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Vauxhall Workshop Service and Repair Manuals

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Removing and installing both camshafts > < Removing and installing both camshafts

Astra H

Camshaft Sprockets, Replace

  Remove

1.   Open bonnet
2.  
1. Remove air cleaner housing - Z16XEP LUREF_1.gif
2. Remove air cleaner housing - Z16XE1 LUREF_1.gif

3.   Raise vehicle
4.   Detach lower engine compartment cover / splashguard
5.   Set engine to 60° (measurement l) before TDC
•   Set crankshaft in direction of engine rotation to 60° (measurement l) before TDC
Object Number: 2412867 Size: DEFAULT


6.   Lower vehicle
7.   Detach front toothed belt cover (top) (1)
•   Unscrew 2x bolts (2)
•   Release upper catch (3)
•   Pull front toothed belt cover (top) upwards by cast projection (arrow), applying slight tension
Object Number: 2412882 Size: DEFAULT


8.   Remove toothed belt
•   Mark direction of rotation
•   Apply tension to toothed belt tension roller (2) in the direction of the arrow, using an Allen key (1). Fix using KM-6333 (3)
– Remove toothed belt
Object Number: 2412854 Size: DEFAULT


9.   Detach exhaust camshaft sprocket
•   Attach KM-6347 (1) in conjunction with KM-956-1 (2) to camshaft sprocket
– Slacken 2x bolt (3) of KM-6347
– Insert KM-6347 in the camshaft sprocket - ensure it is correctly seated
Note:   The grooves of KM-6347 (arrows) must engage with camshaft sprocket
– Turn KM-6347 in the direction of the arrow
– Tighten 2x bolts
•   Release bolt of camshaft sprocket (4)
– Hold using KM-6347
– 2 people
•   Remove KM-6347
– Undo 2x bolts
•   Unscrew bolt, camshaft sprocket
– Remove camshaft sprocket
Object Number: 2412855 Size: DEFAULT


10.   Detach intake camshaft sprocket
•   Attach KM-6347 in conjunction with KM-956-1 to camshaft sprocket
– Slacken 2x bolt of KM-6347
– Insert KM-6347 in the camshaft sprocket - ensure it is correctly seated
Note:   The grooves of KM-6347 must engage in camshaft sprocket
– Turn KM-6347 in the direction of the arrow
– Tighten 2x bolts
•   Slacken bolt of camshaft sprocket
– Hold using KM-6347
– 2 people
•   Remove KM-6347
– Undo 2x bolts
•   Unscrew bolt, camshaft sprocket
– Remove camshaft sprocket

  Install

11.   Attach KM-6347 to exhaust camshaft sprocket
•   Position camshaft sprocket - note marking
•   Fit camshaft sprocket bolt (4)
– Do not tighten
– Attach KM-6347 (1) in conjunction with KM-956-1 (2) to camshaft sprocket
– Slacken 2x bolt (3) of KM-6347
– Insert KM-6347 in the camshaft sprocket - ensure it is correctly seated
Note:   The grooves of KM-6347 (arrows) must engage with camshaft sprocket
– Turn KM-6347 in the direction of the arrow
– Tighten 2x bolts
Object Number: 2412855 Size: DEFAULT


12.   Tighten outlet camshaft sprocket 50 Nm + 60° + 15°
•   Hold using KM-6347
– 2 people
•   Remove KM-6347
13.   Attach KM-6347 to intake camshaft sprocket
•   Position camshaft sprocket - note marking
•   Screw in bolt, camshaft sprocket
– Do not tighten
– Attach KM-6347 in conjunction with KM-956-1 to camshaft sprocket
– Slacken 2x bolt of KM-6347
– Insert KM-6347 in the camshaft sprocket - ensure it is correctly seated
Note:   The grooves of KM-6347 must engage in camshaft sprocket
– Turn KM-6347 in the direction of the arrow
– Tighten 2x bolts
14.   Tighten intake camshaft sprocket 50 Nm + 60° + 15°
•   Hold using KM-6347
– 2 people
•   Remove KM-6347
15.   Lock camshaft sprockets in position with KM-6340
•   Position camshaft sprockets in such a way that the markings (3) are opposite each other
•   Attach KM-6340-Left (1) to intake camshaft sprocket
•   Insert KM-6340-Right (2)
Object Number: 2412847 Size: DEFAULT


16.   Set engine to TDC
•   Move torsional vibration damper in direction of engine rotation to the "cylinder 1 TDC of combustion stroke position" (1)
Object Number: 2412844 Size: DEFAULT


17.   Install toothed belt
•   Position toothed belt
– Place toothed belt on exhaust camshaft sprocket
– Place toothed belt on intake camshaft sprocket
– Apply tension to the toothed belt tension roller and remove KM-6333
18.   Remove KM-6340
19.   Raise vehicle by its full height
20.   Turn crankshaft through 720°
•   2 revolutions in direction of engine rotation
•   Place toothed belt drive gear on the marking, cylinder 1 TDC of combustion stroke (1)
Object Number: 2412844 Size: DEFAULT


21.   Detach lower engine compartment cover / splashguard
22.   Lower vehicle by its full height
23.   Lock camshaft sprockets in position with KM-6340
•   Insert KM-6340-Left (1)
•   Insert KM-6340-Right (2)
Note:   Markings (3) on camshaft sprockets must align - otherwise dismantle toothed belt and place in position again
Object Number: 2412847 Size: DEFAULT


24.   Remove KM-6340
25.   Attach front toothed belt cover (top)
•   Tighten 2x bolt 6 Nm
26.  
1. Install air cleaner housing - Z16XEP LUREF_1.gif
2. Install air cleaner housing - Z16XE1 LUREF_1.gif

27.   Close bonnet

Removing and installing both camshafts > < Removing and installing both camshafts