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Turbocharger Replacement > < Timing Belt Tensioner Pulley Replacement

Astra J

Camshaft Cover Replacement (1.7L Diesel LPL and LPV)

Special Tools

EN-6368   Set of Plugs

For equivalent regional tools, refer to Special Tools .

Removal Procedure

1. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .
2. Remove the engine sight shield. Refer to Engine Sight Shield Replacement .
3. Remove the charge air cooler inlet pipe. Refer to Charge Air Cooler Inlet Pipe Removal .

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4. Detach the vacuum hose (1) from the exhaust gas recirculation cooler.
5. Unclip the vacuum hose from the 4 retainer clips (arrows) and put the vacuum hose aside.

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6. Remove the 3 wiring harness bolts (2) from the wiring harness (1).
7. Disconnect the following engine wiring harness plugs:
  •  Coolant temperature sensor wiring harness plug
  •  Exhaust gas recirculation valve wiring harness plug
  •  Throttle body wiring harness plug
  •  4 Injector wiring harness plugs
  •  4 glow plug wiring harness plugs
  •  Camshaft sensor wiring harness plug
  •  Air intake temperature sensor wiring harness plug
  •  2 solenoid valve wiring harness plugs
  •  Engine control module wiring harness plug
  •  Glow plug controller wiring harness plug
  •  Wiring harness connection plug
8. Remove the wiring harness from the 6 retainer clips and put the wiring harness (1) aside.

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9. Loosen the 8 fuel injection fuel feed pipe connecting nuts.
10. Remove the 4 fuel injection fuel feed pipes (2).
11. Plug the fuel injector connections (1), the fuel injection fuel feed pipes (2) and the fuel rail (3) by using EN-6368   plugs .

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12. Disconnect the 4 fuel injector fuel return hose clips (1).

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13. Disconnect the fuel return hose clip (4).
14. Remove the fuel return hose hollow screw (1) and the 2 copper seal rings.
15. Disconnect the fuel injection fuel return hose (3) from the fuel injection pump connector (5) and the fuel injectors.

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Note:  Plug the fuel injectors and the fuel injection pump in order to prevent contamination.
16. Remove the 4 fuel injector seal rings (1) from the camshaft cover.

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17. Remove the 10 camshaft cover bolts (1).
18. Remove the camshaft cover (2) and the gasket (3).

Installation Procedure


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1. Clean the sealing surfaces.
2. Install a NEW camshaft cover gasket (3).
3. Install the camshaft cover (2).

Caution: Refer to Fastener Caution .
4. Loosely install the 10 camshaft cover bolts (1).

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5. Tighten the 10 camshaft cover bolts to 10 N·m (89 lb in) in sequence as shown in the graphic.
6. Install the 4 NEW fuel injector seal rings.

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7. Install the fuel injection fuel return hose (3)
8. Connect the fuel injection fuel return hose (3) to the fuel injection pump connector (5), to the fuel return hose clip (4) and the fuel injectors.
9. Install the fuel injector fuel return hose hollow screw (1). Install the 2 NEW copper seal rings. Tighten the hollow screw to 10 N·m (89 lb in) .
Warning:  Refer to Fuel Pipe Fitting Warning .

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10. Remove all EN-6368   plugs from the fuel rail (3), fuel injectors (1) and fuel injection fuel feed pipes (2).

Note:  Hand tighten the fuel injection nuts before tighten the final torque.
11. Install the 4 fuel injection fuel feed pipes (2).
12. Tighten the 2 fuel injection fuel rail bolts to 25 N·m (18 lb ft) .

Note:  Tighten union nuts first at injectors, then at pressure chamber.
13. Tighten the 8 fuel injection fuel feed pipe connecting nuts to 25 N·m (18 lb ft) .

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14. Connect the following engine wiring harness plugs:
  •  Coolant temperature sensor wiring harness plug
  •  Exhaust gas recirculation valve wiring harness plug
  •  Throttle body wiring harness plug
  •  4 Injector wiring harness plugs
  •  4 glow plug wiring harness plugs
  •  Camshaft sensor wiring harness plug
  •  Air intake temperature sensor wiring harness plug
  •  2 solenoid valve wiring harness plugs
  •  Engine control module wiring harness plug
  •  Glow plug controller wiring harness plug
  •  Wiring harness connection plug
15. Clip in the wiring harness (1) to the 6 retainer clips.
16. Install the 3 wiring harness bolts (2) to the wiring harness (1) and tighten to 9 N·m (80 lb in) .

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17. Clip in the vacuum hose to the 4 retainer clips (arrows).
18. Attach the vacuum hose (1) to the exhaust gas recirculation cooler.
19. Install the charge air cooler inlet pipe. Refer to Charge Air Cooler Inlet Pipe Removal .
20. Install the engine sight shield. Refer to Engine Sight Shield Replacement .
21. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .

Turbocharger Replacement > < Timing Belt Tensioner Pulley Replacement