Vauxhall Workshop Service and Repair Manuals

Both Camshafts, Remove And Install (Z 17 DTH, with Air Conditioning, LHD)

  Remove

5.   Remove engine control unit (1) •   Disconnect 2 wiring harness plugs •   Unscrew 2 bolts •   Unscrew 2 nuts

6.   Detach engine control unit bracket (1) •   Unscrew 4 bolts

7.   Detach bracket (1) of engine control unit bracket •   Unscrew 2 bolts

8.   Remove engine management wiring harness •   Disconnect wiring harness plug – 4 injectors (1) – 4 glow pins (arrows) – Coolant temperature sensor (4) – Throttle valve module (2) – Exhaust gas recirculation valve (3) – 2 combination plugs – Camshaft sensor – Changeover valve solenoid valves – Charge pressure sensor •   Expose wiring harness

10.   Remove air intake pipe (1) •   Unscrew 2 bolts •   Release clamp •   Detach engine vent hose

11.   Remove charge air pipe (1) •   Unscrew and remove 3 stud bolts •   Unscrew 3 bolts •   Unscrew nut •   Remove 2 gaskets

12.   Remove rear left engine transport shackle (1) •   Unscrew 2 bolts

16.   Remove ribbed V-belt cover •   Unscrew 3 bolts (1) •   Remove clip (arrow)

17.   Loosen coolant pump ribbed V-belt pulley (1) •   Undo 3 bolts

18.   Remove ribbed V-belt •   Tension ribbed V-belt tensioner in direction of arrow •   Use KM-913-A Note:   Mark running direction.

20.   Attach KM-6394 (1) •   Position KM-6394 at the front on the front axle body Note:   Both locating pins (arrows) must be seated in the hole in the front axle body •   Push front bracket (2) in the direction of the arrow •   Place rear bracket (4), right hand side, on front axle body •   Attach rear bracket (3), left hand side – Screw in 2x bolt •   Tighten 6 bolts

21.   Install support •   On KM-6394 – Adjust bracket (2) for support •   Screw on nut (1) 22.   Adjust 3x support •   Transmission side Note:   Turn spindles until mounts (3) are positioned at guide journals free of play •   Engine timing side – Insert journal of the support in the bore of the cylinder block free of play (arrow) – Tighten nuts (1)

24.   Remove 2 high pressure line spacers (2) Note:   Mark installation position •   Unscrew 2 bolts 25.   Detach 4 high-pressure lines (1) •   Use KM-6098

26.   Detach outer fuel return line (1) •   Unscrew banjo bolt •   Unscrew nut •   Release retaining clamp (arrow)

27.   Remove wiring trough •   Unclip vacuum line (4) •   Unclip wiring trough (5) – 2 clips •   Remove bolt (3) •   Disconnect 2 wiring harness plugs – Camshaft sensor (2) – Charge pressure sensor (1) •   Unclip wiring harness 28.   Remove camshaft sensor •   Remove bolt (arrow)

29.   Remove right engine damping block (1) •   Unscrew 4 bolts

30.   Detach right engine bracket (1) •   Unscrew 3 bolts Note:   Lower bolt cannot be removed. •   With right engine bracket adapter

31.   Remove upper toothed belt cover Important:   Take care not to damage the increment counter on the camshaft sprocket when removing the upper toothed belt cover •   Unscrew 8 bolts Note:   Note dissimilar bolt lengths

34.   Remove torsional vibration damper (1) •   Unscrew 4 bolts

35.   Detach lower part of toothed belt cover •   Unscrew 3 bolts

37.   Set 1st cylinder to TDC •   Turn crankshaft evenly until TDC fixing bolt (1) can be screwed in Note:   Mark (3) on toothed belt drive gear must align with mark (2) on oil pump cover

38.   Remove toothed belt •   Mark running direction •   Loosen bolt of toothed belt tension roller (2) •   Rotate toothed belt tension roller (1) anticlockwise approx. 90° •   Tighten bolt of toothed belt tension roller

41.   Detach camshaft pulley •   Unscrew TDC fixing bolt (1) •   Use KM-6347 (3) in combination with KM-956-1 (2) •   Remove bolt

42.   Detach 4x fuel return line (1) •   From injector – Release 4x retaining clamp (arrow)

44.   Remove 4x seal, connection for injector (1) •   Unscrew 8 bolts

45.   Remove 4 injector seal (1) •   Unscrew 8 bolts

46.   Remove camshaft housing cover (1) Important:   Do not damage components •   Unscrew 10 bolts •   Unscrew nut •   Unscrew and remove bolt •   Remove gasket.

47.   Remove 4x injector (1) Note:   Mark the injectors. If the heat insulation sleeve (5) is pulled out together with the injector during removal, the gaskets (3) must be replaced and the heat insulation sleeve driven into the cylinder head using KM-6357 (4) •   Remove 4x bracket (2) – Unscrew 4 bolts •   Remove 4x copper ring

48.   Check injector bracket Note:   If an old injector bracket was installed, it must be replaced with a new one New injector bracket Old injector bracket

49.   Lock exhaust camshaft sprockets •   Remove camshaft bearing cap 5 (3) – Unscrew 2 nuts – Remove bolt •   Using KM-6092-10 (1), lock compensating sprocket, exhaust camshaft (2), with exhaust camshaft sprocket (4) so that it cannot turn

50.   Remove 2x camshaft Note:   Check mark on bearing cap before dismantling the camshafts •   Ease the camshaft bearing covers in stages from 1/2 to 1 turn in a spiral in the order shown Note:   When replacing the exhaust camshaft, the exhaust camshaft compensating sprocket (2) must be pretensioned with KM-6092 (1) and connected to the exhaust camshaft sprocket (3) with locating pin KM-6092-10 (4)

51.   Remove camshaft seal ring (1)

53.   When replacing: Fix tooth backlash compensator of exhaust camshaft •   Use KM-6092 (3) Note:   Turn tooth backlash compensator until pin can be inserted in fixing hole (arrow)

  Install

57.   Install 2x camshaft Important:   When installing the camshafts, care must be taking that the mark (1) on the exhaust camshaft sprocket is between the two marks (2) for the intake camshaft sprocket and that the marks are approximately at the same level as the upper edge of the camshaft housing •   Insert camshaft in camshaft housing Note:   Coat bearing positions with engine oil •   Apply surface sealant (green) to the sealing surfaces (3) of the 1st camshaft bearing cap

58.   Tighten 2x camshaft Note:   Coat bearing positions with engine oil. •   Attach camshaft bearing caps 1 - 4 to camshaft housing Note:   Arrows on bearing caps point towards engine timing side. •   Remove KM-6092-10 from exhaust camshaft sprocket and attach camshaft bearing cap 5 •   Tighten camshaft bearing covers in the sequence illustrated, 1 - 15, in stages of 1/2 to 1 turn – Tighten 10 nuts 21.6 Nm – Tighten 5 bolts 26.5 Nm

59.   Install camshaft seal ring •   Drive in until flush using KM-656 (1)

Warning:   The different camshaft sprockets (with different part numbers) have different torques for the camshaft sprocket bolt. 60.   Attach camshaft sprocket with part number 97320335 •   Camshaft journal (2) must engage in the bore in the camshaft sprocket (1) •   Use KM-6347 in combination with KM-956-1 •   Tighten bolt 64 Nm •   Install TDC-fixing bolt 61.   Attach camshaft sprocket with part number 98021306 •   Camshaft journal (2) must engage in the bore in the camshaft sprocket (1) •   Use KM-6347 in combination with KM-956-1 •   Tighten bolt 111 Nm •   Install TDC-fixing bolt

63.   Rotate crankshaft to 1st cylinder TDC •   Mark on toothed belt drive gear (3) must align with cast lug (2) on oil pump cover •   Screw in TDC fixing bolt (1)

64.   Install toothed belt Note:   TDC locking bolt must be installed in the camshaft sprocket and marking (6) and (7) must align. •   Position toothed belt – Toothed belt must be tensioned in the direction of the arrow from the toothed belt drive gear (5) via the oil pump drive gear (4), via the high pressure pump drive gear (2) to the camshaft sprocket (1) – Note running direction •   Loosen toothed belt tension roller (3) •   Remove TDC locking bolt •   Rotate crankshaft 60° against direction of engine rotation •   Tighten toothed belt tension roller 38Nm

65.   Timing, Check •   Turn crankshaft approx. 780° in direction of engine rotation •   Mark on toothed belt drive gear (3) must align with cast lug (2) on oil pump cover •   Screw in TDC locking bolt (1). If the TDC fixing bolt cannot be screwed in, basic adjustment must be repeated. •   Unscrew TDC fixing bolt

69.   Turn crankshaft •   Turn crankshaft until cam pairs (1) and (2) point upwards 70.   Check valve clearance •   Using feeler gauge Note:   The valve play is checked on a cold engine at room temperature – Test values: Intake valves/Exhaust valves (0.35 – 0.45 mm) Important:   Make sure that the valves are not set when the piston is in "TDC". The valves could strike the piston head 71.   Adjust valve clearance •   Turn cup tappet until tappet groove points outwards •   Press down cup tappets using KM-6090 Note:   Note different tool versions for intake and exhaust valves – Mark – IN = Intake side – Mark – EX = Exhaust side •   Remove adjustment shim

73.   Insert adjustment shim •   Coat new shim (7) with engine oil and insert in cup tappet with identification mark facing downwards 74.   Turn crankshaft •   In direction of engine rotation by 180° – Check and adjust valve pair (6) and (2) •   In direction of engine rotation by 180° – Check and adjust valve pair (5) and (3) •   In direction of engine rotation by 180° – Check and adjust valve pair (4) and (1) •   The clearance of all adjusted valves must be re-checked

76.   Replace 8 injector seals •   4 O-rings (1) •   4 copper seal rings (2)

77.   Install 4 injectors •   Install 4x brackets – Align injectors with EN-48560 (1)

79.   Fasten 4x injectors •   Tighten 4 bolts in three stages – 1. Tighten bolt 40 Nm – 2. Loosen bolt – 3. Tighten bolt 32 Nm

82.   Install camshaft housing cover Important:   The oil hole (2) must not be covered with adhesive sealing compound •   Replace gasket •   Apply adhesive sealing compound to sealing surfaces (1) and (3) •   Tighten 10 bolts 9.8 Nm •   Tighten nut 9.8 Nm •   Tighten bolt 9.8 Nm

84.   Fit 4 injector connection seals •   Replace 4 gaskets Note:   Note installation position (arrow). Coat with engine oil •   Tighten 8 bolts

97.   Install ribbed V-belt Note:   Observe running direction and installation position •   Tension ribbed V-belt tensioner (1) – I Ribbed V-belt without AC – II Ribbed V-belt with AC