Adjust Valve Play Opel Astra G

Important: When working on the fuel system it is essential to pay attention to cleanliness as even the smallest dirt particles can lead to faults in engine operation or in the fuel system. Open fuel connections must be sealed with appropriate plugs from the Opel Parts Catalogue (catalogue number: 45 06 154 / part number: 9201697). Sealing plugs are only intended to be used once.

Remove

1. 1. Open bonnet
2. 2. Disconnect battery
3. 3. Remove bonnet (2) • Remove oil filler cap (1) • Pull off engine cover – 3 off • Replace oil filler cap

Note. Rubber retainers (3) must remain in cover

4. 4. Remove air cleaner housing (4) • 1 wiring harness plug (1) • 1 fastening bolt (3) • Air intake manifold – 1 clamp (2)

5. 5. Remove air intake manifold (1) • Unclip wiring harness – 3 clips • 2 clips • 2 fastening bolts

6. 6. Remove charge air pipe (1) • 6 fastening bolts

7. 7. Detach wiring harness of injectors • 4 wiring harness plugs (2) • 2 fastening bolts (3) • Glow plug wiring harness plug (1) – using KM-717 – 4 wiring harness plugs • Push wiring harness aside

8. 8. Place collecting basin underneath.

Important. After detaching the pressure lines, seal the openings on the injectors and the pressure chamber with protective caps 1)

9. 9. Remove high pressure lines (1) from pressure chamber to injectors • 8 union nuts – with KM-812 or KM-6098 • Remove pressure lines

10. 10. Remove oil leak hose (1) • from injectors – 4 securing clips • from pressure chamber • 2 fastening bolts • 1 fastening nut

Note. Press in direction of arrow

Note. Note different bolt lengths

11. 11. Remove engine transport shackle (1) • rear right • 2 fastening bolts

12. 12. Remove engine transport shackle (1) • rear left • Unclip wiring harness – 1 clip • 1 fastening bolt

13. 13. Remove dipstick guide tube holder (1) • Unclip vacuum line – 2 clips • Remove dipstick guide tube – 1 clip • Detach from camshaft housing – 2 fastening bolts

14. 14. Remove injector connection seals (1) • 4 off • 8 fastening bolts

15. 15. Remove injector seals (1) • 4 off • 8 fastening bolts

16. 16. Remove camshaft housing cover (1) • 9 fastening bolts

Note. Note different bolt lengths

17. 17. Remove injectors (1) • Remove injector brackets (2) – 4 fastening bolts

Note. Identify injectors

Note. If the heat protection sleeve (5) is pulled out with an injector, the seals (3) must be replaced and the sleeve tapped into the cylinder head with KM-6357 (4)

18. 18. Check injector bracket New injector bracket Old injector bracket

Note. If an old injector bracket is fitted, this must be replaced with a new injector bracket

Adjust

19. 19. Turn crankshaft • Turn the crankshaft until cam pairs (1) and (2) are pointing upwards
20. 20. Check valve play • with feeler gauge – Test values: Intake valve/Exhaust valve (0.35 - 0.45 mm)

Note. Valve play must be checked at room temperature when the engine is cold

21. 21. Adjust valve play • Turn the cup tappets until the tappet grooves are facing outwards • Press the cup tappets down with KM-6090 – IN marking = intake side – EX marking = exhaust side • Remove shim

Important. In doing this, make sure that the valves do not knock the floor of the piston

Note. Note different tool versions for intake and exhaust valves

22. 22. Example for determination of shim thickness: 1. Thickness of installed shim 3.15 mm 2. Measurement between cam and cup tappets + 0.45 mm = 3.60 mm 3. Nominal valve play - 0.40 mm 4. Thickness of new shim = 3.20 mm
23. 23. Insert shim • Coat new shim (7) with engine oil and insert in cup tappet with identification mark facing downwards
24. 24. Turn crankshaft • in direction of engine rotation 180° – Check and adjust valve pair (6) and (2) • in direction of engine rotation 180° – Check and adjust valve pair (5) and (3) • in direction of engine rotation 180° – Check and adjust valve pair (4) and (1)

Note. Valve play must be checked again for all adjusted valves

Install

25. 25. Renew injector seals • 1 rubber seal (1) • 1 copper seal (2)

26. 26. Install 4x injector • Use KM-6358 (1) • Tighten 4x bolt firmly in three stages 1. Tighten bolt 40 Nm 2. Loosen bolt 3. Tighten bolt 32 Nm

27. 27. Apply sealing compound • Apply adhesive sealant to sealing surfaces (1) and (3)

Important. Oil return hole (2) must not be covered with adhesive sealing compound

28. 28. Fit camshaft housing cover • Replace seal • Tighten 9x bolt in the stated tightening sequence (1...9) 9.8 Nm

29. 29. Install 4x new injector seal (2) • Align injector seal • Coat 8x contact surface of bolt head (1) with special grease • Tighten injector seal firmly in 2 stages 1. Tighten 2x bolt 10 Nm 2. Tighten 2x bolt 19 Nm

Note. Sealing lip of the seal must be in contact with the injector with no gaps (arrow)

Note. Press injector seal against the camshaft housing cover with your hand during the tightening process

30. 30. Fit injector connection seals • 4 off • 8 fastening bolts

Note. "UP" mark must be at top

31. 31. Fit dipstick guide tube holder • to camshaft housing – 2 fastening bolts • Clip in vacuum hose – 2 clips • Dipstick guide tube – 1 clip
32. 32. Install engine transport shackle • rear left • 1 fastening bolt • Clip wiring harness into position – 1 clip
33. 33. Install engine transport shackle • rear right • 2 fastening bolts
34. 34. Fit oil leak hose • 1 fastening nut • 2 fastening bolts • Attach to injectors – 4 off • Attach to pressure chamber

Note. Note different bolt lengths

Important. Pressure lines must be unstressed when fitted

35. 35. Fit high pressure lines from pressure chamber to injectors • Insert pressure lines • Attach pressure lines to injectors – 4 union nuts – Tightening torque 25 Nm
36. 36. attach injector wiring harness • Glow plug wiring harness plug – 4 off • 2 fastening bolts • Injector wiring harness plug – 4 off
37. 37. Install air intake pipe. • 2 clips – Tightening torque 3.5 Nm • 2 fastening bolts • Clip wiring harness into position – 3 clips
38. 38. Install air cleaner housing • 1 fastening bolt – Tightening torque 15 Nm • Air intake manifold – 1 clip – Tightening torque 3.5 Nm • 1 mass air flow meter wiring harness plug
39. 39. Install engine cover • Remove oil filler cap • Push in engine cover – 3 rubber retainers • Replace oil filler cap
40. 40. Connect battery
41. 41. Programme volatile memories
42. 42. Close bonnet

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) Protective caps are available from the Opel Parts Catalogue under catalogue number: 45 06 154 / part number: 9201697