Removal
Removal using Opel tool No. MKM-891
With the special Opel tool #MKM-891, the camshaft can be removed from the engine without first dismantling the timing case. The tool is installed on the case with the cover removed (see Fig. Removal and installation the timing cover) and allows you to press out the hydraulic valve clearance compensators. Next, the shaft gear is dismantled (see Removal and installation the timing belt tensioner and timing drive gears), end cap and thrust plate (see next paragraph). Now the shaft can be removed from the housing through the hole in its left end.
Before installing the device, rotate the crankshaft 90° from the TDC position (see Checking the compression pressure in the cylinders), which will prevent the risk of engine damage due to the valves coming into contact with the piston crowns.
Removal without using a special tool
Without using a special device, the camshaft can only be removed from the engine together with the valve train housing. Since the housing is bolted with the same bolts as the cylinder head, the latter also has to be removed (see Removal and installation the cylinder head).
Theoretically, it is possible to remove the shaft with the housing while leaving the head on the block, but this is associated with the risk of damaging the sealing gasket. When deciding to perform work using this option, refer to the materials Removing and installing the oil pan, taking into account the fact that there is no need to remove the intake manifold and exhaust manifold. Remember that after installing the camshaft assembly with the timing case, it may be necessary to replace the head sealing gasket, which will negate all efforts to (by the way, quite insignificant) saving time.
1. After removing the timing case with the camshaft installed in it, unscrew the mounting bolts and remove the ignition module.
2. Unscrew the mounting bolts and remove the end cover installed on the left side of the timing case. Remove the sealing ring from the case - you can throw it away, since the ring must be replaced during assembly.
3. Measure the axial clearance of the camshaft by inserting the blades of the measuring gauge between the thrust plate (1) and the shaft. If the measurement result is outside the permissible range (see Specifications), the thrust plate must be replaced. Unscrew the two fixing bolts and remove the thrust plate from the housing - try to remember the installation position of the components.
4. Carefully remove the shaft from the housing, being careful not to damage the bearing journals and the working surfaces of the cams.
Examination
1. Measure the height (I) of the timing case from mating surface to mating surface. If the measurement result is less than 65 mm, replace the case.
2. After removing the shaft, examine the condition of the working surfaces of the plain bearings in the housing beds. If signs of obvious wear or scoring are detected, the housing must be replaced - also check the condition of the corresponding shaft journals.
Also check the patency of the oil drains provided in the housing.
3. The shaft itself should not have any traces of scratches on the journals and working surfaces of the cams. If such defects are present, the shaft should also be replaced. If scoring is detected on the working surfaces of the cams, examine the condition of the drive levers of the corresponding valves (see Removal, inspection and installation of valve drive components).
4. Check that there are no signs of wear or wear on the camshaft thrust plate; replace the plate if necessary.
Installation
1. Using a screwdriver, carefully remove the old oil seal from its seat in the timing case. Check the cleanliness of the seat walls, then press the new oil seal into it (with sealing lips inward) flush with the outer surface of the housing.
2. Generously lubricate the camshaft, housing support bearings and seal lips with clean engine oil, then carefully insert the shaft into the housing - try not to damage the cams, journals and seal lips.
3. Insert the thrust plate into its regular place — make sure it is correctly aligned with the groove in the shaft journal. Tighten the mounting bolts with the required force. Check the amount of axial play of the shaft (see above).
4. Install a new sealing ring on the clean, dry-wiped rear surface of the housing. Install the end cover and tighten the bolts securing it to the required torque.
5. Install the ignition module onto the housing.
6. If removal was carried out using the Vauxhall tool, remove it and refit the camshaft sprocket. Return the crankshaft to TDC and refit the timing belt (see Removal and installation the timing belt and Removal and installation the timing belt tensioner and timing drive gears).
7. If the device was not used, install the timing case with the shaft inserted into it in its place and secure it with the cylinder head bolts (see Removal and installation the cylinder head).
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