Field Remedy: 2212

Remedy:

In case of customer complaint the camshaft bearing bridge has to be 
removed and re-installed with new sealing compound. Due to this 
operation the camshaft seal rings have to be replaced as well.

Note: Ensure that Customer Satisfaction Program 07-R-011 has been 
performed before. 

Working Procedure:

 1. Remove rear toothed belt cover

    Astra-H - Z16XER/Z18XER:

    - see working procedure "Remove rear toothed belt cover",
      group "J", Service Instruction Astra-H.
      (Document Number 01401283)

    Zafira-B - Z18XER:

    - see working procedure "Remove rear toothed belt cover",
      group "J", Service Instruction Zafira-B.
      (Document Number 01401649)

    Vectra-C/Signum - Z18XER:

    - see working procedure "Remove rear toothed belt cover",
      group "J", Service Instruction Vectra-C/Signum.
      (Document Number 01401885)

 2. Remove camshaft bearing bridge (Picture I)

    - unscrew 4x bolts
        - note removal sequence 1 - 4.

    - release bearing bridge by striking it gently with a 
      plastic hammer

 3. Clean sealing surfaces of camshaft bearing bridge and cylinder 
    head with a suitable tool, e.g. plastic wedge (Picture II)

    - free oil duct (arrow) from any sealant residue

    Important:
    Sealing surfaces must be free from oil and grease!

 4. Apply surface sealant (green) to sealing surfaces (arrows) of the 
    camshaft bearing bridge thinly and evenly (Picture III)

    Note:
    The grooves (1) adjacent to the sealing surfaces must remain free 
    from sealant.

    Important:
    It is essential to ensure that no sealant is applied outside the
    marked sealing areas!

 5. Position camshaft bearing bridge on cylinder block and tighten 
    bolts hand-tight (approx. 2 Nm )

 6. Install 2x camshaft seal ring (Picture IV)

    - tighten seal ring with KM-422 (3) on camshaft until this is in 
      contact with 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

 7. Attach camshaft bearing bridge (Picture V)

    Important:
    No sealant may reach the camshafts!

    - place bearing bridge in position
    - tighten 4x bolt 8 Nm
        - note installation sequence 1-4

 8. Insert KM-6628

    - turn intake camshaft against direction of engine rotation
        - insert KM-6628
    - turn exhaust camshaft in direction of engine rotation 
        - insert KM-6628

 9. Install rear toothed belt cover

    Astra-H - Z16XER/Z18XER:

    - see working procedure "Remove rear toothed belt cover",
      group "J", Service Instruction Astra-H.
      (Document Number 01401283)

    Zafira-B - Z18XER:

    - see working procedure "Remove rear toothed belt cover",
      group "J", Service Instruction Zafira-B.
      (Document Number 01401649)

    Vectra-C/Signum - Z18XER:

    - see working procedure "Remove rear toothed belt cover",
      group "J", Service Instruction Vectra-C/Signum.
      (Document Number 01401885)

Spare-Parts:Part-No.:Catalogue-No.:

Surface sealant9054211415 03 170
Seal ring camshaft (2x)555633746 36 930

Labour Times:TC:Hours:

All Models:

U3 221 20Seal camshaft bearing922.6
bridge

The costs for this repair will be covered during the normal warranty.
The regular warranty procedure should be used for claiming Set-up-time.