.30 mm )
11.   Check 4x valve clearance
•   Check valve lash with KM-6361 (1)
– Note down result
Object Number: 26582153 Size: DEFAULT


12.   Rotate crankshaft on torsional vibration damper bolt by 180°
•   In direction of engine rotation.
– Pairs of cams (1) and (2) point upwards at an angle
Object Number: 26582147 Size: DEFAULT


13.   Check 4x valve clearance
•   Check valve lash with KM-6361
– Note down result
14.   Rotate crankshaft on torsional vibration damper bolt by 180°
•   In direction of engine rotation.
– Pairs of cams (1) and (2) point upwards at an angle
Object Number: 26582149 Size: DEFAULT


15.   Check 4x valve clearance
•   Check valve lash with KM-6361
– Note down result
16.   Rotate crankshaft on torsional vibration damper bolt by 180°
•   In direction of engine rotation.
– Pairs of cams (1) and (2) point upwards at an angle
Object Number: 26582150 Size: DEFAULT


17.   Check 4x valve clearance
•   Check valve lash with KM-6361
– Note down result
18.   Rotate crankshaft on torsional vibration damper bolt by 180°, to TDC of combustion stroke of cylinder 1
19.   Raise vehicle by its full height
20.   Immobilise crankshaft via starter ring
•   Attach KM-6625
– Detach screwed connection (1)
– Insert KM-6625 (2)
– Tighten screwed connection (3)
Object Number: 9007701 Size: DEFAULT


21.   Remove torsional vibration damper
•   Unscrew bolt
22.   Remove front toothed belt cover (bottom)
•   Unscrew 4x bolts
23.   Insert KM-6173 (3)
•   Slacken 4x bolts (arrows) and hand-tighten
•   Align KM-6173 at front axle body
•   Wind up the support bearing (1)
– Journal (2) must sit in mount at cylinder block
•   Tighten 4x bolts
Object Number: 3446250 Size: DEFAULT


Object Number: 2414110 Size: DEFAULT

24.   Attach KM-6001-A (1)
Note:   Attaching KM-6001-A guarantees perfect alignment of the drive unit with the front axle body.
•   Slacken 3x bolts (arrows) in adjusting rails
•   Insert KM-6001-A
– The journals (2) and (5) must sit in the guide holes of the front axle body
•   Tighten 3x 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.

25.   Lower vehicle by its full height
26.   Remove engine damping block, right hand side
•   Unscrew 6x bolts (1)
Object Number: 9007868 Size: DEFAULT


27.   Remove engine damping block support (1)
•   Unscrew 3x bolts (2)
Object Number: 9007869 Size: DEFAULT


28.   Remove front toothed belt cover (centre) (1)
•   Unclip 2x from rear of toothed belt cover
Object Number: 26582151 Size: DEFAULT


29.   Stop toothed belt tensioner
•   Apply tension to toothed belt tension roller (2) clockwise using an Allen key (1), and fix using KM-6333 (3)
Object Number: 26582152 Size: DEFAULT


30.   Remove toothed belt
31.   Remove toothed belt tensioner (2)
Note:   Do not remove locking using KM-6333 (3).
•   Unscrew bolt (1)
Object Number: 26582155 Size: DEFAULT


32.   Raise vehicle by its full height
33.   Attach fastening bolt with washer to the torsional vibration damper of the crankshaft. Tighten by hand.
34.   Remove KM-6625
•   Detach screwed connection
35.   Turn the crankshaft 60° against the direction of engine rotation to the fastening bolt of the torsional vibration damper
Note:   Check using the TDC marks on the toothed belt drive gear (1) and oil pump housing (2)
Object Number: 26582156 Size: DEFAULT


36.   Lower vehicle by its full height
37.   Place collecting basin underneath.
38.   Unscrew closure bolt, exhaust camshaft adjuster
39.   Unscrew intake camshaft closure bolt
40.   Slacken exhaust camshaft adjuster
Note:   2 mechanics required
•   Counterhold against the camshaft hex (2) using an open-ended spanner socket (1)
Object Number: 26582157 Size: DEFAULT


41.   Detach exhaust camshaft adjuster
•   Unscrew bolt
42.   Slacken intake camshaft adjuster
Note:   2 mechanics required
•   Counterhold against the camshaft hex (2) using an open-ended spanner socket (1)
Object Number: 26582158 Size: DEFAULT


43.   Detach intake camshaft adjuster
•   Unscrew bolt
44.   Remove rear toothed belt cover
•   Unclip wiring trough cover
•   Unscrew 4x bolts
45.   Remove camshaft bearing support
•   Unscrew 4x bolts
– Note removal sequence 1 - 4
•   Release bearing support by striking it gently with a plastic hammer
Object Number: 10677753 Size: DEFAULT


46.   Remove intake camshaft
Note:   Mark the camshaft bearing caps before removing them.
•   Slacken camshaft bearing caps 1 - 4, working in spiral from outside to inside in steps of 1/2 up to 1 turn
•   Remove the camshaft bearing cover from the cylinder head and take out the camshaft
Note:   Note marking on the camshaft bearing cap with stamped numbers from 1 to 8 (there is a dot at bottom left before each number to avoid mistakes).
Object Number: 9008515 Size: DEFAULT


Object Number: 26582163 Size: DEFAULT

47.   Remove exhaust camshaft
Note:   Mark the camshaft bearing caps before removing them.
•   Slacken camshaft bearing caps 5 - 8, working in spiral from outside to inside in steps of 1/2 up to 1 turn
•   Remove the camshaft bearing cover from the cylinder head and take out the camshaft
Note:   Note marking on the camshaft bearing cap with stamped numbers from 1 to 8 (there is a dot at bottom left before each number to avoid mistakes).

48.   Remove cup tappet with KM-845 (1)
Object Number: 2412921 Size: DEFAULT


49.   Determine cup tappet size

Example of determining the size of a cup tappet, intake side:

Dimension of fitted cup tappet

  

3.20 mm

(Identification no. 20)

Valve clearance measurement between cams and cup tappets

+

0.35 mm

  
 

=

3.55 mm

  

Required value, valve lash, intake side

-

0.25 mm

  

Nominal dimension of the new cup tappet

  

3.30 mm

(Identification number 30X)
Note:   The identification number (arrow) is on the inside of the cup tappet
•   Now use a cup tappet with this dimension or one that is nearest to it
Currently available cup tappet sizes LUREF_1.gif
Object Number: 26582159 Size: DEFAULT


  Install

50.   Insert cup tappet with KM-845
•   Lightly coat sliding surfaces with oil
51.   Install intake camshaft
•   Coat with MoS 2 lubricating paste
•   Insert camshaft
Note:   Note the identification marking on the camshaft bearing cover.
•   Install camshaft bearing cover
– Tighten camshaft bearing caps 1 - 4 in a spiral from the inside outward 8 Nm
Note:   Note correct tightening sequence 1 - 4.
Object Number: 9008516 Size: DEFAULT


52.   Install exhaust camshaft
•   Coat with MoS 2 lubricating paste
•   Insert camshaft
Note:   Note the identification marking on the camshaft bearing cover.
•   Install camshaft bearing cover
– Tighten camshaft bearing caps 1 - 8 in a spiral from the inside outward 8 Nm
Note:   Note correct tightening sequence 1 - 4.
Object Number: 9008517 Size: DEFAULT


53.   Clean sealing surfaces of 1st camshaft bearing support and the cylinder head with a suitable tool, e.g. plastic wedge
•   Free oil duct (arrow) from any sealant residue
Object Number: 10677970 Size: DEFAULT


54.   Place the camshaft bearing cap on the cylinder head without sealant and hand-tighten the bolts (approx. 2 Nm )
Note:   Note correct tightening sequence 1 - 4.
Object Number: 10677971 Size: DEFAULT


55.   Fit the camshaft adjuster for the intake camshaft to the intake camshaft
•   Hand-tighten the bolt
56.   Fit the camshaft adjuster for the exhaust camshaft to the exhaust camshaft
•   Hand-tighten the bolt
Important:   If the actual value deviates from the required value, these values must be noted and the adjustment procedure repeated
57.   Check the valve clearance at both intake valves for cylinder 1
•   Turn the intake camshaft to the camshaft adjuster bolt in the direction of engine rotation until the cams for cylinder 1 are located in test position (1)
•   Insert feeler gauge EN-6361 and check valve clearance
Note:   Required value, intake side valve clearance: 0.25 mm
Object Number: 26582161 Size: DEFAULT


58.   Check the valve clearance at both intake valves for cylinder 3
•   Turn the intake camshaft to the camshaft adjuster bolt in the direction of engine rotation until the cams for cylinder 3 are located in test position
•   Insert feeler gauge EN-6361 and check valve clearance
Note:   Required value, intake side valve clearance: 0.25 mm .
59.   Check the valve clearance at both intake valves for cylinder 4
•   Turn the intake camshaft to the camshaft adjuster bolt in the direction of engine rotation until the cams for cylinder 4 are located in test position
•   Insert feeler gauge EN-6361 and check valve clearance
Note:   Required value, intake side valve clearance: 0.25 mm .
60.   Check the valve clearance at both intake valves for cylinder 2
•   Turn the intake camshaft to the camshaft adjuster bolt in the direction of engine rotation until the cams for cylinder 2 are located in test position
•   Insert feeler gauge EN-6361 and check valve clearance
Note:   Required value, intake side valve clearance: 0.25 mm .
Important:   If the actual value deviates from the required value, these values must be noted and the adjustment procedure repeated
61.   Check the valve clearance at both exhaust valves for cylinder 4
•   Turn the exhaust camshaft to the camshaft adjuster bolt in the direction of engine rotation until the cams for cylinder 4 are located in test position (1)
•   Insert feeler gauge EN-6361 and check valve clearance
Note:   Required value, exhaust side valve clearance: 0.30 mm
Object Number: 26582162 Size: DEFAULT


62.   Check the valve clearance at both exhaust valves for cylinder 2
•   Turn the exhaust camshaft to the camshaft adjuster bolt in the direction of engine rotation until the cams for cylinder 2 are located in test position
•   Insert feeler gauge EN-6361 and check valve clearance
Note:   Required value, exhaust side valve clearance: 0.30 mm
63.   Check the valve clearance at both exhaust valves for cylinder 1
•   Turn the exhaust camshaft to the camshaft adjuster bolt in the direction of engine rotation until the cams for cylinder 1 are located in test position
•   Insert feeler gauge EN-6361 and check valve clearance
Note:   Required value, exhaust side valve clearance: 0.30 mm
64.   Check the valve clearance at both exhaust valves for cylinder 3
•   Turn the exhaust camshaft to the camshaft adjuster bolt in the direction of engine rotation until the cams for cylinder 3 are located in test position
•   Insert feeler gauge EN-6361 and check valve clearance
Note:   Required value, exhaust side valve clearance: 0.30 mm
65.   Detach camshaft adjuster for intake camshaft
•   Counterhold against the intake camshaft hex
66.   Detach camshaft adjuster for exhaust camshaft
•   Counterhold against the exhaust camshaft hex
67.   Detach camshaft bearing support
Important:   It is necessary to ensure that no sealant is applied outside the designated sealing surfaces.
68.   Apply surface sealant to sealing surfaces (arrows) of the camshaft bearing support thinly and evenly
Note:   The grooves (1) adjacent to the sealing surfaces must remain free from sealant.
Object Number: 10677972 Size: DEFAULT


69.   Place the camshaft bearing support on the cylinder head and hand-tighten the bolts (approx. 2 Nm )
Note:   Note correct tightening sequence 1 - 4.
Object Number: 10677971 Size: DEFAULT


70.   Install 2x camshaft seal ring
•   Hoist the seal ring (3) using KM-422 (4) on the camshaft until this abuts against the cylinder head
– To install, use camshaft sprocket bolt (1) in conjunction with shims (2) with a total thickness of approx. 10 mm
•   Remove KM-422
– Unscrew bolt
Object Number: 26582154 Size: DEFAULT


71.   Tighten the camshaft bearing support
Important:   No sealant may reach the camshafts.
•   Tighten 4x bolt 8 Nm
– Note correct tightening sequence 1-4
Object Number: 10677971 Size: DEFAULT


72.   Clean 4x thread, rear toothed belt cover
73.   Install rear toothed belt cover
•   Tighten 4x new bolt 6 Nm
– Coat 4x bolt with locking compound
•   Clip in wiring trough cover
74.   Attach exhaust camshaft adjuster
•   Insert new sealing sleeve in adjuster
•   Screw in new bolt
75.   Attach intake camshaft adjuster
•   Insert new sealing sleeve in adjuster
•   Screw in new bolt
76.   Insert KM-6328-A (1) into camshafts
Note:   Align camshafts horizontally by the hexagon until KM-6328-A (1) can be inserted in the grooves (arrows)
Object Number: 9007888 Size: DEFAULT


77.   Prepare KM-6340-Right for use on engines A16XER, Z16XER, A18XER and Z18XER
•   Detach front panel (1) from KM-6340-Right
Unscrew 2x bolts (2)
Object Number: 9007699 Size: DEFAULT


78.   Insert KM-6340 into camshaft sprockets
Insert KM-6340-Left (1) and KM-6340-Right (2) in the camshaft adjuster as shown
Note:   The spot-type marking (4) on the intake camshaft adjuster does not correspond to the groove of KM-6340-Left during this process but must be somewhat above as shown
The spot type marking (3) on the exhaust camshaft adjuster must correspond to the groove on KM-6340-Right
Object Number: 9007700 Size: DEFAULT


79.   Fasten exhaust camshaft adjuster
Note:   2 mechanics required
•   Tighten bolt 65 Nm+125°+15°
•   Counterhold at camshaft hexagon
80.   Fasten intake camshaft adjuster
Note:   2 mechanics required.
•   Tighten bolt 65 Nm+125°+15°
•   Counterhold at camshaft hexagon
81.   Tighten exhaust camshaft adjuster closure bolt 30 Nm
•   Replace seal ring
82.   Tighten closure bolt, intake camshaft adjuster 30 Nm
•   Replace seal ring
83.   Remove KM-6628-A
84.   Raise vehicle by its full height
85.   Rotate the crankshaft about 60° in the direction of engine rotation against the torsional vibration damper bolt
•   Marking, toothed belt drive gear (1) and oil pump housing (2) must align
Object Number: 26582160 Size: DEFAULT


86.   Block crankshaft.
•   Insert KM-6625
– Install bolted connection
87.   Lower vehicle by its full height
88.   Clean thread, toothed belt tensioner
Object Number: 8125648 Size: DEFAULT

89.   Intake toothed belt tensioner
•   Insert toothed belt tension roller
– Use new bolt
– Free leg of spring (1) of the toothed belt tension roller must engage in the cut-out (arrow) of the pump module
•   Tighten bolt 20 Nm + 120° + 15°

90.   Remove fastening bolt with washer from the torsional vibration damper of the crankshaft
Important:   Use assembly tool.
91.   Insert toothed belt
92.   Release tension on toothed belt tensioner
•   Apply preliminary tension clockwise to toothed belt tension roller
– Remove KM-6333
93.   Raise vehicle by its full height
94.   Install front toothed belt cover (lower)
•   Tighten 4x bolt 6 Nm
95.   Install torsional vibration damper
Important:   Use new bolt.
•   Tighten bolt 95 Nm + 45° + 15°
96.   Remove KM-6625
•   Detach screwed connection
•   Tighten screwed joint 40 Nm
97.   Lower vehicle by its full height
98.   Remove KM-6340
99.   Check position of camshaft sprockets
•   Turn crankshaft 720° in the direction of engine rotation by the bolt on the torsional vibration damper
Note:   Note marking, camshaft sprockets.
•   Insert KM-6340 into camshaft sprockets
100.   Check camshaft positions
Insert KM-6628-A into camshafts
Note:   If KM-6628-A cannot be inserted in the camshafts, the timings must be set
101.   Raise vehicle by its full height
102.   Check crankshaft position
•   Marking on torsional vibration damper must align with the marking (1) on the lower part of the toothed belt cover
Object Number: 2412844 Size: DEFAULT


103.   Lower vehicle by its full height
104.   Insert front toothed belt cover (centre)
•   Clip 2x onto the rear toothed belt cover
105.   Install support for engine damping block
•   Tighten 3x bolt 50 Nm
106.   Install engine damping block
•   Fasten engine bracket adapter
– Tighten 3x bolt 55 Nm
•   Fasten engine damping block
– Tighten 2x bolt 55 Nm
– Tighten nut 55 Nm
107.   Raise vehicle by its full height
108.   Remove KM-6001-A
•   Slacken 3x screwed connections
109.   Remove KM-6173
•   Undo 4x bolts
110.   Clean thread of bolt, ribbed V-belt tensioner
111.   Install ribbed V-belt tensioner LUREF_1.gif
112.   Lower vehicle by its full height
113.   Remove KM-6628-A
114.   Install cylinder head cover LUREF_1.gif
115.   Remove KM-6340
•   Attach bracket
– Tighten 2x bolts
116.   Install front toothed belt cover (top) LUREF_1.gif
117.   Install air cleaner housing
  • A 16 XER, Z 16 XER
  • A 18 XER, Z 18 XER
118.   Connect battery
•   Attach ground connection to ground terminal
– Tighten nut
119.   Program volatile memories
120.   Close bonnet

Cylinder Head Cover, Remove and Install > < Attaching Parts - Cylinder Head, Remove and Install