vauxhall Workshop Repair Guides

Vauxhall Workshop Service and Repair Manuals

ABOUT US
Camshaft Sprockets, Replace > < Camshaft Sprockets, Remove and Install

Astra H

Removing and installing both camshafts

  Remove

1.   Open bonnet
2.   Remove air cleaner housing
•   Disconnect mass air flow sensor wiring harness plug (2)
•   Unclip tank vent line (3)
•   Detach engine vent hose (4) from air intake hose
– Release clamp
•   Detach air intake hose (5) from throttle valve body
– Release clamp
•   Detach air cleaner housing
– Unscrew bolt (1)
– Unclip rubber mounting at the bottom
– Remove air intake pipe (6)
Object Number: 3446127 Size: DEFAULT


3.   Disconnect wiring harness plugs for camshaft sensor (1), hot film mass air flow meter (2), oil pressure switch (3) and coolant temperature sensor (4)
4.   Unclip wiring trough (5) from cylinder head cover
•   Set aside to the rear
Object Number: 3446263 Size: DEFAULT


5.   Remove engine vent hoses (2) from cylinder head cover
•   Undo 2 clamps
6.   Remove ignition module
•   Disconnect cooling module wiring harness plug (4)
•   Pull the cover of the ignition module (1) away from the cylinder head cover in the direction of the arrow
•   Unscrew 2x bolts (6)
Important:   Do not tilt
•   Remove ignition module (5) from spark plugs with KM-6009 (3)
7.   Detach cylinder head cover (7) from cylinder head
•   Unscrew 13x bolts
Object Number: 3446273 Size: DEFAULT


8.   Remove gasket remnants and clean sealing surfaces
9.   Move crankshaft in direction of engine rotation to just before "cylinder 1 TDC of combustion stroke"
•   The marking (3) on the crankshaft belt pulley is just before the cast projection (2) on the timing case
•   In this position, the cams (1) of cylinder 1 are at "TDC of combustion stroke" (both cams point outwards)
Object Number: 2398441 Size: DEFAULT


10.   Remove closure bolt of chain tensioner (1) from timing case
11.   Lock chain tensioner with KM-955-1 (2)
•   Apply tension to intake camshaft in the direction of engine rotation via hexagon (direction of arrow)
Object Number: 2398459 Size: DEFAULT


12.   Detach sliding rail (1) from cylinder head
•   Unscrew 2x bolts
13.   Remove camshaft sprockets
•   Unscrew 2x bolts (2)
– Counterhold with open-ended wrench against the hexagon of the camshafts (3)
•   Take out camshaft sprockets
Object Number: 2399410 Size: DEFAULT


14.   Note marking before dismantling camshaft bearing cap

Marking, exhaust camshaft

= 1 - 3 - 5 - 7 - 9

Marking, intake camshaft

= 2 - 4 - 6 - 8 - 10
15.   Remove exhaust camshaft
Note:   When releasing the camshaft bearing caps, ensure that the camshaft is seated evenly on the bearing seats
•   Slacken camshaft bearing caps in stages 1/2 to 1 turn
•   Unscrew 10x bolt
•   Take out camshaft bearing caps
– Set aside in the correct order
•   Remove exhaust camshaft
16.   Remove intake camshaft
Note:   When releasing the camshaft bearing caps, ensure that the camshaft is seated evenly on the bearing seats
•   Slacken camshaft bearing caps in stages 1/2 to 1 turn
•   Unscrew 10x bolt
•   Take out camshaft bearing caps
– Set aside in the correct order
•   Remove intake camshaft
Object Number: 2399411 Size: DEFAULT


17.   Clean all parts

  Install

18.   Check camshaft and camshaft bearing for wear
Note:   If the camshaft bearings are faulty, the cylinder head must be replaced. When replacing the camshaft, the roller cam followers (1) and hydraulic valve lifters (2) must be replaced
19.   Install intake camshaft
•   Coat sliding surfaces with MoS2 lubricating paste
•   Insert intake camshaft
Note:   Insert camshaft in such a way that the cams of cylinder 1 are set at "TDC of combustion stroke" (cams point outwards)
Important:   Note mark and allocation
•   Insert camshaft bearing caps
•   Install camshaft bearing cover
Note:   Tighten camshaft bearing caps in stages, working in a spiral from inside to outside
– Tighten 10x bolt 8 Nm
20.   Install exhaust camshaft
•   Coat sliding surfaces with MoS2 lubricating paste
•   Insert exhaust camshaft
Note:   Insert camshaft in such a way that the cams of cylinder 1 are set at "TDC of combustion stroke" (cams point outwards)
Important:   Note mark and allocation
•   Insert camshaft bearing caps
•   Install camshaft bearing cover
Note:   Tighten camshaft bearing caps in stages, working in a spiral from inside to outside
– Tighten 10x bolt 8 Nm
21.   Tighten camshaft sprockets hand-tight with new bolts
•   Screw in 2x bolts
– Use new bolts
– Tighten hand-tight
Note:   It must still be possible to turn the phase sensor disc on the intake camshaft by hand
22.   Attach sliding rail to cylinder head
•   Tighten 2x bolt 8 Nm
Object Number: 2399412 Size: DEFAULT


23.   Turn camshafts by the hexagon (short distance) until KM-953 (1) can be inserted in the grooves of the camshafts
Note:   Turn camshafts carefully and evenly
•   KM-953 must engage as far as the stop in the grooves of the camshafts
Object Number: 2410445 Size: DEFAULT


24.   Turn phase sensor disc (2) in such a way that KM-954 (1) can be inserted on the timing case
Object Number: 2410436 Size: DEFAULT


25.   Attach KM-954 to timing case
•   Tighten 2x bolts
26.   Take KM-955-1 out of chain tensioner
27.   Unscrew closure bolt, crankshaft bearing bridge (1)
28.   Adjust TDC of combustion stroke of cylinder 1
•   Insert KM-952 (2)
– Turn crankshaft evenly until KM-952 engages
– Marking on the crankshaft belt pulley (4) must align with the cast projection (3) on the timing case
Object Number: 2410427 Size: DEFAULT


29.   Remove locking pin of chain tensioner KM-955-1
•   Tighten chain tensioner closure bolt 50 Nm
– Use new seal ring
30.   Fasten camshaft sprockets
Note:   Tightening torque 10 Nm serves to fix the camshaft sprockets and the phase sensor disc temporarily
•   Tighten 2x bolt (2) 10 Nm
Note:   First of all tighten bolt of intake camshaft sprocket
– Counterhold the camshafts on the hexagon (1)
Object Number: 2399406 Size: DEFAULT


31.   Remove locking tools KM-954 , KM-953 and KM-952
Note:   Locking tools may not be used for counterholding
32.   Tighten camshaft sprockets
Note:   Use a second person
•   Tighten 2x bolt 50 Nm + 60°
33.   Timing, Check
•   Turn crankshaft through 720°
– Insert KM-952
•   Insert KM-953 into camshafts
•   Attach KM-954 on phase sensor disc
Note:   if KM-954 cannot be inserted, the operation "Timing, Adjust" must be repeated
34.   Remove KM-954 , KM-953 and KM-952
35.   Attach cylinder head cover (1)
•   Replace gasket (2)
Important:   Complete assembly work within 10 minutes
•   Apply a bead of silicone sealing compound (dimension I) approx. 2 mm thick to the dividing joints of the cylinder head and timing case
Important:   Bolts must be checked visually to check whether the elastomer seal is damaged. If the elastomer seal is damaged, the bolt must be replaced with a new one.
•   Tighten 13x bolt 8 Nm
Object Number: 2410670 Size: DEFAULT


36.   Install ignition module
•   Connect ignition module to spark plugs
•   Tighten 2x bolt 8 Nm
•   Attach ignition module cover to cylinder head cover
•   Connect ignition module wiring harness plug
37.   Clip wiring trough to cylinder head cover
38.   Connect wiring harness plugs for camshaft sensor, hot film mass air flow meter, oil pressure switch and coolant temperature sensor
39.   Install air cleaner housing
•   Screw in bolt
•   Connect air intake hose
– Attach 2x clamps
•   Attach engine vent hose
– Fasten clamp
•   Connect 2x wiring harness plugs
– Hot film air mass flow meter, tank vent valve
40.   Close bonnet

Camshaft Sprockets, Replace > < Camshaft Sprockets, Remove and Install