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Vauxhall Workshop Service and Repair Manuals

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Replace timing chain (secondary) > < Hydraulic Chain Tensioner, Replace (Primary)

Astra H

Replace timing chain (primary)

Spezialwerkzeugliste:
  • KM-6148

  Remove

1.   Remove cylinder head cover
2.   Remove timing case
3.   Adjust ignition TDC of cylinder 4
•   Place crankshaft on marking
Note:   Rotate crankshaft slowly and evenly in direction of engine rotation.
4.   Lower vehicle by its full height
5.   Remove upper sliding rail (1)
•   Unscrew 2x bolts (2)
Object Number: 2416678 Size: DEFAULT


6.   Remove chain tensioner of camshaft timing chain (1)
Object Number: 2416679 Size: DEFAULT


7.   Detach exhaust camshaft sprocket
•   Unscrew bolt (1)
Note:   Counterhold at camshaft hexagon (arrow).
8.   Detach intake camshaft sprocket
•   Unscrew bolt (2)
Note:   Counterhold at camshaft hexagon (arrow). Secure camshaft timing chain against falling in using a cable tie.
Object Number: 2405279 Size: DEFAULT


9.   Loosen guide rail of camshaft timing chain
•   Unscrew closure bolt (1)
•   Unscrew upper bolt (2)
Object Number: 2405266 Size: DEFAULT


10.   Remove guide rail of camshaft timing chain (1)
•   Unscrew lower bolt (2)
Object Number: 2405278 Size: DEFAULT


11.   Loosen tension rail of camshaft timing chain
•   Unscrew bolt
Object Number: 2405280 Size: DEFAULT


12.   Remove tension rail of camshaft timing chain
13.   Remove camshaft timing chain

  Install

14.   Insert camshaft timing chain
Note:   Secure camshaft timing chain against falling in.
15.   Insert tension rail of camshaft timing chain
16.   Fasten tension rail of camshaft timing chain
•   Tighten bolt 10 Nm
17.   Install guide rail of camshaft timing chain
•   Tighten 2x bolt 10 Nm
18.   Install timing case
19.   Attach intake camshaft sprocket
•   Replace bolt
•   Screw in bolt
20.   Attach KM-6148
21.   Adjust intake camshaft
Note:   Rotate intake camshaft on hexagonal section until locating bolt of KM-6148 fits in corresponding hole.
22.   Raise vehicle by its full height
23.   Adjust ignition TDC of cylinder 4
•   Place crankshaft on marking
Note:   Ensure that camshaft timing chain does not get stuck.
24.   Lower vehicle by its full height
25.   Position camshaft timing chain
Note:   The green marking must be positioned at marking "INT" of the intake camshaft sprocket.
Important:   The red marking must be positioned at marking "EXH" of the exhaust camshaft sprocket. Rotate exhaust camshaft on hexagonal section until exhaust camshaft sprocket can be inserted.
26.   Attach exhaust camshaft sprocket
•   Replace bolt
•   Screw in bolt
27.   Pull back locating bolts
•   From intake camshaft sprocket
28.   Pre-tension chain tensioner
•   Replace 2x seal rings
•   Detach retaining ring (2)
•   Pull piston (3) out of housing (1)
– Tension piston at square in vice
– Lock inner piston (4) to last detent (5) by turning clockwise
•   Insert piston into housing
Object Number: 8132431 Size: DEFAULT


29.   Tension chain tensioner 75 Nm
•   Tension chain tensioner
Note:   Undo lock by pressing down the chain in the area of the tension rail for the camshaft timing chain.
Object Number: 2402051 Size: DEFAULT


30.   Raise vehicle by its full height
31.   Adjust ignition TDC of cylinder 4
Note:   Turn crankshaft 720° in the direction of rotation of the engine
•   Place crankshaft on marking
32.   Lower vehicle by its full height
33.   Timing, Check
•   Slide in locating bolts
Note:   If the locating bolts do not fit in the camshaft sprocket holes provided, the camshaft timing chain must be reseated. The coloured chain links are no longer valid as TDC reference points.
34.   Remove KM-6148
35.   Clean 2x threads
36.   Install upper sliding rail
•   Tighten 2x bolt 8 Nm
Note:   Use screw locking compound (red)
37.   Fasten exhaust camshaft sprocket
Note:   2nd mechanic is required.
•   Tighten bolt 85 Nm + 30°
Note:   Counterhold at camshaft hexagon.
38.   Fasten intake camshaft sprocket
Note:   2nd mechanic is required.
•   Tighten bolt 85 Nm + 30°
Note:   Counterhold at camshaft hexagon.
39.   Install cylinder head cover LUREF_1.gif
40.   Top up engine oil.
•   Observe specified engine oil quantity
•   Start engine and allow to run until oil pressure control indicator goes off
•   Check engine oil level, correct if necessary
41.   Close bonnet
42.   Program volatile memories

Replace timing chain (secondary) > < Hydraulic Chain Tensioner, Replace (Primary)