vauxhall Workshop Repair Guides

Vauxhall Workshop Service and Repair Manuals

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Timing, Check > < Timing, Check

Astra H

Timing, Adjust

  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.   Remove ignition module
•   Disconnect wiring harness plug (3) from ignition module
•   Pull the cover of the ignition module (1) away from the cylinder head cover in the direction of the arrow
•   Unscrew 2x bolts (5)
Important:   Do not tilt
•   Remove ignition module (4) from spark plugs with KM-6009 (2)
Object Number: 3446274 Size: DEFAULT


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


6.   Remove engine vent hoses (2) from cylinder head cover
•   Undo 2 clamps
7.   Remove ignition module
•   Disconnect ignition 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)
8.   Detach cylinder head cover (7) from cylinder head
•   Unscrew 13x bolts
Object Number: 3446273 Size: DEFAULT


9.   Remove gasket remnants and clean sealing surfaces
10.   Raise vehicle
11.   Remove right engine splash guard (2)
•   Unscrew 4x bolts (1)
•   Remove 2x body-bound rivets (3)
Object Number: 3446244 Size: DEFAULT


12.   Remove closure bolt crankshaft bearing bridge (1)
13.   Lower vehicle
14.   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


15.   Lock chain tensioner
•   Remove closure bolt (1)
•   Apply tension to the intake camshaft in the direction of the arrow on the hexagon with open-ended wrench
•   Insert KM-955-1 (2)
Object Number: 2398459 Size: DEFAULT


16.   Release camshaft sprockets
•   Unscrew 2x bolts (2)
– Counterhold with open-ended wrench against the hexagon (1) of the camshafts
Object Number: 2399406 Size: DEFAULT


17.   Bolts of Camshaft Sprockets, Remove
•   Screw in 2x bolts
•   It must still be possible to turn the phase sensor disc of the intake camshaft by hand
18.   Adjust the camshafts
•   Turn the camshafts by the hexagon
•   Insert KM-953 (1)
Object Number: 2410445 Size: DEFAULT


19.   Take KM-955-1 out of chain tensioner.
20.   Attach KM-954 (1)
•   Place on phase sensor disc (2)
•   KM-954 must engage in groove of phase sensor disc
Object Number: 2410436 Size: DEFAULT


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


23.   Remove locking tools KM-954 , KM-953 and KM-952
Note:   Locking tools may not be used for counterholding
24.   Tighten camshaft sprockets
Note:   Use a second person
•   Tighten 2x bolt 50 Nm + 60°
25.   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
26.   Remove KM-954 , KM-953 and KM-952

  Install

27.   Raise vehicle
28.   Attach right engine splash guard
•   Tighten 4x bolts
•   Install 2x body-bound rivets
29.   Lower vehicle
30.   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


31.   Install ignition module
•   Connect ignition module to spark plugs
•   Tighten 2x bolt 8 Nm
•   Attach ignition module cover to cylinder head cover
•   Attach wiring harness plug to ignition module
32.   Clip wiring trough to cylinder head cover
33.   Connect wiring harness plugs for camshaft sensor, hot film mass air flow meter, oil pressure switch and coolant temperature sensor
34.   Install air cleaner housing
•   Attach air cleaner housing to wheelhouse
– Tighten bolt
•   Attach air intake hose to throttle valve module
– Fasten clamp
•   Attach engine vent hose to timing case
– Fasten clamp
•   Connect wiring harness plug, air mass flow meter
•   Clip in tank vent line
35.   Close bonnet

Timing, Check > < Timing, Check