How to Replace the Both Camshafts Opel Combo C

Important: Cleanliness is absolutely essential when working on the fuel system because even small dirt particles can lead to disruption to engine operation or the fuel system. Open fuel systems must be sealed with appropriate sealing plugs from the kit (45 06 154). Sealing plugs are only designed to be used once.

Note. The customer should be informed of the choice between ECOService and ECOService-Flex before the oil change.

Important: On vehicles with ESP - the steering angle sensor loses its basic adjustment each time the battery is disconnected. It must be recalibrated.

Remove

1. 1. Open bonnet

Important. On vehicles with ESP - the steering angle sensor loses its basic adjustment each time the battery is disconnected. It must be recalibrated.

2. 2. Disconnect battery
3. 3. Remove engine cover. • Detach engine cover

Note. Rubber retainers must remain on the engine cover.

4. 4. Remove air cleaner housing (1) • Disconnect wiring harness plug of mass air flow meter (3) – Unclip from retaining clip (arrow) • Release clamp (4) • Remove bolt (2) • Detach front intake hose (5)

5. 5. Remove charge air pipe (1) • Release 2x clamp • Unscrew 2x bolt (arrows) • Unclip wiring harness • Detach hose

6. 6. Separate wiring harness plug for differential pressure sensor (1) and temperature sensor (3) • Unclip wiring harness from bracket (2)

Note. On vehicles with diesel particle filter

7. 7. Remove fuel filter housing (2) • Disconnect 4 lines (1) and (4) – Use KM-796-A • Disconnect 2 wiring harness plugs – Housing cover (3) – Housing bottom (arrow) • Close 4 fuel lines

8. 8. Loosen coolant compensation tank • Unclip coolant compensation tank
9. 9. Remove crash box • Remove nut • Remove nut
10. 10. Remove wiring harness for engine management • Disconnect 7x wiring harness plugs – Oil pressure switch – Crankshaft sensor – MAP sensor – EGR valve – Fuel rail pressure valve – Fuel rail pressure sensor – Starter/alternator wiring harness plug • Disconnect wiring harness – Unscrew 3 bolts – Release cable ties • Set wiring harness to one side
11. 11. Detach 4x high-pressure lines for injectors • Loosen 8 union nuts
12. 12. Detach 2x fuel line (1) • Release 2x clamp

13. 13. Detach high pressure line (2) • High-pressure line from high-pressure pump to fuel rail • Loosen 2 union nuts
14. 14. Detach accumulator (1) • Detach oil leak line • Detach 2 return lines – Release clamp • Use KM-796-A • Unscrew 2x bolt (arrows)

15. 15. Detach 4x oil leak line • Release 4x retaining clamp (arrows)

16. 16. Release 2x injector bracket (3) • Unscrew 2 nuts (1)
17. 17. Remove 4 injectors

Note. The injectors (2) can only be removed in pairs (cylinder 1+2 or cylinder 3+4).

18. 18. Remove right engine damping block
19. 19. Remove support for engine damping block (1) from cylinder head and cylinder block • Unscrew 4 bolts (2)

20. 20. Unscrew closure bolt (1)
21. 21. Remove closure cap (2) • Unscrew 4 bolts (arrows)

22. 22. Remove 2 closure bolts from camshaft housing • Unscrew 2 bolts • Clean 4x threads on closure bolt and camshaft housing

23. 23. Lock camshafts • Screw 2x reference drift EN-46781 (1) into camshafts • The reference drift used for fixing must be fitted in a horizontal position. • Turn the camshafts on the camshaft drive pinion screw in direction of engine rotation until EN-46781 latches into both camshafts

Note. Check for proper installation position!

Note. As an aid, apply marking (2) to reference drift.

Note. Using a suitable tool through the opening in the timing case, turn the screw on camshaft drive gear for exhaust camshaft.

Note. The reference drift is securely engaged in the camshaft when it can no longer be turned.

24. 24. Raise vehicle all the way
25. 25. Lock the crankshaft • Insert EN-46785 (1) through the opening in the bottom of the gearbox bell housing • To fix EN-46785 , attach screw (2) to gearbox bolt screw head. • Carefully turn crankshaft until EN-46785 engages in flywheel

26. 26. Lower vehicle fully
27. 27. Detach drive gear for exhaust camshaft • Detach drive gear screw (1) with suitable tool through the opening in the timing case.

Note. Do not unscrew bolt.

28. 28. Tighten timing chain tensioner • Tighten timing chain tensioner (1) with a suitable tool and lock in pretensioned position with KM-955-1 (2).

29. 29. Detach exhaust camshaft drive gear from exhaust camshaft • Remove bolt • Remove drive gear from exhaust camshaft with a rigid angled wire (1).

30. 30. Detach timing case from camshaft housing • Unscrew bolt, bracket (1) • Unscrew 8 bolts (arrows)

31. 31. Remove camshaft housing (3) • Unscrew 16x bolt (2) • Unscrew 2x threaded pin (1) • Carefully detach camshaft housing from timing case using a rubber mallet • Carefully detach gasket between camshaft housing and timing case from the camshaft housing using a plastic spatula • Remove camshaft housing • Remove gasket (4)

Note. Note dissimilar bolt lengths

32. 32. Remove timing case gasket • Cut the elastomer sealing lip (arrow) flush to the cylinder head using a sharp knife • Detach gasket from timing case with a plastic spatula and carefully fold up at the nominal break point (1). • Remove gasket. • Remove gasket residue and thoroughly clean all sealing surfaces

Note. Ensure that no gasket residue remains at the joining points between the timing case and cylinder head, and that no gasket residue drops into the timing case.

33. 33. Detach vacuum pump (1) from camshaft housing • Unscrew 2 bolts, vacuum pump

34. 34. Remove high pressure pump (1) from camshaft housing • Unscrew 3 bolts

35. 35. Detach camshaft sensor (2) • Remove bolt (1)

36. 36. Release 2x pinions, camshaft • Release bolt (2) pinion, intake camshaft • Release bolt (1) pinion, exhaust camshaft

37. 37. Remove 2 camshaft reference drifts EN-46781
38. 38. Remove intake camshaft • Remove bolt • Remove gear wheel

Note. Pay attention to mark (IN)

39. 39. Remove exhaust camshaft • Remove bolt • Remove gear wheel

Note. Pay attention to mark (EX)

Install

40. 40. Install exhaust camshaft • Coat bearing surfaces with engine oil • Insert pinion – Bolt in bolt

Note. Pay attention to mark (EX)

41. 41. Install intake camshaft • Coat bearing surfaces with engine oil • Insert pinion – Bolt in bolt

Note. Pay attention to mark (IN)

42. 42. Lock camshafts • Screw 2x reference drift EN-46781 (1) into camshafts • The reference drift used for fixing must be fitted in a horizontal position. • Turn the camshafts on the camshaft drive pinion screw in direction of engine rotation until EN-46781 latches into both camshafts

Note. Check for proper installation position!

Note. As an aid, apply marking (2) to reference drift.

Note. Using a suitable tool through the opening in the timing case, turn the screw on camshaft drive gear for exhaust camshaft.

Note. The reference drift is securely engaged in the camshaft when it can no longer be turned.

43. 43. Attach 2x pinions, camshaft • Tighten bolt (1) pinion, exhaust camshaft 150 Nm • Tighten bolt (2) pinion, intake camshaft 150 Nm

Note. Attach pinions (3) in position shown!

44. 44. Attach camshaft sensor • Use new gasket • Tighten bolt 7 Nm
45. 45. Attach high pressure pump to camshaft housing • Replace seal ring • Tighten 3x bolts 15 Nm

Note. Adapter plate (1) must engage in groove (2) of camshaft

46. 46. Install vacuum pump • Replace gasket • Tighten 2 bolts – Tighten bolt (1) 5 Nm – Tighten bolt (2) 5 Nm – Tighten bolt (1) 20 Nm – Tighten bolt (2) 20 Nm

Note. There are 2 steps to the tightening sequence

47. 47. Cut elastomer sealing lip (arrow) at nominal break point of new gasket using a sharp knife.

48. 48. Separate new timing case gasket at lower nominal break point • Separate gasket at both nominal break points (arrow) with pincers (1)

Note. The cutting tool must have a straight cutting surface.

Important. The new upper gasket and old lower gasket must not overlap!

49. 49. Adapt new seal on timing case • Adapt the new gasket (1) to the contact surface of cylinder block to timing case using pincers until the gasket lies flush on the cylinder head and timing case (arrow), and the holes in the gasket and timing case align

50. 50. Clean all contact surfaces
51. 51. Attach new camshaft housing gasket • Clean all contact surfaces • Apply sealant to the contact surface of cylinder head to timing case (1) • Apply camshaft housing gasket • Apply sealant to contact surface of gasket, camshaft housing to timing case (1)

Note. Check 2x centring pins

52. 52. Install camshaft housing • Unscrew 2x screw connection on timing case gasket • Apply camshaft housing • Tighten 16x bolts in tightening sequence until camshaft housing lies flat on the cylinder head

Note. Do not tighten bolts yet

Note. Note longer bolt (14)

53. 53. Attach timing case to camshaft housing • Carefully align camshaft housing to timing case using a rubber mallet • Screw in 5x bolts (arrows) until camshaft housing lies on timing case

54. 54. Attach camshaft housing • Tighten 16x bolts M7 according to tightening sequence 18 Nm • Tighten 2 stud bolts (M8) 25 Nm

55. 55. Attach timing case • Tighten 8x bolts (arrows) 9 Nm • Screw in bolt (1) bracket, and tighten 9 Nm

Important. Contact surfaces of exhaust camshaft, drive gear, bolts and threads in exhaust camshaft must be free from oil and grease!

56. 56. Insert drive gear for exhaust camshaft • Lay drive gear on exhaust camshaft with suitable tool • Bolt in bolt

Note. Do not tighten yet

57. 57. Tension timing chain tensioner • Release timing chain tensioner with suitable tool and remove KM-955-1
58. 58. Attach drive gear for exhaust camshaft • Tighten bolt 150 Nm

Note. During tightening of the timing chain, a second person must tension the timing chain tensioner (1) with a suitable tool (2).

59. 59. Remove exhaust camshaft lock • Remove camshaft reference drift EN-46781
60. 60. Raise vehicle all the way
61. 61. Remove crankshaft lock • Remove EN-46785
62. 62. Timing, Check • Turn crankshaft in direction of engine rotation at torsional vibration damper flange bolt by approx. 700° (2 revolutions) • Lower vehicle fully • Fit camshaft reference drift EN-46781 (1) in camshaft housing for exhaust camshaft • Check for proper installation position • Turn crankshaft in direction of engine rotation until EN-46781 engages in exhaust camshaft • Raise vehicle all the way • Fit EN-46785 • Turn crankshaft until EN-46785 engages in flywheel • If EN-46785 does not engage in the flywheel, repeat the "Timing adjustment" procedure

Note. The fixing reference drift must be fitted in a horizontal position. Fit the guide mark on the reference drift (arrow).

63. 63. Remove EN-46785
64. 64. Lower vehicle fully
65. 65. Remove EN-46781
66. 66. Fit exhaust camshaft closure bolt • Coat closure bolt with thread locking compound • Tighten closure bolt 15 Nm

Note. Complete working step within 10 minutes because of the reaction time of the thread locking compound.

67. 67. Fit timing case closure cap • Check gasket for damage • Tighten 4 bolts 9 Nm
68. 68. Install timing case closure bolt • Check gasket for damage • Tighten closure bolt
69. 69. Attach support for engine damping block to cylinder head and cylinder block • Insert and tighten 4x bolts 60 Nm
70. 70. Install right engine damping block
71. 71. Replace 4x seal ring • For injectors in camshaft housing
72. 72. Install 4 injectors • Replace 4 injector seal rings (1)

Note. Injectors can only be inserted in pairs (cylinder 1+2 or cylinder 3+4).

73. 73. Fasten 2 injector brackets • Tighten 2 nuts 20 Nm
74. 74. Attach 4x oil leak line • Lock 4x retaining clamp
75. 75. Attach accumulator • Tighten 2 bolts • Attach 2 return lines – Fasten clamp
76. 76. Attach high pressure line for high pressure pump to fuel rail • Tighten union nut (M14) 28 Nm • Tighten union nut (M12) 24 Nm
77. 77. Attach 2x fuel line • Secure 2x clamp
78. 78. Attach 4 high-pressure lines • Tighten 4 union nuts (M14) 28 Nm • Tighten 4 union nuts (M12) 24 Nm
79. 79. Attach wiring harness for engine management • Connect 7 wiring harness plugs • Tighten 3 bolts
80. 80. Install crash box • Tighten 2 nuts 25 Nm
81. 81. Install fuel filter housing • Connect 2 wiring harness plugs • Connect 4 lines
82. 82. Connect wiring harness plug for differential pressure sensor and temperature sensor • Clip wiring harness to bracket

Note. On vehicles with diesel particle filter

83. 83. Fasten coolant compensation tank • Clip in coolant compensation tank
84. 84. Install charge air pipe • Attach 2 clamps 3.5 Nm • Tighten 2 bolts • Attach wiring harness • Attach hose
85. 85. Install air cleaner housing • Attach front intake hose • Tighten bolt • Fasten clamp • Connect wiring harness plug of mass air flow meter – Clip to retaining clip
86. 86. Install engine cover.
87. 87. Connect battery
88. 88. Program volatile memory
89. 89. Close bonnet