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Vauxhall Workshop Service and Repair Manuals

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Seal Ring - Camshaft, Replace > < Camshaft Sprocket, Replace

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Camshafts, Remove and Install

  Remove

1.   Remove right engine damping block adapter LUREF_1.gif
2.   Detach engine venting pipe (2)
•   Detach engine venting hose (3) from engine venting pipe
– Release clamp
•   Unscrew 2x bolts (1)
Object Number: 7360967 Size: DEFAULT


3.   Install EN-46789 (1) in camshaft housing
•   Unscrew exhaust camshaft closure bolt
•   Screw in EN-46789
4.   Set cylinder no. 1 to TDC of combustion stroke
•   Rotate crankshaft in direction of engine rotation until reference drift EN-46789 audibly engages in exhaust camshaft
Object Number: 2408564 Size: DEFAULT


5.   Remove toothed belt (1)
•   Remove toothed belt tension roller
– Unscrew bolt (2)
Object Number: 2408566 Size: DEFAULT


6.   Remove charge air hose (1)
•   Undo 2 clamps
Object Number: 7360939 Size: DEFAULT


7.   Detach intake connection piece (1) from throttle valve module
•   Unscrew 2x bolts (2)
Object Number: 7361581 Size: DEFAULT


8.   Remove brake servo vacuum line
•   Undo quick-release fitting (1)
9.   Remove engine oil filling nozzle (3)
•   Detach engine vent hose (2)
– Release clamp
•   Unscrew 3 bolts
Object Number: 3446063 Size: DEFAULT


10.   Remove vacuum pump (2)
•   Remove vacuum hose (1)
•   Unscrew 4x bolts
Object Number: 8125300 Size: DEFAULT


11.   Release 2x camshaft drive gear
Note:   2nd mechanic needed. Release intake camshaft bolt first.
•   Undo 2x bolts
•   Use KM-956-1 (3) in conjunction with KM-6347 (2)
– Counterhold in drive gear (1) for camshafts
Object Number: 8125301 Size: DEFAULT


12.   Release camshaft drive gear (1)
•   Loosen bolt
•   Use KM-956-1 (3) in conjunction with KM-6347 (2)
Object Number: 7360321 Size: DEFAULT


13.   Detach vacuum line from cable conduit
•   Detach 2x vacuum hose
•   Unclip 3x clip
Object Number: 8125482 Size: DEFAULT


14.   Detach engine management wiring harness
•   Disconnect 8x wiring harness plug
•   Charge pressure control solenoid valve
•   Camshaft sensor
– Unclip 2x clips
•   4x injector
– Detach cable conduit
– Unscrew 2x bolts
•   Pressure-regulating valve
•   Rail pressure sensor
15.   Remove vacuum line (1)
•   Detach 4x vacuum hoses
Note:   Mark vacuum hoses
•   Unscrew 3 bolts
Object Number: 7361575 Size: DEFAULT


16.   Detach leak oil line (1)
Note:   Oil leak line may not be detach from damping case for fuel return
•   Release 4x retaining clamp (arrows)
•   Pull off oil leak line
Object Number: 2408582 Size: DEFAULT


Important:   When releasing the retaining nut, counterhold with open-ended wrench against the injector
17.   Detach 4x high pressure line (1), pressure chamber on injector
Important:   Seal injector and pressure chamber openings with protective caps 1)
•   Release 8x retaining nut
Object Number: 2408575 Size: DEFAULT


Important:   When releasing the retaining nut, counterhold with open-ended wrench against the connection for the high pressure fuel pump
18.   Remove high pressure line (1) from high pressure pump to pressure chamber
Important:   Seal pressure chamber and high pressure pump with sealing caps 1)  
•   Unscrew 2x union nuts
Object Number: 2408577 Size: DEFAULT


19.   Remove accumulator (1)
•   Detach return line (2)
– Release clamp
•   Unscrew 2x bolts (3)
Object Number: 8125480 Size: DEFAULT


20.   Detach bracket (1) for toothed belt cover
•   Unscrew bolt
Object Number: 8125481 Size: DEFAULT


21.   Remove 4x injector (2)
Note:   If injectors cannot be removed by hand, use EN-46786 in conjunction with KM-328-B
•   Unscrew 4x nuts (1)
Important:   Seal apertures of injectors and of pressure chamber with protective caps
•   Remove 4x injector with bracket
•   Remove 4x seal rings
Object Number: 8125486 Size: DEFAULT


Object Number: 8125487 Size: DEFAULT

22.   Detach camshaft housing
Note:   Unscrew bolts carefully in the tightening sequence stated (1 - 18). Camshaft housing must be released evenly from cylinder head.
•   Unscrew 18x bolt
•   Remove gasket

23.   Detach 2x camshaft drive gear (3)
•   Unscrew 2x bolts (4)
24.   Remove camshaft sprocket (1)
•   Unscrew bolt (2)
Object Number: 7360328 Size: DEFAULT


25.   Attach EN-46789
26.   Remove closure cap (1) of intake camshaft
Note:   Do not damage sealing surface
•   Remove with suitable tool
27.   Remove camshaft seal ring (2)
Note:   Do not damage sealing surface.
•   Remove with suitable tool
28.   Remove 2x camshaft (3) and (4)
Object Number: 7360406 Size: DEFAULT


  Install

29.   Install 2x camshaft
•   Coat bearing surfaces with engine oil
•   Insert 2x camshaft drive gear
– Screw in 2x bolts
Important:   Use EN-46780
•   Attach seal ring for camshaft sprocket
•   Attach closure cap for intake camshaft
Important:   Guide pin in camshaft drive gear must engage in guide slot in camshaft sprocket
•   Attach camshaft drive gear
– Screw in bolt
30.   Set 2x camshaft to TDC of combustion stroke for cylinder 1
•   Position 2x camshaft
•   Attach EN-46789 to exhaust camshaft
•   Attach EN-46789-100 to intake camshaft
•   Ensure correct installation position
Note:   Reference drifts must engage audibly
31.   Cleaning work
•   Camshaft housing, cylinder head, vacuum pump
32.   Position camshaft housing
•   Replace gasket
•   Note guide sleeves
Object Number: 8125488 Size: DEFAULT

33.   Tighten camshaft housing
•   Tighten 18x bolt in the stated order (1 - 18) 25 Nm
Note:   Note different bolt lengths

34.   Tighten 2x camshaft drive gear
•   Tighten 2x new bolt 120 Nm
Note:   2nd mechanic required
35.   Clean 4x injector casing
Note:   To clean the injector seats, insert EN-47632 with coarse fleece in the injector casing and pre-clean injector seat by turning. Then complete cleaning process with fine fleece.
36.   Install 4x injector
•   Replace 4x seal rings
•   Insert 4x injector with bracket
Note:   Note sequence, cylinder 4, 3, 2, 1
•   Tighten 4x nuts 25 Nm
37.   Attach bracket, toothed belt cover
•   Tighten bolt
38.   Fit accumulator
•   Attach return line
– Fasten clamp
•   Tighten 2x bolt 25 Nm
Important:   When tightening the retaining nut on the counterhold on the connection for the fuel high pressure pump with open-ended wrench
39.   Attach new high-pressure pump high-pressure line to pressure chamber
•   Tighten 2x retaining nut
– (M12) 25 Nm
– (M14) 23 Nm
Important:   When tightening the retaining nut, counterhold against the injector with open-ended wrench, Use new pressure lines
40.   Attach 4x high pressure line for pressure chamber to injector
•   Tighten 8x retaining nut
– (M12) 25 Nm
– (M14) 23 Nm
41.   Attach oil leak line
•   Clip 4x oil leak line into injector
42.   Install vacuum line
•   Connect 4x vacuum hoses
Note:   Pay attention to marks
•   Tighten 3x bolts
43.   Attach engine management wiring harness
•   Connect 8x wiring harness plug
•   Charge pressure control solenoid valve
•   Camshaft sensor
– Clip in 2x clips
•   4x injector
– Attach cable conduit
– Tighten 2x bolts
•   Pressure-regulating valve
•   Rail pressure sensor
44.   Clip vacuum line into cable conduit
•   Clip in 3x clips
•   Attach 2x vacuum hoses
45.   Clean sealing surfaces.
•   Vacuum pump, engine oil filler port, throttle valve module
46.   Install vacuum pump
•   Replace gasket
•   Tighten 4x new bolt 5 Nm + 50°
•   Attach vacuum hose
47.   Install engine oil filling nozzle
•   Replace gasket
•   Tighten 3x bolts
Note:   Recut thread before re-using and insert bolt with locking compound (red). The maximum installation time including torque check is 10 minutes
•   Attach engine venting hose
– Tighten clamp
Warning:   Connection must audibly engage
48.   Connect brake servo vacuum line
49.   Attach intake port to throttle valve module
•   Replace gasket
Note:   Coat with special grease (white)
•   Tighten 2x bolts
50.   Attach intercooler charge air pipe to throttle body
•   Fasten 2x clamp 3.5 Nm
51.   Clean the thread
52.   Install toothed belt tension roller
Note:   Insert tension roller in guide
•   Screw in bolt
Note:   Clean thread before re-using and insert bolt with locking compound (red). The maximum installation time including torque check is 10 minutes.
Important:   Tightened end must be taut
53.   Install toothed belt
Note:   Observe direction of rotation
54.   Lock crankshaft with EN-46788
•   Unscrew bolt (arrow)
•   Tighten stud bolt (1) EN-46788
•   Attach positioning disk (4) EN-46788
– Screw in bolt (3)
– Screw in nut (2)
Object Number: 3446087 Size: DEFAULT


55.   Raise vehicle by its full height
Important:   Toothed belt tension roller must be at maximum tension
56.   Tension the toothed belt
•   Tighten bolt - toothed belt tension roller
57.   Lower vehicle by its full height
58.   Fasten camshaft drive gear
•   Counterhold drive gear with EN-47634 in combination with KM-956-1
•   Tighten bolt 120 Nm
59.   Raise vehicle by its full height
60.   Toothed Belt Tension, Adjust
•   Screw in bolt (6)
•   Tension the toothed belt
Note:   Push adjusting lever in direction of arrow with a screwdriver (5) until pointer (4) of toothed belt tension roller aligns with mark (2)
•   Tighten bolt, toothed belt tension roller (3) 25 Nm
Object Number: 2408567 Size: DEFAULT


61.   Lower vehicle by its full height
62.   Remove positioning disk EN-46788
•   Unscrew nut
•   Unscrew bolt
63.   Turn crankshaft 720° in the direction of rotation of the engine
•   Disengage EN-46789
•   Rotate crankshaft in direction of engine rotation until reference drift EN-46789 audibly engages in exhaust camshaft
64.   Check crankshaft setting with EN-46788
Note:   If EN-46788 cannot be fitted, repeat the toothed belt positioning procedure
•   Attach positioning disk EN-46788
– Screw in bolt
– Screw in nut
•   Remove EN-46788
– Unscrew stud bolt EN-46788
•   Tighten bolt
65.   Remove EN-46789 from camshaft housing
•   Tighten closure bolt 16 Nm
66.   Attach engine venting pipe
•   Attach engine venting hose to engine venting pipe
– Fasten clamp
•   Tighten 2x bolt 9 Nm
67.   Install right engine damping block adapter LUREF_1.gif
1 ) Protective caps are available from the Opel parts catalogue under catalogue number 45 06 154 / part number: 9201697

Seal Ring - Camshaft, Replace > < Camshaft Sprocket, Replace