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Camshaft Timing Chain Inspection > < Valve Stem Oil Seal and Valve Spring Replacement

Astra J

Camshaft Timing Chain Adjustment

Special Tools

•  EN-470-B   Torque Angle Sensor
•  EN-662-C   Holding Wrench
•  EN-46781   Fixing Tool Camshaft
•  EN-46778   Fixing Tool Crankshaft, if the transmission is removed
•  EN-46785   Fixing Tool Crankshaft, if the transmission is Installed

For equivalent regional tools, refer to Special Tools .

Removal Procedure

1. Remove the crankshaft pulley. Refer to Crankshaft Pulley Removal .
2. Remove the catalytic converter heat shield. Refer to Catalytic Converter Heat Shield Removal .
3. Remove the catalytic converter. Refer to Catalytic Converter Removal .
4. Remove the turbocharger oil feed pipe. Refer to Turbocharger Oil Feed Pipe Removal .
5. Remove the turbocharger oil return hose. Refer to Turbocharger Oil Return Hose Removal .
6. Remove the turbocharger wastegate actuator vacuum control solenoid valve splash shield. Refer to Turbocharger Wastegate Actuator Vacuum Control Solenoid Valve Splash Shield Removal .
7. Remove the turbocharger. Refer to Turbocharger Removal .

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Note:  No pressure on the fuel injection fuel rail, if the fuel injection fuel rail bracket is dismantled.
8. Remove the 2 fuel injection fuel rail bolts (3).
9. Remove the 3 fuel injection fuel rail bracket bolts (2) and (5).
10. Remove the fuel injection fuel rail bracket with the rear engine lift bracket (1).

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11. Remove the cylinder head core hole plug - exhaust (2) from the camshaft housing (1).
12. Remove the cylinder head core hole plug - intake (3) from the camshaft housing (1).
13. Clean the threads from the cylinder head core hole plugs and the camshaft housing.

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14. Remove the oil pump housing plug (1) from the oil pump housing (3).
15. Remove the oil pump housing plug seal (2).

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16. Mark (arrow) the 2 EN-46781   fixing tool (1).

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Note:  The EN-46781   fixing tool (1) must be install in horizontal position.
17. Install the EN-46781   fixing tool (1) into the intake side.

Note:  If the EN-46781   fixing tool does not rotate any longer, the tool is correctly engaged.
18. Turn the exhaust camshaft carefully at the camshaft sprocket bolt, until the EN-46781   fixing tool (1) engages at the intake camshaft.

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Note:  If the transmission is installed.
19. Turn the crankshaft carefully until the EN-46785   fixing tool (1) engages in the flywheel.

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Note:  If the transmission is removed.
20. Turn the crankshaft carefully until the EN-46778   fixing tool (1) engages with the bore at flywheel (2) and the cylinder block.

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21. Install the EN-662-C   holding wrench (2).
22. Install the 2 bolts.

Note:  Mind the left-hand thread.
23. Loosen the crankshaft sprocket bolt (1).

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Note:  Counterhold at the camshaft sprocket bolt with the aid of a second technician.
24. Loosen the camshaft intake sprocket bolt (1).
25. Rotate the exhaust camshaft 15° against the direction of engine rotation.
26. Install the EN-46781   fixing tool at the cylinder head core hole exhaust side.

Note:  If the EN-46781   fixing tool does not rotate any longer, the EN-46781   fixing tool is correctly engaged.
27. Turn the exhaust camshaft at the camshaft sprocket bolt in direction of the engine rotation until the EN-46781   fixing tool engages in the exhaust camshaft.

Caution: Refer to Fastener Caution .

Note:  Counterhold at the camshaft sprocket bolt, use a second person.
28. Tighten the camshaft intake sprocket bolt to 150 N·m (111 lb ft) .

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29. Tighten the crankshaft sprocket bolt (1) to 50 N·m (37 lb ft). .
30. Tighten the crankshaft sprocket bolt (1) to an additional 90° , use EN-470-B   torque angle .
31. Remove the 2 bolts.
32. Remove the EN-662-C   holding wrench (2).
33. Remove the 2 EN-46781   fixing tool from the intake camshaft and the exhaust camshaft.
34. Remove the EN-46785   fixing tools and the EN-46778   fixing tool .
35. Turn crankshaft the 720° in the direction of the engine rotation at the crankshaft sprocket bolt.
36. Check the position of the camshafts. Refer to Camshaft Timing Chain Inspection .

Installation Procedure


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1. Install the oil pump housing plug seal (2).
2. Install the oil pump housing plug (1) to the oil pump housing (3) and tighten to 20 N·m (15 lb ft) .

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3. Clean the threads from the cylinder head core hole plugs and the camshaft housing.
4. Install the cylinder head core hole plug - intake (3) to the camshaft housing (1) and tighten to 15 N·m (11 lb ft) .
5. Install the cylinder head core hole plug - exhaust (2) to the camshaft housing (1) and tighten to 15 N·m (11 lb ft) .

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6. Install the fuel injection fuel rail bracket with the rear engine lift bracket (1).
7. Install the 3 fuel injection fuel rail bracket bolts (2) and (5) and tighten to 25 N·m (18 lb ft) .
8. Install the 2 fuel injection fuel rail bolts (3) and tighten to 25 N·m (18 lb ft) .
9. Install the turbocharger. Refer to Turbocharger Installation .
10. Install the turbocharger wastegate actuator vacuum control solenoid valve splash shield. Refer to Turbocharger Wastegate Actuator Vacuum Control Solenoid Valve Splash Shield Installation .
11. Install the turbocharger oil return hose. Refer to Turbocharger Oil Return Hose Installation .
12. Install the turbocharger oil feed pipe. Refer to Turbocharger Oil Feed Pipe Installation .
13. Install the catalytic converter. Refer to Catalytic Converter Installation .
14. Install the catalytic converter heat shield. Refer to Catalytic Converter Heat Shield Installation .
15. Install the crankshaft pulley. Refer to Crankshaft Pulley Installation .

Camshaft Timing Chain Inspection > < Valve Stem Oil Seal and Valve Spring Replacement