Vauxhall Workshop Service and Repair Manuals

Camshaft Housing, Replace

Important:   When working on the fuel system it is essential to pay attention to cleanliness as even the smallest dirt particles can lead to faults in engine operation or in the fuel system. Open fuel connections must be sealed with appropriate plugs from the Opel Parts Catalogue (catalogue number: 45 06 154 / part number: 9201697). Sealing plugs are only intended to be used once.

  Remove

2.   Detach radiator grille (2) •   Detach 4x body-bound rivets (1) •   Unclip from front panelling

3.   Empty climate control system •   Connect service station •   Blue hose to low-pressure service connection with small diameter •   Red hose to high-pressure service connection with large diameter Note:   Read Service Station operating instructions carefully •   Determine quantity of condenser extracted at the oil separator of the Service Station

8.   Drain coolant •   Open drain bolt on radiator (1) •   Collect coolant •   Close drain bolt

9.   Insert KM-6173 (3) •   Align support bearing (1) •   Raise support bearing until journal (2) sits flush in mount (4) •   Fasten KM-6173 – Screw in 2x bolts

10.   Attach KM-6001-A (1) Note:   Attaching KM-6001-A guarantees perfect alignment of the drive unit with the front axle body •   Slacken 4x bolts (arrows) in adjusting rails •   Insert KM-6001-A – Insert journals (2) and (5) in guide holes in front axle body •   Tighten 4x bolts in adjusting rails •   Adjust support bearings, front (4) and rear (3) – Raise support bearings up to the stop on the guide journals Note:   The guide journals must be seated free from play in the support bearings

12.   Remove engine cover (2) •   Detach oil filler port closure cap (1) •   Pull off engine cover Note:   Rubber retainers (3) must remain on engine cover •   Attach oil filler port closure cap

13.   Remove air intake manifold (1) •   Detach wiring harness – Release 3x clip •   Undo 2 clamps •   Unscrew 2x bolts

14.   Remove throttle valve body (1) •   Detach charge air hose (3) – Release clamp •   Release bracket, throttle valve body (4) – Detach from throttle valve body – Release on camshaft housing •   Disconnect wiring harness plug (2). •   Unscrew 4x bolts

15.   Remove charge air pipe (1) •   Unscrew 6x bolts

16.   Detach wiring harness for injectors •   Disconnect 4x wiring harness plugs for injector (2) •   Unscrew 2x bolts (3) •   Disconnect 4x wiring harness plug for glow plug (1) with KM-717 •   Push wiring harness to one side

Important:   After detaching the pressure lines, seal off injector and pressure chamber openings with protective caps 1) 18.   Remove high pressure lines (1), pressure chamber to injectors •   Unscrew 8x union nut with KM-812 or KM-6098 •   Take out pressure lines •   Seal 4x pressure chamber opening with protective cap •   Seal 4x injector opening with protective cap

19.   Detach fuel return line (1) •   Detach 4x fuel return line from injector – Press 4x retaining clamps in direction of arrow •   Detach fuel return line from pressure chamber •   Unscrew 2x bolts Note:   Note different bolt lengths •   Unscrew nut

20.   Remove rear right engine transport shackle (1) •   Unscrew 2x bolts

21.   Remove rear left engine transport shackle (1) •   Detach wiring harness – Unclip clip •   Unscrew bolt

22.   Remove bracket, oil dipstick guide tube (1) •   Unclip vacuum line – Unclip 2x clips •   Remove oil dipstick guide tube – Release clamp •   Detach bracket, oil dipstick guide tube, from camshaft housing – Unscrew 2x bolts

23.   Remove compressor (1) •   Detach refrigerant lines – Unscrew bolt •   Disconnect wiring harness connector. •   Unscrew 3 bolts Note:   Note different bolt lengths

24.   Remove compressor bracket (1) •   Unscrew 3 bolts

25.   Detach cooler, exhaust gas recirculation (1) from camshaft housing •   Unscrew bolt

26.   Detach right front engine transport shackle (1) •   Unscrew bolt

27.   Detach bracket, throttle valve body (1), from camshaft housing •   Unscrew bolt

28.   Remove 4x seals, connection for injectors (1) •   Unscrew 8x bolts

29.   Remove 4x seal, injectors (1) •   Unscrew 8x bolts

30.   Remove camshaft housing cover (1) •   Unscrew 11x bolts Note:   Note different bolt lengths

31.   Remove 4x injector (1) Note:   Mark injectors •   Remove 4x bracket, injector (2) – Unscrew 4x bolts Note:   If a heat protection sleeve (5) also has to be removed when removing an injector, the gaskets (3) must be replaced and the heat protection sleeve must be hammered into the cylinder head with KM-6357 (4)

32.   Remove air cleaner housing (5) with air intake hose •   Detach wiring harness plug (2) from hot film mass air flow meter •   Detach air intake hose from air intake pipe – Release clamp (1) •   Detach air cleaner housing from wheel housing – Unscrew bolt (4) •   Detach water drain hose (3) from air cleaner housing – Release clamp

33.   Remove ribbed V-belt •   Mark direction of rotation •   Apply tension to ribbed V-belt tensioner via bolt (1) in the direction of the arrow •   Fix ribbed V-belt tensioner to bore (2) •   Remove ribbed-V-belt

34.   Detach wiring trough (4) from front toothed belt cover (top) •   Unscrew bolt (2) •   Detach wiring harness (3) – Disconnect camshaft sensor wiring harness plug – Release 2x clip •   Detach vacuum line (1) – Release 2x clip •   Unclip wiring trough in direction of arrow – Undo clip

35.   Detach front toothed belt cover (top) (4) •   Detach vacuum line (3) – Unclip 3x clip •   Unscrew 8x bolts Note:   Note different bolt lengths •   Remove camshaft sensor bracket (1) – Unscrew bolt (2)

36.   Remove engine damping block support •   Detach from engine damping block bracket – Unscrew 3x bolts (2) •   Detach from cylinder block – Unscrew 3x bolts (3) •   Remove engine damping block adapter (1)

37.   Remove coolant pump drive gear (1) •   Unscrew 3 bolts

38.   Detach torsional vibration damper (1) •   Unscrew 4x bolts Note:   Counterhold at bolt (2)

39.   Remove front toothed belt cover (lower) (1) •   Unscrew 3x bolts (2)

40.   Move crankshaft in direction of engine rotation to "Cylinder no.1 combustion stroke TDC" Note:   Marking on toothed belt drive gear must align with projection on oil pump cover (arrows) •   Fix with TDC fixing bolt (M6) (1) camshaft drive gear •   Fix with TDC fixing bolt (M8) (2) high pressure pump gear

41.   Remove toothed belt •   Mark direction of rotation •   Slacken the toothed belt tension roller – Loosen bolt (1) •   Apply preliminary tension to toothed belt tension roller with hexagon (2) in direction of arrow •   Fix toothed belt tension roller in pre-tensioned position – Tighten bolt

42.   Turn crankshaft 60° against the direction of engine rotation

43.   Remove camshaft sprocket •   Remove TDC fixing bolt (1) •   Unscrew bolt Note:   Counterhold with KM-6347 (2) in conjunction with KM-956-1 (3)

44.   Detach rear toothed belt cover from camshaft housing •   Unscrew 2x bolts (1)

45.   Remove camshaft housing •   Unscrew 17x bolt – Slacken in the order shown (1 - 17) 1/2 turn and then remove

  Install

48.   Install camshaft housing •   Replace gasket •   Attach to cylinder head and tighten in the order shown (1-17) – Tighten 12x bolt (M8) 21.6 Nm – Tighten 5x bolt (M10) 26.5 Nm

50.   Install camshaft sprocket Note:   Camshaft journal (2) must engage in the bore (1) in the camshaft sprocket •   Tighten bolt 63.7 Nm Note:   Counterhold with KM-6347 in conjunction with KM-956-1 •   Screw in TDC fixing bolt

51.   Install toothed belt Note:   TDC fixing bolts must be installed in the high pressure drive gear and camshaft drive gear and markings (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) and high pressure pump drive gear (2) to the camshaft sprocket (1) – Observe direction of rotation •   Slacken the toothed belt tension roller (3) •   Remove 2x TDC fixing bolt •   Turn crankshaft 60° against the direction of engine rotation •   Tighten toothed belt tension roller 38.2 Nm

52.   Timing, Check •   Turn crankshaft 6 revolutions in direction of engine rotation to the adjustment position •   The following factors must be present at the adjustment position Note:   If one of these factors is not present, the timing must be adjusted 1. TDC fixing bolt M6 (1) must be able to be inserted in the camshaft drive gear 2. TDC fixing bolt M8 (2) must be able to be inserted in the high pressure pump drive gear 3. Marking (4) on the toothed belt drive gear must align with the marking (3) on the oil pump housing cover •   Remove 2x TDC fixing bolt

53.   Turn the crankshaft until the cam pair (1) and (2) faces upwards. 54.   Check valve lash with feeler gauge Note:   Valve lash must be checked at room temperature when the engine is cold. •   Test values: Intake valve/exhaust valve (0.35 - 0.45 mm) 55.   Adjust valve play •   Turn the bucket tappet until the tappet groove faces outwards Important:   Care should be taken that the valves do not strike the piston head •   Press down cup tappet with KM-6090 Note:   Note different tool designs for intake and exhaust valve – Marking - IN = intake side – Marking - EX = exhaust side •   Remove shim

56.   Example for determination of shim thickness: 1. Thickness of installed shim   3.15 mm 2. Measurement between cams and cup tappets + 0.45 mm     = 3.60 mm 3. Nominal valve play - 0.40 mm 4. Thickness of new shim = 3.20 mm 57.   Insert shim •   Coat new shim (7) with engine oil and insert in cup tappet with code facing down 58.   Check and adjust remaining valves •   Turn crankshaft 180° in the direction of rotation of the engine – Check and adjust valve pair (6) and (2) •   Turn crankshaft 180° in the direction of rotation of the engine – Check and adjust valve pair (5) and (3) •   Turn crankshaft 180° in the direction of rotation of the engine – Check and adjust valve pair (4) and (1) Note:   Valve lash must be checked again on all adjusted valves

Important:   Journal (1) of toothed belt drive gear must engage in the bore (2) of the torsional vibration damper 60.   Install torsional vibration damper •   Tighten 4x bolt 19.6 Nm Note:   Counterhold against bolt, toothed belt drive gear

66.   Replace injector gaskets •   Rubber gasket (1) •   Copper gasket (2)

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

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

72.   Apply sealing compound Important:   Oil return bore (2) may not be covered with adhesive sealing compound •   Apply adhesive sealing compound (white) to sealing surfaces (1) and (3)

73.   Install camshaft housing cover •   Replace gasket •   Tighten 9x bolt in the stated order (1...9) 9.8 Nm

74.   Install 4x new seal, injectors (2) •   Align seal for injectors Note:   Sealing lip of seal must be in full contact with the injector with no gaps (arrow) •   Coat 8x bolt head contact surface (1) with special grease (white) •   Tighten injector seal in 2 stages Note:   During the tightening process, press injector seal against the camshaft housing cover with your hand 1. Tighten 2x bolt 10 Nm 2. Tighten 2x bolt 19 Nm

75.   Install 4x new seal, connection for injectors Note:   Marking "UP" must point upwards •   Tighten 8x bolts

90.   Insert ribbed V-belt Note:   Note running direction of ribbed V-belt •   Position ribbed V-belt – I. Ribbed V-belt without air conditioning – II. Ribbed V-belt with air conditioning •   Apply tension to ribbed V-belt tensioner via bolt (1) in the direction of the arrow •   Take out fixing •   Release ribbed V-belt tensioner

101.   Top up climate control system •   Connect service station •   Connect blue hose to low pressure service connection with small diameter •   Connect red hose to high pressure service connection with large diameter Note:   Read Service Station operating instructions carefully •   Use the Service Station to insert the quantity of new compressor lubricant into the climate control system that was extracted when it was emptied. – Fill air conditioning system with R 134a refrigerant