Vauxhall Workshop Service and Repair Manuals

Camshaft Housing, Replace

Important:   When working on the fuel system maintaining cleanliness is essential, as even the smallest of dirt particles may result in engine operating faults or fuel system faults. Open fuel connections must be sealed off with suitable sealing plugs from the Opel parts catalogue. Sealing plugs are designed for single use only.

  Remove

3.   Remove air intake manifold (1) •   Release clamp

5.   Remove battery •   Detach positive terminal (3) from positive pole – Slacken nut •   Remove bracket 1) – Unscrew bolt (2)

6.   Remove battery support. •   Unclip control unit of pre-heating system (4) •   Unclip coolant hose bracket (5) •   Detach wiring harness – Unclip 2x from battery support (1) •   Unclip wiring harness plug (3) •   Unscrew 3x bolts (2)

8.   Detach wiring harness from engine control unit •   Release and unplug wiring harness plug (1) from engine control unit •   Unclip wiring harness from bracket •   Unclip 3x wiring harnesses from engine

10.   Disconnect upper engine timing wiring harness •   Detach fuse carrier cover •   Detach positive cable (1) from fuse carrier Note:   Mark installation position – Unscrew nut •   Release and unplug wiring harness plug (2) •   Unclip wiring harness and expose

11.   Detach fuel return line (1) from injector •   4x from injector – Release retaining clamps (2) •   Seal off line and connections with sealing caps

12.   Detach charge air pipe (3) from camshaft housing cover •   Detach camshaft vent hose (1) from charge air pipe – Release clamp •   Unclip hose for wastegate unit of exhaust gas recirculation cooler bypass valve (2) •   Unscrew bolt

13.   Detach vacuum hose (1) of wastegate unit for exhaust gas recirculation cooler •   Unclip 3x •   Set vacuum hose aside

14.   Detach engine management wiring trough (1) from camshaft housing cover •   Unscrew 3 bolts (arrows)

16.   Remove 4x high-pressure lines •   Unscrew 8x union nut (1) •   Seal off connections on pressure chamber with suitable sealing caps

17.   Remove camshaft housing cover (2) •   Unscrew 10x bolt •   Remove 4x injector seals (1) •   Remove camshaft housing cover •   Seal off connections on injector with EN-48559

18.   Remove 4x injector (1) •   Remove 4x brackets (2) – Unscrew 4x bolts

19.   Detach coolant hose (1) from thermostat housing cover •   Release clamp

20.   Remove exhaust gas recirculation valve (1) •   Detach EGR cooler pipe (2) – Unscrew 2x bolts – Remove gasket •   Unscrew 4x bolts – Remove gasket

21.   Detach charge air hose for throttle valve connection (1) •   Release clamp

22.   Detach intake pipe rear bracket (2) from intake pipe (6) •   Unscrew 2x bolts (1) 23.   Remove intake pipe together with throttle valve module •   Disconnect wiring harness plug for throttle valve module – Unclip wiring harness •   Remove intake pipe lower bracket (5) – Unscrew bolt (3) – Unscrew nut (4) •   Unscrew 3 bolts (arrows) •   Unclip vacuum hose •   Remove gasket

24.   Detach brake servo vacuum line (2) from vacuum pump 25.   Detach vacuum hose (1) from vacuum pump

26.   Remove vacuum pump (2) •   Unscrew 3x bolts (1)

30.   Remove camshaft sprocket •   Remove TDC fixing bolt (1) – Unscrew bolt Note:   Counterhold it with KM-6347 (3) together with KM-956-1 (2)

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

32.   Remove camshaft housing •   Unscrew 17x bolts in the specified sequence Note:   Slacken the bolt half a turn and then unscrew •   Remove gasket

33.   Remove camshaft bearing cap 5 (1) •   Unscrew 2x nuts (3) •   Unscrew bolt (2)

34.   Lock exhaust camshaft gear wheels •   Lock balancer gear wheel, exhaust camshaft (3), with balancer camshaft gear wheel (1) with KM-6092-10 (2) so that it cannot twist

35.   Remove 2x camshafts Note:   Note marking before dismantling camshaft bearing cap •   Release the camshaft bearing caps in the order specified, working in a spiral pattern in stages of 1/2 to 1 turn Note:   When replacing the exhaust camshaft, the balancer gear wheel (2) must be pre-tensioned with KM-6092 (1) and connected to the gear wheel of the exhaust camshaft (3) with fixing pin KM-6092-10 (4)

36.   Remove camshaft seal ring (1)

  Install

Important:   When installing the camshafts, ensure that the mark (1) on the exhaust camshaft gear wheel is between the two marks (2) on the intake camshaft gear wheel and that the marks on the camshaft bearing cap (4) are in line with the two marks on the camshafts (3) 38.   Insert 2x camshafts •   Insert camshaft in camshaft housing Note:   Coat bearing positions with engine oil

39.   Tighten 2x camshafts 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 •   Attach camshaft bearing cap 5 – Remove KM-6092-10 from exhaust camshaft gear wheel •   Tighten the camshaft bearing caps in the order specified (1 - 15) in stages of 1/2 to 1 turn – Tighten 10x nuts 22 Nm – Tighten 5x bolts 27 Nm

40.   Insert camshaft seal ring •   Drive in flush using KM-656 (1)

41.   Install camshaft housing •   Replace gasket •   Tighten 17x bolts in the specified tightening sequence (1-17) – Tighten 12x bolt (M8) 22 Nm – Tighten 5x bolt (M10) 27 Nm Note:   Coat bolts with engine oil

42.   Turn the camshaft until the cam pair (1) and (2) faces upwards.

43.	Check valve clearances and adjust if necessary

44.   Install camshaft sprocket Note:   Camshaft journal (2) must engage in the bore (1) in the camshaft sprocket •   Tighten bolt 111 Nm – Counterhold with KM-6347 in conjunction with KM-956-1 Important:   Do not damage increment disc •   Screw in TDC fixing bolt

55.   Install 4x injector •   Install 4x brackets – Align injectors with EN-48560 (1) – Tighten 4x bolt in three stages – 1. Tighten bolt 40 Nm – 2. Loosen bolt – 3. Tighten bolt 32 Nm

Important:   Oil return bore (2) may not be covered with adhesive sealing compound 57.   Apply sealing compound Note:   Select a suitable sealing compound from the replacement parts catalogue •   Apply adhesive sealing compound to sealing surfaces (1) and (3)

76.	Install air cleaner housing