Vauxhall Workshop Service and Repair Manuals

Seal camshaft housing to cylinder head

Warning:   When working on the Common Rail system, wait for one minute after switching off the engine. The system reduces the pressure automatically.

Important:   When working on the fuel system, pay strict attention to cleanliness as even the smallest particle of dirt may lead to malfunctions in engine operation or the fuel system. Seal opened fuel connections with suitable sealing plugs1. Sealing plugs are intended for single use.

  Remove

2.   Remove engine cover (1) •   Pull off engine cover Note:   Rubber retainers (3) must remain on engine cover. – Unclip coolant return hose from bracket – Unclip vacuum line (2) from bracket

3.   Disconnect battery •   Detach ground connection (1) from ground terminal – Slacken nut

5.   Remove air cleaner housing (1) with air intake hose (5) •   Disconnect 2x wiring harness plugs (2) •   Remove air intake hose from turbocharger – Release clamp (4) •   Detach oil separator hose from air intake hose – Release clamp (3) •   Detach water drain hose from lower part of air cleaner housing – Pull off hose from air cleaner housing •   Detach air cleaner housing from wheel housing – Press out from rubber retainer in 3 places

6.   Remove coolant expansion tank •   Unscrew bolt (1)

8.   Detach charge air pipe (1) from throttle valve module (3) •   Unscrew 2x bolts (2) •   Detach charge air pipe from transmission bracket – Unscrew bolt

10.	Remove mixture regulation oxygen sensor

11.   Detach turbocharger heat shield (1) •   Unscrew 2x nut (2) •   Undo nut (3)

20.   Remove oil leak line (1) •   Detach from fuel return pipe (2) •   Unlock 4x retaining clamps (3) in direction of arrow

Important:   Counterhold bolt at high pressure pump with open-ended wrench 21.   Remove high pressure line of high pressure pump (3) from accumulator (1) •   Unscrew 2x union nut Important:   Counterhold bolt at injector with open-ended wrench. 22.   Detach 4 high pressure lines from accumulator to injector (4) •   Unscrew 8x union nut 23.   Detach accumulator •   Unscrew 2x bolts (2)

28.	Remove 2x front wheelhouse front liner

30.   Remove engine compartment electronics module (1) •   Unclip from bracket •   Rotate the fuse box clockwise and release •   Release left headlamp wiring harness plug and pull it off •   Free the wiring harness in the vicinity of the left headlamp

31.   Detach wiring harness bracket (2) •   Unclip 2 wiring harnesses (3) •   Unscrew nut (1)

32.   Use CH-48373-3 (left-hand) •   Unfold support (1) Note:   Use a second person to hold the engine compartment electronics module

33.	Attach support frame and engine bridge

35.   Detach right engine damping block •   Unscrew 3 side member bolts (1) •   Unscrew 3 bolts (2) from the engine damping block support

37.   Insert CH-48373-2 (right-hand) from above •   Unfold support (1)

39.   Attach CH-48373-7 (1) to transmission •   Tighten 2 bolts (2)

40.   Place KM-904 (2) and CH-48373-1 with CH-48373-12 (3) on hydraulic jack (4) •   Attach 2x retaining pins •   Attach 2x cotter pins (1) •   Attach CH-48373-11 (5) •   Place probes (arrows) downward

41.   Support engine and transmission with hydraulic jack •   Connect CH-48373-2 (1) and CH-48373-3 (1) to CH-48373-1 •   Tighten 4 bolted connections •   Screw support (2) up until it is pressing gently against the rear reaction member bracket •   Screw support (3) up until it is pressing gently against CH-48373-7 •   Screw support (4) up until it is seated under gentle pressure in the hole provided for it in the cylinder block

44.	Remove the engine bridge and support frame

45.   Remove engine damping block adapter (1) •   Unscrew 4x bolts (2)

46.   Remove pressure reservoir bracket (1) with engine transport shackle (2) •   Unscrew 3x bolts (3)

47.   Remove 4x injector (3) •   Remove 2x injector bracket (2) – Unscrew 2x nuts (1) •   Remove 4x seal ring (arrows) •   Seal 4x injector with protective cap Note:   If the injectors cannot be removed manually, use EN-46786 connected to KM-328-B .

48.   Remove closure bolt (arrow) from intake side of camshaft housing

49.   Disconnect intake camshaft Note:   Apply guidance marking on reference drift (arrow). •   Screw in camshaft reference drift EN-46781 (1) •   Ensure correct installation position Note:   Reference drift fixing must be installed in a horizontal position.

51.   Lock crankshaft •   Insert EN-46785 (1) through hole in transmission bell housing •   Carefully turn crankshaft bolt until EN-46785 engages in flywheel

52.   Remove ribbed V-belt (1) •   Mark direction of rotation •   Apply tension clockwise to tensioner at tension roller bolt (arrow) •   Lock tensioner with KM-6130 (2) Note:   The ribbed V-belt must be removed to prevent contamination.

53.   Remove closure bolt (1) from timing case 54.   Remove chain tensioner closure cap (2) •   Unscrew 4x screw (arrows) Note:   Reuse gaskets.

56.   Tension timing chain tensioner •   Apply tension to chain tensioner (1) using a suitable tool, lock in pre-tensioned position KM-955-1 (2)

57.   Detach exhaust camshaft drive gear •   Unscrew fastening bolt Note:   Bolt is to be re-used. •   Using a bent piece of rigid wire (1), pull drive gear from exhaust camshaft

58.   Release timing case top from camshaft housing •   Unscrew 5x bolts (arrows) 59.   Detach engine cover bracket •   Unscrew bolt (1)

60.   Remove camshaft sensor (2) •   Unscrew bolt (1)

61.   Release camshaft housing (3) •   Unscrew 16x bolt (2) Note:   Note different bolt lengths. •   Unscrew 2x threaded pin (1) •   Remove gasket (4)

  Install

63.   Remove timing case gasket •   Cut into the elastomer sealing lips (arrows) using a sharp knife pressed against the cylinder head, •   With a plastic spatula, loosen the seal from the timing case and carefully snap it off at the designated point (1) •   Remove gasket •   Remove any gasket residue and clean all sealing surfaces thoroughly Note:   Make sure that no residues remain at the joint between the timing case and cylinder head, and that no bits of the gasket fall into the timing case.

64.   Fit timing case gasket •   Using a sharp knife, cut into the elastomer sealing lips (arrows) at the breaking points of the new gasket

65.   Cut the new timing case gasket off at the lower breaking points •   Using pincers (1), cut the seal at both breaking points (arrow) Note:   It is essential for the cutting tool to have a straight cutting surface.

Important:   The upper new gasket and the old lower gasket must not be allowed to overlap. 66.   Fit new timing case gasket •   Using the pincers, fit the new gasket (1) to the contact surface between the cylinder block and the timing case until the seal lies flush on the cylinder head and timing case (arrows) and the holes in the gasket and the timing case match up.

68.   Attach new camshaft housing gasket •   Clean all sealing surfaces •   Apply sealant to contact surfaces (1) of cylinder head and timing case •   Place gasket on camshaft housing

69.   Install camshaft housing •   Remove 2x fastening bolts and nuts from timing case gasket •   Position camshaft housing •   Screw in 16x bolts according to tightening sequence until the camshaft housing is lying evenly on the cylinder head, but do not tighten them yet Note:   Note longer bolt (14)

70.   Fasten timing case to camshaft housing •   Carefully align the camshaft housing on the timing case, using the rubber mallet. •   Screw in 5x bolt (arrows) until the camshaft housing is in contact with the timing case

71.   Fasten the crankshaft housing •   Tighten 16x bolt, observing the correct tightening sequence 18 Nm •   Tighten 2x stud bolt 25 Nm

72.   Tighten all bolts holding timing case to camshaft housing •   Tighten 5x bolts 9 Nm

Important:   The exhaust camshaft, drive gear, bolt and thread in exhaust camshaft must be free of oil and grease. 73.   Place drive gear on exhaust camshaft •   Position drive gear on exhaust camshaft using a suitable tool •   Screw in bolt Note:   Don not tighten yet!

75.   Fasten the exhaust camshaft drive gear •   Tighten bolt 150 Nm Note:   A second mechanic must hold the timing chain tensioner (1) under tension with a suitable tool (2) while the gear is being tightened.

86.   Clean 4x injector seat with EN-47632 •   Loosen dirt with the brush side (1) •   Remove dirt with the sponge side (2)

87.   Install 4x injector •   Replace 4x injector shaft seal ring •   Replace 4x injector seal ring (1) •   Tighten 2x nut 20 Nm

89.	Attach the engine bridge and support frame

103.	Remove the engine bridge and support frame

122.	Install 2x front wheelhouse front liners