Camshaft Position Actuator Replacement Opel Agila B

Remove

1. 1. Disconnect battery negative lead • Release nut
2. 2. Raise vehicle to suitable working height
3. 3. Remove wheel from vehicle, right side • Remove wheel trim cover – Pull off • Remove 4x wheel bolt
4. 4. Raise vehicle
5. 5. Remove splash panel from vehicle, right side • Remove 2x bolt (1), 4x clip (2)

6. 6. Lower vehicle
7. 7. For vehicles with air conditioning, release tension from air conditioning compressor drive belt • Release bolt (1) • Rotate bolt (2) anti-clockwise until tension is released
8. 8. Remove air conditioning compressor drive belt

9. 9. Remove ribbed V-belt • Release 2x bolt (1, 2) • Rotate belt tensioner adjuster bolt (3) anti-clockwise until tension is released
10. 10. Remove ribbed V-belt

11. 11. Release engine harness from air cleaner housing (1) • Release clip
12. 12. Release air cleaner housing with resonator from cylinder head cover and bracket • Remove 2x bolt (2)

13. 13. Remove air cleaner element from air cleaner housing (3) • Release cover (1) from air cleaner housing – Release 2x clip (2), 2x locator
14. 14. Remove air cleaner housing with resonator from cylinder head cover • Pull off to release 2x rubber locator

15. 15. Remove 4x ignition coil module (3) from 4x spark plug • Disconnect 4x harness connector (2) • Remove 4x bolt (1)

16. 16. Disconnect engine vent hose (1) from engine vent valve (2) • Release clip

17. 17. Remove dipstick from engine
18. 18. Release engine harness from cylinder head cover • Release 2x clip
19. 19. Disconnect breather hose from cylinder head cover • Release clip
20. 20. Release 2x harness bracket from cylinder head cover • Remove 2x bolt
21. 21. Remove cylinder head cover (1) from cylinder head • Remove 14x bolt in stages, in sequence shown
22. 22. Remove rubber gasket from cylinder head cover

23. 23. Rotate crankshaft clockwise until notch (4) on crankshaft pulley aligns with '0' timing mark (3) on timing chain cover, with No. 1 piston at top dead centre on compression stroke • Align intake camshaft position actuator (2) and exhaust camshaft position actuator (1) timing marks with surface of cylinder head

Note. Ensure valves on No.1 cylinder are fully closed.

24. 24. Apply match marks to 2x timing chain links (1) which align with timing marks (2) on intake camshaft position actuator (3) and exhaust camshaft position actuator (4)

25. 25. Install Holding Tool KM-6047 to crankshaft pulley • Install 2x bolt
26. 26. Release crankshaft pulley from crankshaft • Release bolt – Counter-hold pulley using Holding Tool KM-6047

Note. 2x technician are required.

27. 27. Remove Holding Tool KM-6047 from crankshaft pulley • Remove 2x bolt

28. 28. Raise vehicle to suitable working height
29. 29. Remove pulley (1) from crankshaft • Remove bolt • Use Puller KM-210-3 (2) and Pad EN-49150

30. 30. Remove cover plate (1) from timing chain cover • Remove 3x bolt (2) • Remove rubber gasket
31. 31. Remove timing chain tensioner (3) from cylinder block • Install suitable fixing bolt (4) to timing chain tensioner – Use M3 bolt of 30 mm length and 0.5 mm pitch • Tighten fixing bolt until tip of bolt contacts plunger of timing chain tensioner • Then tighten fixing bolt by 45° (a) • Remove 2x bolt (5)

32. 32. Install crankshaft pulley to crankshaft • Install bolt; do not tighten at this stage
33. 33. Lower vehicle
34. 34. Release timing chain (1) from 2x sprocket on intake camshaft position actuator (2) and exhaust camshaft position actuator (3) • Counter-hold intake camshaft (4) and exhaust camshaft (5) • Position timing chain on top of 2x camshaft position actuator

35. 35. Remove intake camshaft then exhaust camshaft from cylinder head • Release 21x bolt, 9x camshaft bearing cap in stages, in sequence shown • Release timing chain from 2x camshaft position actuator and position to one side • Remove 21x bolt, 9x camshaft bearing cap
36. 36. Install camshaft as required to soft jawed vice • Secure hexagonal section of camshaft to soft jawed vice
37. 37. Remove camshaft position actuator from camshaft • Remove bolt

Install

38. 38. Install new camshaft position actuator to camshaft • Install bolt 60 Nm
39. 39. Remove camshaft from soft jawed vice
40. 40. Clean mating surfaces of 9x camshaft bearing cap and cylinder head
41. 41. Install exhaust camshaft then intake camshaft to cylinder head • Apply clean engine oil to sliding surfaces of camshafts • Position timing chain on to 2x camshaft position actuator; do not locate to 2x sprocket on 2x camshaft position actuator at this stage • Install 9x camshaft bearing cap, 21x bolt; do not tighten at this stage • Align intake camshaft position actuator and exhaust camshaft position actuator timing marks with surface of cylinder head

42. 42. Secure intake camshaft and exhaust camshaft to cylinder head • Install 21x bolt 11 Nm in stages, in sequence shown
43. 43. Secure timing chain to 2x sprocket on 2x camshaft position actuator • Check notch (4) on crankshaft pulley aligns with '0' timing mark (3) on timing chain cover, with No. 1 piston at top dead centre on compression stroke • Align intake camshaft position actuator (2) and exhaust camshaft position actuator (1) timing marks with surface of cylinder head • Counter-hold intake camshaft and exhaust camshaft with spanner and adjust as necessary • Align match marks on 2x timing chain link with timing marks on intake camshaft position actuator and exhaust camshaft position actuator

44. 44. Raise vehicle to suitable working height
45. 45. Remove pulley from crankshaft • Remove bolt
46. 46. Remove fixing bolt (1) from timing chain tensioner (2)
47. 47. Reset timing chain tensioner • Rotate plunger (3) clockwise, then install suitable retainer (4) of approximately 1.4 mm diameter into hole in tensioner body to lock plunger in position

48. 48. Install timing chain tensioner (3) to cylinder block • Rotate intake camshaft anti-clockwise until timing chain becomes taut, then Install 2x bolt (5) 11 Nm • Apply tension to timing chain – Remove retainer from timing chain tensioner

Note. 2x technician are required.

49. 49. Clean mating surface of timing chain cover and cover plate
50. 50. Install cover plate (1) to timing chain cover • Install new rubber gasket • Install 3x new bolt (2) 11 Nm

51. 51. Install pulley to crankshaft • Install bolt; do not tighten at this stage
52. 52. Lower vehicle
53. 53. Install Holding Tool KM-6047 to crankshaft pulley • Install 2x bolt
54. 54. Secure crankshaft pulley to crankshaft • Secure bolt 150 Nm – Counter-hold pulley using Holding Tool KM-6047

Note. 2x technician are required.

55. 55. Remove Holding Tool KM-6047 from pulley • Remove 2x bolt

56. 56. Check timing chain alignment • Rotate crankshaft clockwise 2x revolutions clockwise until notch (4) on crankshaft pulley aligns with '0' timing mark (3) on timing chain cover, with No. 1 piston at top dead centre on compression stroke • Ensure intake camshaft position actuator (2) and exhaust camshaft position actuator (1) timing marks align with surface of cylinder head

Note. Ensure valves on No.1 cylinder are fully closed.

57. 57. Clean mating surfaces of cylinder head cover and cylinder head
58. 58. Install new rubber gasket to cylinder head cover
59. 59. Apply silicone sealant to positions A on cylinder head cover (2) – see “Sealants, Adhesives and Lubricants”

60. 60. Install cylinder head cover (1) to cylinder head • Install 14x bolt, do not tighten at this stage • Secure 14x bolt 7.5 Nm in sequence shown

61. 61. Secure 2x harness bracket to cylinder head cover • Install 2x bolt
62. 62. Connect breather hose to cylinder head cover • Secure clip
63. 63. Secure engine harness to cylinder head cover • Secure 2x clip
64. 64. Install dipstick to engine
65. 65. Connect engine vent hose (1) to engine vent valve (2) • Secure clip

66. 66. Install 4x ignition coil module to 4x spark plug • Install 4x bolt 11 Nm • Connect 4x harness connector

67. 67. Install air cleaner housing with resonator (3) to cylinder head cover • Push on to secure 2x rubber locator
68. 68. Install air cleaner element to air cleaner housing • Secure cover (1) to air cleaner housing – Secure 2x locator, 2x clip (2)

69. 69. Secure air cleaner housing with resonator (1) to cylinder head cover and bracket • Install 2x bolt (2)
70. 70. Secure engine harness to air cleaner housing • Secure clip

71. 71. Install ribbed V-belt • Rotate bolt (3) clockwise until deflection of belt when thumb pressure applied is 4.0 mm - 4.5 mm at position arrowed • Secure bolt (1) 25 Nm • Secure bolt (2) 45 Nm

Note. If new belt is installed, deflection is 3.0 mm - 3.5 mm .

72. 72. For vehicles with air conditioning, install compressor ribbed V-belt • Rotate bolt (2) clockwise until deflection of belt when thumb pressure applied is 7.0 mm - 8.0 mm at position arrowed • Secure bolt (1)

Note. If new belt is installed, deflection is 6.0 mm - 7.0 mm .

73. 73. Raise vehicle
74. 74. Install splash panel vehicle, right side • Install 4x clip (2), 2x bolt (1)

75. 75. Lower vehicle to suitable working height
76. 76. Install wheel to vehicle, right side • Grease centering seat of wheel hub • Install 4x wheel bolt
77. 77. Lower vehicle
78. 78. Secure wheel to vehicle, right side • Secure 4x wheel bolt 85 Nm • Install wheel trim cover – Push on
79. 79. Connect battery negative lead • Secure nut 11 Nm
80. 80. Program all volatile memories – see operation “Program Volatile Memories”
81. 81. Check and correct engine oil level