Removing and Installing Both Camshafts Opel Astra H

Caution

Before removing toothed belt – set engine to approx. 60° before TDC mark.

Remove

1. 1. Remove air filter housing with mass air flow meter • Detach mass air flow meter wiring harness plug (3) • Detach air intake hose from air intake pipe – Release clamp (2) • Unscrew bolt (1)

2. 2. Remove 2x bolts (1) and remove top front toothed belt cover from rear toothed belt cover

3. 3. Mark direction of travel of ribbed V-belt.
4. 4. Tension ribbed V-belt tensioner in direction of arrow
5. 5. Remove ribbed-V-belt

6. 6. Remove lower engine splash guard
7. 7. Tension ribbed V-belt tensioner (clockwise) • Lock using suitable drift
8. 8. Remove 2x bolt (1) and remove ribbed V-belt tensioner • Remove from compressor support

9. 9. Remove torsional vibration damper • Counterhold at toothed belt drive gear fastening bolt
10. 10. Remove 4 bolts (1) • Detach lower section of toothed belt cover from rear toothed belt cover

11. 11. Move crankshaft to "Cylinder no.1 ignition TDC" in direction of engine rotation • Rotate at toothed belt drive gear fastening bolt

Note. Notches on camshaft sprockets must align with marks (1) on cylinder head cover

12. 12. Lock camshaft in position • using KM-853 (2)
13. 13. Slacken the toothed belt tension roller
14. 14. Remove toothed belts from camshaft sprockets

15. 15. Disconnect wiring harness plug (2) from ignition module (4)
16. 16. Detach ignition module cover (1) in direction of arrow
17. 17. Remove 2x ignition module bolts and detach ignition module from spark plugs using KM-6009 (3)

18. 18. Detach wiring harness plug from camshaft sensor
19. 19. Unclip crankshaft pulse pick-up cable and dynamic oil level control from cylinder head cover
20. 20. Detach cylinder head cover from cylinder head • pay attention to seal rings
21. 21. Clean sealing surfaces and remove gasket remnants.
22. 22. Remove KM-853
23. 23. Release fixing bolts (3) from KM-6347 (1)

Note. Grooves in KM-6347 (arrows) must engage in camshaft sprocket.

24. 24. Insert KM-6347 into camshaft sprocket in conjunction with KM-956-1 (2)

Note. Ensure correct fitting

25. 25. Turn KM-6347 in direction of arrow and tighten fixing bolts
26. 26. Remove camshaft sprocket fixing bolt (4)
27. 27. Undo fixing bolts of KM-6347 and remove KM-6347 .
28. 28. Remove camshaft timing gear fixing bolt
29. 29. Remove camshaft timing gear

30. 30. Slacken camshaft bearing caps working in spiral from outside to inside in steps of 1/2 up to 1 turn
31. 31. Detach camshaft bearing caps from cylinder head and remove camshafts

32. 32. Clean sealing surfaces and remove gasket remnants.
33. 33. Check camshafts and bearing seats for wear, replace if necessary.

Install

34. 34. Coat sliding surfaces of hydraulic valve lifters and camshafts with MoS 2 lubricating paste (grey)
35. 35. Insert camshafts into cylinder head

Important. Code numbers on camshaft bearing caps must correspond with those on cylinder head. Apply surface sealant (green) to sealing surfaces (arrows) of guide bearings

36. 36. Attach camshaft bearing cap to cylinder head 8 Nm • Tighten in a spiral, starting at the centre and working outwards
37. 37. Push seal rings into camshaft bearing cover • using KM-422

Note. Use camshaft sprocket bolts and washers

38. 38. Install camshaft pulleys with timing marks on front.
39. 39. Attach camshaft sprockets with new bolts to camshaft 50 Nm + 60° + 15°
40. 40. Move camshaft sprockets to mark using KM-6347 Intake camshaft sprocket Exhaust camshaft sprocket

Note. Mark (1) on cylinder head cover aligns with notches on camshaft sprockets

41. 41. Lock camshaft sprockets in position with KM-853 (2)
42. 42. Detach KM-6347 from camshaft sprockets with KM-956-1

43. 43. First move camshafts, then crankshaft to "Cylinder no.1 ignition TDC" marks (short distance)
44. 44. Fixing camshaft sprockets in position • using KM-853 – See operation "Adjust timing"
45. 45. Position toothed belt
46. 46. Adjust timing
47. 47. Apply sealing compound (black) to sealing surfaces (arrows).
48. 48. Attach cylinder head cover to cylinder head with new seal rings (1) and new gaskets (2) 8 Nm
49. 49. Clip on crankshaft pulse pick-up cable and dynamic oil level control to cylinder head cover.
50. 50. Connect ignition module to spark plugs and attach to cylinder head 8 Nm
51. 51. Attach ignition module cover to cylinder head cover
52. 52. Connect wiring harness plug to ignition module
53. 53. Attach wiring harness plug to camshaft sensor.

54. 54. Attach lower section of toothed belt cover to rear toothed belt cover 6 Nm
55. 55. Attach torsional vibration damper to toothed belt drive gear 20 Nm • Counterhold at toothed belt drive gear fastening bolt
56. 56. Attach ribbed V-belt tensioner to compressor support 25 Nm
57. 57. Tension ribbed V-belt tensioner (clockwise) and remove fixing rod.
58. 58. Install lower engine splash guard
59. 59. Position ribbed V-belt • Ensure running direction and installation position of ribbed V-belt is correct
60. 60. Tension ribbed V-belt using ribbed V-belt tensioner
61. 61. Attach top front toothed belt cover to rear toothed belt cover 6Nm
62. 62. Install air cleaner housing with mass air flow meter • Insert air cleaner housing • Attach air intake hose to air intake pipe – Fasten clamp • Screw in bolt • Connect mass air flow meter wiring harness plug