vauxhall Workshop Repair Guides

Vauxhall Workshop Service and Repair Manuals

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Timing Case Seal Ring, Replace > < Replace engine oil with oil filter

Astra H

Timing Case, Remove and Install

  Remove

1.   Open bonnet
2.   Disconnect battery
•   Detach earth connection from negative terminal
– Slacken nut
Object Number: 3446127 Size: DEFAULT

3.   Remove air cleaner housing
•   Disconnect mass air flow sensor wiring harness plug (2)
•   Unclip tank vent line (3)
•   Detach engine vent hose (4) from air intake hose
– Release clamp
•   Detach air intake hose (5) from throttle valve body
– Release clamp
•   Detach air cleaner housing
– Unscrew bolt (1)
– Unclip rubber mounting at the bottom
– Remove air intake pipe (6)

4.   Raise vehicle by its full height
5.   Remove right engine splash guard (2)
•   Unscrew 4x bolts (1)
•   Remove 2x body-bound rivets (3)
Object Number: 3446244 Size: DEFAULT


6.   Drain coolant
•   Place collecting pan underneath.
•   Attach suitable hose to drain connection (2)
•   Open coolant drain screw (1)
– Drain coolant
•   Close coolant drain screw
Object Number: 3446245 Size: DEFAULT


7.   Remove oil pan
8.   Remove compressor
Note:   For vehicles with air conditioning
•   Unscrew 3 bolts
– Suspend compressor
9.   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

10.   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

11.   Lower vehicle by its full height
12.   Remove engine damping block, right hand side
•   Unscrew 6x bolts (1) and (2)
•   Remove engine damping block with bracket
Object Number: 2398424 Size: DEFAULT


13.   Remove ribbed V-belt
•   Mark direction of rotation
•   Apply tension to ribbed V-belt tensioner (arrow) clockwise with KM-6131
•   Insert KM-955-2 (1)
•   Relieve tension on ribbed V-belt tensioner
Object Number: 2410376 Size: DEFAULT


14.   Detach engine damping block support (1) from timing case and cylinder block
•   Unscrew 3 bolts
Object Number: 2398426 Size: DEFAULT


15.   Remove ribbed V-belt tensioner
•   Apply tension to ribbed V-belt tensioner in the direction of the arrow with KM-6131
•   Remove KM-955-2 (1)
•   Release ribbed V-belt tensioner
•   Unscrew 2x bolts (arrows)
•   Take out ribbed V-belt tensioner
Object Number: 2410378 Size: DEFAULT


Object Number: 3446279 Size: DEFAULT

16.   Detach alternator
•   Detach alternator wiring harness
– Unscrew 2x nuts (1)
•   Detach 2x screwed connections (2) and (3)
•   Take out alternator

17.   Remove coolant hose (1) from thermostat housing
•   Release clamp
18.   Remove thermostat housing
•   Unscrew 3 bolts
19.   Remove coolant hose (2) from coolant pump
•   Release clamp
20.   Disconnect oil pressure switch (3) wiring harness plug
Object Number: 3446282 Size: DEFAULT


21.   Disconnect wiring harness plug for camshaft sensor (1) and coolant temperature sensor (3)
22.   Detach coolant hose (2)
•   Release clamp
23.   Unclip wiring trough (4)
Object Number: 3446281 Size: DEFAULT


24.   Remove belt pulley (1) from coolant pump
•   Unscrew 3 bolts
25.   Remove coolant pump (2) from timing case
Note:   Be careful of the guide sleeves when taking out the coolant pump
•   Unscrew 8x bolts
Note:   Note different bolt lengths
Object Number: 10681033 Size: DEFAULT


26.   Remove engine vent hose (2) from cylinder head cover
•   Release clamp
27.   Remove ignition module
•   Disconnect ignition module wiring harness plug (4)
•   Pull the cover of the ignition module (1) away from the cylinder head cover in the direction of the arrow
•   Unscrew 2x bolts (6)
•   Remove ignition module (5) from spark plugs with KM-6009 (3)
Note:   Do not tilt
28.   Detach cylinder head cover (7) from cylinder head
•   Unscrew 13x bolts
Object Number: 3446283 Size: DEFAULT


Object Number: 2410668 Size: DEFAULT

29.   Remove closure bolt crankshaft bearing bridge (1)
30.   Adjust TDC of combustion stroke of cylinder 1
Note:   Marking on the crankshaft belt pulley (4) must align with the cast projection (3) on the timing case
•   Insert KM-952 (2)
– Turn crankshaft evenly until KM-952 engages

Object Number: 2410671 Size: DEFAULT

31.   Check position of camshafts
•   Insert KM-953 (1)
– KM-953 must engage in groove of camshafts
•   Remove KM-953

Object Number: 2411046 Size: DEFAULT

32.   Detach crankshaft ribbed V-belt pulley (1)
•   Unscrew 6x bolts
– Counterhold against bolt, crankshaft hub
33.   Slacken bolt, crankshaft hub
Note:   Use a second person
•   Remove KM-952
•   Insert KM-6013 (3)
– Tighten 2x bolts
•   Attach KM-956-1/-2 (4)
– Tighten bolt
•   Hold using KM-956-1/-2
34.   Detach crankshaft hub (2)
•   Insert KM-952
•   Unscrew bolt
•   Take out crankshaft hub

Object Number: 3446284 Size: DEFAULT

35.   Remove timing case
•   Unscrew 15x bolts (1) and (2)

Object Number: 2398446 Size: DEFAULT

36.   Detach chain drive
•   Lock chain tensioner (1)
– Press back and insert KM-955-1 (2)
•   Remove sliding rail (3)
– Unscrew 2x bolts
•   Remove guide rail (5)
– Unscrew 2x bolts
•   Remove guide rail (7)
– Unscrew bolt
•   Take out timing chain (4) and drive gear (6)
37.   Take out timing case gasket
38.   Clean sealing surfaces and remove gasket remnants.
Note:   if a two-part timing case gasket has been used, the sealing compound must be removed in the area of the cylinder head gasket

39.   Prise seal ring out of timing case with suitable tool
Note:   Do not damage sealing surfaces

  Install

Object Number: 3446285 Size: DEFAULT

40.   Clean sealing surfaces and remove gasket remnants.
41.   Coat sealing lip of new seal ring with silicone grease
42.   Push seal ring on to KM-960 (2)
43.   Drive seal ring into timing case until flush using KM-960

44.   Insert new coolant pump gasket into timing case
45.   Ensure guide sleeves are correctly seated (arrows)
46.   Attach coolant pump to timing case with short bolts (1)
•   Tighten 3x bolt 8 Nm
Object Number: 3446286 Size: DEFAULT


Object Number: 2398449 Size: DEFAULT

Important:   The timing case must be fitted within 10 minutes of applying the silicone sealing compound
47.   Apply sealant
•   Any elastomer projections present from the cylinder head gasket (1) must be cut off flush and replaced by a bead of silicone sealing compound (2) approx. 2 mm thick
Note:   If no projecting elastomer is present, the bead of silicone sealant (2) can be applied direct

Object Number: 2398450 Size: DEFAULT

48.   Timing Case Gasket, Replace
•   Place new timing case gasket in position
– Ensure guide sleeves are correctly seated (arrows)
49.   Place drive gear (6) on crankshaft
Important:   Ensure that the tension side (exhaust side) of the timing chain is under tension
50.   Place timing chain (4) over drive gear and camshaft sprockets
51.   Attach tension rail (7) to cylinder block
•   Tighten bolt 20 Nm
52.   Attach guide rail (5) to cylinder block
•   Tighten 2x bolt 8 Nm
53.   Attach sliding rail (3) to cylinder head
•   Tighten 2x bolt 8 Nm
54.   Take KM-955-1 (2) out of chain tensioner (1)

Object Number: 3446287 Size: DEFAULT

55.   Attach timing case.
Note:   Comply with assembly sequence
•   Screw in all bolts
•   Attach coolant pump to cylinder head and cylinder block
– Tighten 5x bolts (1) 8 Nm
•   Attach timing case to cylinder head, cylinder block and to base plate of cylinder block
– Tighten 13x bolt M6 (2) 8 Nm
– Tighten 2x bolt M10 (3) 35 Nm

56.   Remove KM-952 and KM-953
Note:   Special tools may not be used for counterholding
Object Number: 2398452 Size: DEFAULT

57.   Note installation position of crankshaft hub (2) -.
•   Marking (1) must point upwards
58.   Attach crankshaft hub to crankshaft with new bolt
•   Attach KM-6013 (4)
•   Counterhold with KM-956 (5)
•   Tighten bolt 150 Nm + 45° + 15°
59.   Attach crankshaft belt pulley (3) to crankshaft hub
•   Counterhold against the bolt of the crankshaft hub
•   Tighten 6x bolt 8 Nm

Object Number: 2398441 Size: DEFAULT

60.   Set crankshaft to just before cylinder 1 TDC of combustion stroke
Note:   Turn crankshaft slowly and smoothly
•   Turn the bolt of the crankshaft hub approx. 720°
•   The marking (3) on the crankshaft belt pulley is just before the cast projection (2) on the timing case
•   In this position, the cams of cylinder 1 are just before "TDC of combustion stroke" (both cams point outwards)

Object Number: 2398453 Size: DEFAULT

61.   Insert KM-952 (3) in aperture and simultaneously
•   Continue turning the crankshaft slowly in the direction of engine rotation by the bolt of the crankshaft hub until the crankshaft locking pin engages as far as the stop in the base plate of the cylinder block or crank web
•   In this position, the marking (2) on the crankshaft belt pulley must align with the projection (1) on the timing case

Object Number: 2398444 Size: DEFAULT

62.   Insert KM-953 (1) into camshaft
Note:   If KM-953 cannot be inserted, perform basic setting - see operation "Timing, Adjust"
•   KM-953 must engage as far as the stop in the grooves of the camshafts

Object Number: 2398454 Size: DEFAULT

63.   Place KM-954 (1) on the phase sensor disc (2) and attach to timing case
Note:   If KM-954 cannot be inserted, perform basic setting - see operation "Timing, Adjust"

64.   Take out or remove KM-954 , KM-953 and KM-952
65.   Install closure bolt with new seal ring into cylinder block base plate 60 Nm
66.   Clean sealing surfaces and remove gasket remnants.
Object Number: 2399469 Size: DEFAULT

67.   Apply sealant
Note:   The cylinder head cover must be fitted within 10 minutes of applying the silicone sealing compound
•   Disconnect projecting part of timing case gasket (1) flush with cylinder head/timing case
•   Apply a bead of silicone sealing compound approx. 2 mm thick (dimension I)

68.   Install cylinder head cover
•   Insert new gasket (2) in cylinder head cover (1)
•   Tighten 13x bolt 8 Nm
•   Connect ignition module to spark plugs and attach to cylinder head
– Tighten 2x bolt 8 Nm
•   Attach ignition module cover to cylinder head cover
•   Connect ignition module wiring harness plug
•   Attach engine vent hose to cylinder head cover
– Fasten clamp
Object Number: 2398455 Size: DEFAULT


69.   Attach coolant hose to coolant pump
•   Tighten 3x bolt 20 Nm
70.   Connect wiring harness plugs, coolant temperature sensor, camshaft sensor and oil pressure switch
71.   Clip wiring trough to cylinder head cover
72.   Attach coolant hoses to coolant pump
•   Attach 3x clamps
73.   Attach thermostat housing
•   Insert new gasket
•   Tighten 3x bolt 8 Nm
74.   Install alternator
•   Insert alternator into bracket
•   Tighten 2x screwed joint 35 Nm
•   Attach alternator wiring harness
– Tighten 2x nuts
75.   Attach ribbed V-belt tensioner -
•   Tighten bolt M8 20 Nm
•   Tighten bolt M10 55 Nm
•   Apply tension to ribbed V-belt tensioner in the direction of the arrow with KM-6131 (2)
– Insert KM-6130 (1)
Object Number: 2410376 Size: DEFAULT


76.   Insert ribbed V-belt
•   Position ribbed V-belt
– Ensure correct running direction and installation position
•   Apply tension to ribbed V-belt tensioner with KM-6131
•   Remove KM-955-2
•   Relieve tension on ribbed V-belt tensioner
77.   Fit engine damping block to body
•   Tighten 3x bolt (2) 35 Nm
78.   Attach engine damping block bracket to engine damping block support
•   Tighten 3x bolt (1) 55 Nm
Object Number: 2398424 Size: DEFAULT


79.   Install air cleaner housing
•   Attach air cleaner housing to wheelhouse
– Tighten bolt
•   Attach air intake hose to throttle valve module
– Fasten clamp
•   Attach engine vent hose to timing case
– Fasten clamp
•   Connect wiring harness plug, air mass flow meter
•   Clip in tank vent line
80.   Raise vehicle
81.   Remove KM-6001-A and KM-6173
•   Slacken 5x bolt
82.   Attach right engine splash guard
•   Tighten 4x bolts
•   Install 2x body-bound rivets
83.   Attach compressor
Note:   For vehicles with air conditioning
•   Tighten 3x bolt 25 Nm
84.   Install oil pan
85.   Attach earth connection to battery
•   Tighten nut
86.   Program volatile memories
87.   Fill and bleed cooling system LUREF_1.gif

Timing Case Seal Ring, Replace > < Replace engine oil with oil filter