Vauxhall Workshop Service and Repair Manuals

Both Camshafts, Replace

Important:   Cleanliness is absolutely essential when working on the fuel system because even small dirt particles can lead to disruption to engine operation or the fuel system. Open fuel systems must be sealed with appropriate sealing plugs from the kit (45 06 154). Sealing plugs are only designed to be used once.

Note:   The customer should be informed of the choice between ECOService and ECOService-Flex before the oil change.

Important:   On vehicles with ESP - the steering angle sensor loses its basic adjustment each time the battery is disconnected. It must be recalibrated.

  Remove

4.   Remove air cleaner housing (1) •   Disconnect wiring harness plug of mass air flow meter (3) – Unclip from retaining clip (arrow) •   Release clamp (4) •   Remove bolt (2) •   Detach front intake hose (5)

5.   Remove charge air pipe (1) •   Release 2x clamp •   Unscrew 2x bolt (arrows) •   Unclip wiring harness •   Detach hose

6.   Separate wiring harness plug for differential pressure sensor (1) and temperature sensor (3) Note:   On vehicles with diesel particle filter •   Unclip wiring harness from bracket (2)

7.   Remove fuel filter housing (2) •   Disconnect 4 lines (1) and (4) – Use KM-796-A •   Disconnect 2 wiring harness plugs – Housing cover (3) – Housing bottom (arrow) •   Close 4 fuel lines

12.   Detach 2x fuel line (1) •   Release 2x clamp

13.   Detach high pressure line (2) •   High-pressure line from high-pressure pump to fuel rail •   Loosen 2 union nuts 14.   Detach accumulator (1) •   Detach oil leak line •   Detach 2 return lines – Release clamp •   Use KM-796-A •   Unscrew 2x bolt (arrows)

15.   Detach 4x oil leak line •   Release 4x retaining clamp (arrows)

16.   Release 2x injector bracket (3) •   Unscrew 2 nuts (1) 17.   Remove 4 injectors Note:   The injectors (2) can only be removed in pairs (cylinder 1+2 or cylinder 3+4).

18.	Remove right engine damping block

19.   Remove support for engine damping block (1) from cylinder head and cylinder block •   Unscrew 4 bolts (2)

20.   Unscrew closure bolt (1) 21.   Remove closure cap (2) •   Unscrew 4 bolts (arrows)

22.   Remove 2 closure bolts from camshaft housing •   Unscrew 2 bolts •   Clean 4x threads on closure bolt and camshaft housing

23.   Lock camshafts •   Screw 2x reference drift EN-46781 (1) into camshafts Note:   Check for proper installation position! •   The reference drift used for fixing must be fitted in a horizontal position. Note:   As an aid, apply marking (2) to reference drift. •   Turn the camshafts on the camshaft drive pinion screw in direction of engine rotation until EN-46781 latches into both camshafts Note:   Using a suitable tool through the opening in the timing case, turn the screw on camshaft drive gear for exhaust camshaft. Note:   The reference drift is securely engaged in the camshaft when it can no longer be turned.

25.   Lock the crankshaft •   Insert EN-46785 (1) through the opening in the bottom of the gearbox bell housing •   To fix EN-46785 , attach screw (2) to gearbox bolt screw head. •   Carefully turn crankshaft until EN-46785 engages in flywheel

27.   Detach drive gear for exhaust camshaft •   Detach drive gear screw (1) with suitable tool through the opening in the timing case. Note:   Do not unscrew bolt.

28.   Tighten timing chain tensioner •   Tighten timing chain tensioner (1) with a suitable tool and lock in pretensioned position with KM-955-1 (2).

29.   Detach exhaust camshaft drive gear from exhaust camshaft •   Remove bolt •   Remove drive gear from exhaust camshaft with a rigid angled wire (1).

30.   Detach timing case from camshaft housing •   Unscrew bolt, bracket (1) •   Unscrew 8 bolts (arrows)

31.   Remove camshaft housing (3) •   Unscrew 16x bolt (2) Note:   Note dissimilar bolt lengths •   Unscrew 2x threaded pin (1) •   Carefully detach camshaft housing from timing case using a rubber mallet •   Carefully detach gasket between camshaft housing and timing case from the camshaft housing using a plastic spatula •   Remove camshaft housing •   Remove gasket (4)

32.   Remove timing case gasket •   Cut the elastomer sealing lip (arrow) flush to the cylinder head using a sharp knife •   Detach gasket from timing case with a plastic spatula and carefully fold up at the nominal break point (1). •   Remove gasket. •   Remove gasket residue and thoroughly clean all sealing surfaces Note:   Ensure that no gasket residue remains at the joining points between the timing case and cylinder head, and that no gasket residue drops into the timing case.

33.   Detach vacuum pump (1) from camshaft housing •   Unscrew 2 bolts, vacuum pump

34.   Remove high pressure pump (1) from camshaft housing •   Unscrew 3 bolts

35.   Detach camshaft sensor (2) •   Remove bolt (1)

36.   Release 2x pinions, camshaft •   Release bolt (2) pinion, intake camshaft •   Release bolt (1) pinion, exhaust camshaft

  Install

42.   Lock camshafts •   Screw 2x reference drift EN-46781 (1) into camshafts Note:   Check for proper installation position! •   The reference drift used for fixing must be fitted in a horizontal position. Note:   As an aid, apply marking (2) to reference drift. •   Turn the camshafts on the camshaft drive pinion screw in direction of engine rotation until EN-46781 latches into both camshafts Note:   Using a suitable tool through the opening in the timing case, turn the screw on camshaft drive gear for exhaust camshaft. Note:   The reference drift is securely engaged in the camshaft when it can no longer be turned.

43.   Attach 2x pinions, camshaft Note:   Attach pinions (3) in position shown! •   Tighten bolt (1) pinion, exhaust camshaft 150 Nm •   Tighten bolt (2) pinion, intake camshaft 150 Nm

45.   Attach high pressure pump to camshaft housing Note:   Adapter plate (1) must engage in groove (2) of camshaft •   Replace seal ring •   Tighten 3x bolts 15 Nm

46.   Install vacuum pump •   Replace gasket •   Tighten 2 bolts Note:   There are 2 steps to the tightening sequence – Tighten bolt (1) 5 Nm – Tighten bolt (2) 5 Nm – Tighten bolt (1) 20 Nm – Tighten bolt (2) 20 Nm

47.   Cut elastomer sealing lip (arrow) at nominal break point of new gasket using a sharp knife.

48.   Separate new timing case gasket at lower nominal break point •   Separate gasket at both nominal break points (arrow) with pincers (1) Note:   The cutting tool must have a straight cutting surface.

Important:   The new upper gasket and old lower gasket must not overlap! 49.   Adapt new seal on timing case •   Adapt the new gasket (1) to the contact surface of cylinder block to timing case using pincers until the gasket lies flush on the cylinder head and timing case (arrow), and the holes in the gasket and timing case align

51.   Attach new camshaft housing gasket •   Clean all contact surfaces •   Apply sealant to the contact surface of cylinder head to timing case (1) •   Apply camshaft housing gasket Note:   Check 2x centring pins •   Apply sealant to contact surface of gasket, camshaft housing to timing case (1)

52.   Install camshaft housing •   Unscrew 2x screw connection on timing case gasket •   Apply camshaft housing •   Tighten 16x bolts in tightening sequence until camshaft housing lies flat on the cylinder head Note:   Do not tighten bolts yet Note:   Note longer bolt (14)

53.   Attach timing case to camshaft housing •   Carefully align camshaft housing to timing case using a rubber mallet •   Screw in 5x bolts (arrows) until camshaft housing lies on timing case

54.   Attach camshaft housing •   Tighten 16x bolts M7 according to tightening sequence 18 Nm •   Tighten 2 stud bolts (M8) 25 Nm

Important:   Contact surfaces of exhaust camshaft, drive gear, bolts and threads in exhaust camshaft must be free from oil and grease! 56.   Insert drive gear for exhaust camshaft •   Lay drive gear on exhaust camshaft with suitable tool •   Bolt in bolt Note:   Do not tighten yet

58.   Attach drive gear for exhaust camshaft •   Tighten bolt 150 Nm Note:   During tightening of the timing chain, a second person must tension the timing chain tensioner (1) with a suitable tool (2).

70.	Install right engine damping block

72.   Install 4 injectors Note:   Injectors can only be inserted in pairs (cylinder 1+2 or cylinder 3+4). •   Replace 4 injector seal rings (1)