Vauxhall Workshop Service and Repair Manuals

Remove thermostat housing and coolant hose (5) from coolant pump and radiator.

Detach coolant hoses (6), (7) and (8) from coolant pump.

Disconnect wiring harness plug from camshaft sensor (1), oil pressure switch (2) and coolant temperature sensor (3).

Unclip wiring trough (4) from cylinder head cover and lay aside to rear.

Detach pulley (1) from coolant pump.

Caution

Note guide sleeves when removing coolant pump.

  Remove

Detach coolant pump (2) from timing case and note dissimilar length bolts (arrows = short bolts).

Detach engine vent hose (2) from cylinder head cover.

Disconnect wiring harness plug (4) from ignition module.

Detach ignition module cover (1) from cylinder head cover in direction of arrow.

Remove fastening bolts (6) and disconnect ignition module (5) from spark plugs using KM-6009 (3) – do not tilt as otherwise the spark plug connectors can be damaged.

Detach cylinder head cover (7) from cylinder head.

The mark (3) on the crankshaft pulley is located just before the lug (2) on the timing case.

In this position the cams for the 1st cylinder (1) are located just before "TDC" (both cams point outwards).

Remove crankshaft belt pulley (1) – counterhold at the fastening bolt for the crankshaft hub.

Release fastening bolt for crankshaft hub (2) (do not remove) – attach KM-6013 (3) for this and counterhold with KM-956 (4).

Detach closure bolt (1) for cylinder block base plate.

  Adjust

Insert KM-952 (2) into opening and, at the same time, at the fastening bolt of the crankshaft hub, slowly further turn crankshaft in the engine rotational direction until KM-952 engages in base plate of cylinder block or crankshaft webs to the stop.

  Inspect

In this position, the marking (3) on the crankshaft hub must point upwards.

Insert KM-953 (1) into camshaft – KM-953 must engage in grooves of camshafts to the stop.

Remove crankshaft hub (1).

Detach timing case (2) from cylinder head, cylinder block and cylinder head base plate.

Push back chain tensioner (1) and lock with KM-955-1 (2).

Remove sliding rail (3), guide rail (5) and tension rail (7).

Timing chain (4), drive sprocket (6) and timing case gasket.

  Clean

Clean sealing surfaces and remove gasket remnants.

Caution

If a two-part timing case gasket has been used, sealant must be removed in the vicinity of the cylinder head gasket (arrows).

Lever seal ring (1) out of timing case with suitable tool.

Caution

Do not damage sealing surfaces.

  Clean

Clean sealing surfaces and remove gasket remnants.

  Install

Slide seal ring on KM-960 (2).

Drive seal ring flush into timing case using KM-960.

Insert new coolant pump (1) seal into timing case.

Caution

Ensure guide sleeves (arrows) are seated correctly.

  Install

Attach coolant pump to timing case with short bolts (2) – tightening torque 8 Nm / 6 lbf. ft.

Cut off elastomer projections of cylinder head gasket (1) so they are flush and replace with an approx. 1 mm thick bead of silicon sealant (grey) (2).

The bead of silicon sealant (grey) (2) can be applied directly if there is no protruding elastomer.

The timing case must be mounted within 10 minutes of applying the silicon sealant (grey).

Install new timing case gasket – ensure correct seating of guide sleeves (arrows). Place drive gear (6) onto crankshaft.

Install timing chain (4) on drive sprocket and camshaft sprockets. Thereby ensure that tension side (exhaust side) of timing chain is tensioned.

Attach tension rail (7) to cylinder block – tightening torque 20 Nm / 15 lbf. ft.

Attach guide rail (5) to cylinder block – tightening torque 8 Nm / 6 lbf. ft.

Attach sliding rail (3) to cylinder head – tightening torque 8 Nm / 6 lbf. ft.

  Remove

Remove KM-955-1 (2) out of chain tensioner (1).

1. Hand-tighten all fastening bolts.
2. Attach coolant pump/ timing case fastening bolts (1) to cylinder head and cylinder block – tightening torque 8 Nm / 6 lbf. ft.
3. Attach timing case fastening bolts (2) and (3) to cylinder head, cylinder block and to base plate of cylinder block.

Attach timing case with M6 fastening bolts (2) to cylinder head, cylinder block and to base plate of cylinder block- tightening torque 8 Nm / 6 lbf. ft.

Attach timing case with M10 fastening bolts (3) to cylinder block, and base plate of cylinder block- tightening torque 35 Nm / 26 lbf. ft.

Ensure installation position of crankshaft hub (2) is correct – mark (1) must point upwards.

  Install

Attach crankshaft hub to crankshaft with new fastening bolts – attach KM-6013 (4) for this operation and counterhold with KM-956 (5) – tightening torque 150 Nm / 111 lbf. ft. + 45°.

Attach crankshaft belt pulley (3) to crankshaft hub – counterhold at the fastening bolts for the crankshaft hub – tightening torque 8 Nm / 6 lbf. ft.

The mark (3) on the crankshaft pulley is located just before the lug (2) on the timing case.

In this position, the cams for the 1st cylinder are located just before "TDC" (both cams point outwards).

Insert KM-952 (3) into opening and, at the same time, at the fastening bolt of the crankshaft hub, slowly further turn crankshaft in the engine rotational direction until crankshaft locking pin engages in base plate of cylinder block or crankshaft webs to the stop.

  Inspect

In this position, the mark (2) on the crankshaft pulley must be flush with the lug (1) on the timing case.

Insert KM-953 (1) into camshaft – KM-953 must engage in grooves of camshafts to the stop.

Note:   If KM-953 cannot be inserted, then a basic adjustment should be performed – see operation "Timing, Adjust".

Position KM-954 (1) on the phase sensor disc (2) and attach to timing case.

Note:   If KM-954 cannot be inserted, then a basic adjustment should be performed – see operation "Timing, Adjust".

Procedure

Cut off protruding cylinder head gasket (1) flush with cylinder head/ timing case and replace with an approx. 2 mm thick bead of silicon sealant (grey) (dimension I).

Caution

The cylinder head cover must be mounted within 10 minutes of applying the silicon sealant (grey).

Insert new seal (2) in cylinder head cover (1).

Attach cylinder head cover to cylinder head – tightening torque 8 Nm / 6 lbf. ft.

Connect ignition module to spark plugs and attach to cylinder head – tightening torque 8 Nm / 6 lbf. ft.

Attach ignition module cover to cylinder head cover.

Connect wiring harness plug to ignition module.

Attach engine vent hose to cylinder head cover.