Removal and installation the timing cover (Opel Astra G)

Removal

Engines 1.7L SOHC

1. Remove the air cleaner housing assembly with the air ducts and air flow meter (see Chapter Power and exhaust systems).

2. Loosen the clamps and disconnect the PCV hoses that run to the front and rear of the cover - you will need to remove the two bolts that secure the wiring to the camshaft cover, lifting the wiring to gain access to the rear PCV hose.



3. Remove the crankshaft pulley. Unscrew the mounting bolts and remove the timing cover together with the sealing gasket.

Engines 1.7L DOHC

1. Remove the air cleaner and air intake ducts together with the air mass meter (see Chapter Power and exhaust systems).

2. Remove the engine control module (ECM) from the timing cover (see Chapter Power and exhaust systems).

3. Disconnect the wiring harness, loosen the mounting screws/nut and remove the ECM mounting bracket.

4. Loosen the mounting bolt, disconnect the wiring harness and remove the engine lifting eye from the rear right side of the cylinder head. Loosen the mounting bolt of the left rear lifting eye.

5. Loosen the union connectors securing the fuel pipes to the high-pressure fuel pump.

Access to the nipple connections is limited - the authors of this Manual consider it necessary to unscrew the filter/oil cooler housing fastening bolt and remove the sponge filling from the space between the high-pressure fuel pump and the filter housing.

6. Disconnect the fuel supply lines from the injectors.

7. Loosen the mounting bolts and remove the outer injector seals.

8. Remove the bolt securing the wiring routing channel to the rear of the cylinder head. Release the two fasteners and remove the channel.

9. Loosen the bolts securing the upper timing drive cover to the valve train drive.

10. Unscrew the mounting bolts and remove the timing cover together with the sealing gasket.

11. Check the condition of the sealing gasket and replace it if necessary.

2.0L Engines

1. Loosen the mounting screws and remove the upper plastic cover from the timing cover.

2. Loosen the clamps and disconnect the PCV hose from the rear of the cover zafira models remove the engine compartment seal and the cover of the fairing installed in front of the windshield.

3. On engines with low-pressure turbocharging (X20DTL or Y20DTL) loosen the clamps securing the metal tube to the turbocharger assembly and the rubber sleeve to the pipeline, unscrew the two mounting bolts and remove the air duct assembly from the engine together with the sealing ring installed between the tube and the compressor engines with high-pressure turbocharging (Y20DTH) release the clamps, unscrew the bracket mounting bolts and remove the air hose laid between the turbocharger and the intercooler.





4. On all models release the glow plug wiring from the retainers on the back of the cover. Remove the bolt securing the intake manifold wiring channel to the cover. Disconnect the vacuum hose connected to the right side of the cover.

5. Unscrew the cover mounting bolts and remove them together with the sealing washers. Lift the cover and remove it together with the sealing gasket. Check the condition of the sealing gaskets and washers; replace any defective elements.

Installation

Engines 1.7L SOHC

1. Make sure that the mating surfaces of the cover and the body are absolutely clean and dry. Carefully place the sealing gasket on the cover.



2. Press the cover onto the body, making sure that the sealing gasket does not move. Screw in the mounting bolts and tighten them to the required torque.



3. Connect the crankcase ventilation hoses and secure them with clamps.

4. Install the air intake ducts and air cleaner housing.

Engines 1.7L DOHC

1. Make sure the mating surfaces are absolutely clean and dry, place the sealing gasket in the cover groove. Check the condition of the sealing ring at the bottom of the cover, replace if necessary.



2. Apply sealant to the mating surfaces, being careful not to get any into the oil hole in the right rear of the exhaust camshaft. The injector seals are marked "UPPER" and "OUTSIDE".





3. Carefully place the cover in its regular place, making sure that the sealing gasket does not shift. Install the upper section of the timing cover. Screw in the timing cover mounting bolts and tighten them to the required force.



4. Further installation is carried out in the reverse order of removal of the components, please note the following points:

5. All bolts must be tightened strictly to the required force;

6. The outer seals of the injectors are marked with the words "UPPER" and "OUTSIDE" - install the seals, making sure that they are placed on the cones of the injectors;

7. After starting the engine, carefully inspect it for signs of developing leaks.

2.0L Engines

1. Make sure that the mating surfaces are absolutely clean and dry, place the sealing gasket in the cover groove.



2. Place the sealing washers on the cover mounting bolts. Install the bolts on the cover, making sure that the lower shoulders of their heads secure the sealing washers.



3. Apply sealant to the semicircular cutout on the right side of the mating surface of the cylinder head and to both sides of the left bearing cover.





4. Carefully place the cover back in place, screw in and hand tighten all mounting bolts.

5. Tighten all mounting bolts to the required torque.

6. Connect the vacuum hoses to your fittings, secure the electrical wiring in the clamps. Connect the PCV hose to the back of the cover.

7. On low-pressure turbo models, install the air intake duct and air tube - be sure to replace the O-ring. Make sure the clamps and fasteners are tight. On high-pressure turbo models, reinstall the turbocharger-to-intercooler sleeve. Make sure the fasteners are tight.

8. On all models, fit the plastic cover and tighten the bolts securely. On Zafira models, fit the engine bay seal and front fairing panel.