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Replace Camshaft Timing Gears Opel Astra G

DOHC Petrol Engine 11 illustrations ~786 words

Remove

  1. 1. Open bonnet
  2. 2. Disconnect battery
  3. 3. Remove air cleaner housing (5) and air intake manifold (3) • 1 mass air flow meter wiring harness plug (4) • Unclip tank ventilation hose (1) • 1 fastening bolt (2) • 1 clip
  1. 4. Remove air intake manifold
  2. 5. Raise vehicle
  3. 6. Remove engine splash guard (2) • 4 bolts (1)
  1. 7. Set engine to 60° (measurement l) before TDC • Set crankshaft in direction of engine rotation to 60° (measurement l) before TDC
  1. 8. Lower vehicle
  2. 9. Remove upper part of toothed belt cover (1) • 2 bolts (2) • Release upper catch (3) • Pull upper part of toothed belt cover upwards by pulling gently on the stalk (arrow)
  1. 10. Remove toothed belt • Mark direction of rotation • Apply tension to toothed belt tension roller (2) in the direction of the arrow, using an Allan key (1). Fix using KM-6333 (3) – Remove toothed belt
  1. 11. Remove exhaust-side camshaft timing gear • Fit KM-6347 (1) and KM-956-1 (2) to the camshaft timing gear – Release fixing bolts (3) from KM-6347 – Fit KM-6347 to camshaft timing gear - ensure correct fitting – Turn KM-6347 in the direction of the arrow – Tighten fixing bolt • Release camshaft timing gear fixing bolt (4) – Hold using KM-6347 – 2 people • Remove KM-6347 – Release fixing bolts • Remove camshaft timing gear fixing bolt – Remove camshaft timing gear

Note. The grooves of KM-6347 (arrows) must engage with camshaft timing gear

  1. 12. Detach intake side camshaft pulley • Fit KM-6347 and KM-956-1 to the camshaft timing gear – Release fixing bolts from KM-6347 – Fit KM-6347 to camshaft timing gear - ensure correct fitting – Turn KM-6347 in the direction of the arrow – Tighten fixing bolt • Release camshaft timing gear fixing bolt – Hold using KM-6347 – 2 people • Remove KM-6347 – Release fixing bolts • Remove camshaft timing gear fixing bolt – Remove camshaft timing gear

Note. The grooves of KM-6347 must engage with camshaft timing gear

Install

  1. 13. Fit KM-6347 to exhaust-side camshaft timing gear • Initiate camshaft timing gear - observe marks • Insert camshaft timing gear fixing bolt (4) – Do not tighten – Fit KM-6347 (1) and KM-956-1 (2) to the camshaft timing gear – Release fixing bolts (3) from KM-6347 – Fit KM-6347 to camshaft timing gear - ensure correct fitting – Turn KM-6347 in the direction of the arrow – Tighten fixing bolt

Note. The grooves of KM-6347 (arrows) must engage with camshaft timing gear

  1. 14. Tighten exhaust-side camshaft timing gear • Hold using KM-6347 – 2 people – Tightening torque 50 Nm + 60° + 15° • Remove KM-6347
  2. 15. Fit KM-6347 to exhaust-side camshaft timing gear • Initiate camshaft timing gear - observe marks • Insert camshaft timing gear fixing bolt – Do not tighten – Fit KM-6347 and KM-956-1 to the camshaft timing gear – Release fixing bolts from KM-6347 – Fit KM-6347 to camshaft timing gear - ensure correct fitting – Turn KM-6347 in the direction of the arrow – Tighten fixing bolt

Note. The grooves of KM-6347 must engage with camshaft timing gear

  1. 16. Tighten exhaust-side camshaft timing gear • Hold using KM-6347 – 2 people – Tightening torque 50 Nm + 60° + 15° • Remove KM-6347
  2. 17. Fix camshaft timing gears using KM-6340 • Set camshaft timing gears in such a way that the marks (3) are opposite one another • Fit KM-6340-Left (1) to camshaft timing intake pulley • Insert KM-6340-Right (2)
  1. 18. Set engine to TDC • Set torsional vibration balancer in direction of engine rotation to "1st cylinder TDC position" (1)
  1. 19. Install toothed belt • Position toothed belt – Position toothed belt onto camshaft timing gear outlet – Position toothed belt on camshaft timing gear inlet – Apply tension to the toothed belt tension roller and remove KM-6333
  2. 20. Remove KM-6340
  3. 21. Turn crankshaft 720° • 2 revolutions in direction of engine rotation • Set toothed belt drivewheel to mark "1st cylinder TDC position" (1)
  1. 22. Fix camshaft timing gears using KM-6340 • Insert KM-6340-Left (1) • Insert KM-6340-Right (2)

Note. The marks (3) on the camshaft timing gears must be aligned - otherwise remove toothed belts and refit

  1. 23. Remove KM-6340
  2. 24. Fit front toothed belt cover • Upper part • 2 bolts – Tightening torque 6Nm
  3. 25. Fit air intake manifold pipe
  4. 26. Install air cleaner housing and air intake manifold • Place 1 mass air flow meter wiring harness plug • Clip in tank ventilation hose • 1 fastening bolt • 1 clip – Tightening torque 3.5Nm
  5. 27. Connect battery
  6. 28. Programme transient memory
  7. 29. Close bonnet

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