Contents: Petrol engines ⬇ Features for the Z16XEP engine ⬇ Features for the Z18XE engine ⬇ Features for Z20LE(L/R/H) engines ⬇ Features for the Z14XEP engine ⬇ Diesel engines ⬇
Petrol engines
Removal
1. On models with a timing belt drive, to remove the camshafts, it is first necessary to remove the toothed belt (see Section 8). Before loosening the timing belt, move the engine out of TDC by turning the crankshaft 60° counterclockwise so that none of the pistons are at TDC.
2. Remove the camshaft gears (see section 5).
Note: Removal of the Z14XEP engine sprockets is described below.
3. Remove the cylinder head cover, for which you must first remove the ignition module (see Chapter 1, Section 22).
4. First of all, remove the exhaust camshaft: moving in a spiral from the edges inwards (in the sequence shown in the accompanying illustration), in several steps, 1-0.5 turns per approach, evenly loosen the bolts securing the upper shaft covers, then completely unscrew the bolts.
5. When removing the upper camshaft covers, pay special attention to the numbering of the covers - they must be installed strictly in their original places during assembly. If for some reason the marks are missing, they must be applied independently using a marker.
Caution: Failure to exercise caution when loosening the fasteners of the support bearing caps may result in their mechanical damage; careless handling may damage the camshaft supports. If even one cap is broken, the entire cylinder head will have to be replaced - during manufacture, the caps are processed together with the head and are not supplied to the spare parts market individually!
6. Lift the camshaft and remove it from the engine, carefully remove the oil seal (models with toothed belt).
7. Proceeding in a similar manner, remove the intake camshaft - when installing, the shafts must be installed only in their places.
8. Prepare 16 small transparent plastic bags or clean plastic cups and label them according to the valve numbers. Using the tools, remove the tappets from the head and place them in the appropriate cups.
Note: To prevent oil leakage from hydraulic lifters (with appropriate equipment) place the pushers with the working ends facing up.
Examination
9. Wipe the timing belt parts with a clean rag and carefully examine the condition of the bearing journals and camshaft cams. If scoring, scratches or signs of wear are detected on the camshafts, they must be replaced along with the hydraulic tappets. If wear or damage to the support bearings is detected, the cylinder head assembly must be replaced (see paragraph 5).
10. Alternately placing the camshafts in the prisms, use a plunger-type dial gauge to determine the value of their radial runout (by bearing journals). If the measurement results are outside the permissible range, the camshaft must be replaced.
11. Check the condition of the tappets and their mounting seats in the head. If signs of excessive wear of the working surfaces, cracks, scoring and other damage are detected, replace the tappets. Note: The tappets should also be replaced if the valve mechanism operation has recently been accompanied by increased noise.
Installation
12. Before installation, lubricate the mating surfaces of the camshafts with molybdenum-containing grease (with MoS2 content). Install the intake valve shaft first and tighten the mounting bolts in the reverse order of loosening (see illustration 10.4), then install the exhaust valve shaft.
13. Press in new seals using the KM-422 tool (see accompanying illustration) or other suitable tool. Before installation, lubricate the outer surfaces of the seals with silicone grease (white color). Install the cylinder head covers.
14. Install the camshaft gears (see Section 5).
15. Adjust the valve timing and install the timing belt (with appropriate equipment) (see Section 8). Reinstall all removed components.
Features for the Z16XEP engine
16. Before removing the cylinder head cover, it is necessary to disconnect all the supply connectors of the electrical wiring and the hoses of the crankcase ventilation system. Then unscrew the 3 front mounting bolts (see accompanying illustration), pull them up and secure them to the cover using adhesive tape. Remove the 6 remaining mounting bolts and remove the cover. Make sure that the front support bearing covers are (shown by arrows) if there are no traces of sealant left, wipe them off with a clean cloth.
17. The numbering of the camshaft support bearing caps is shown in the accompanying illustration.
18. Install a new gasket (see accompanying illustration 10.18a) into the cylinder head cover, unscrew the spark plug (see Chapter 1, Section 22) of the first cylinder and screw the KM-6354 device into its place (see contrast illustration 10.18b).
19. Carefully install the head cover so that the gasket does not fall out (see accompanying illustration): First the back side, and then gently press the front side of the cover.
Caution: If the gasket is not seated evenly when installing the cover, the engine may subsequently fail! Remove the device.
20. Remove the adhesive tape and tighten all cover mounting bolts. Screw in the spark plug of the first cylinder.
Features for the Z18XE engine
21. Before removing the cylinder head cover, disconnect all electrical wiring connectors and hoses. Unscrew the mounting bolts and remove the cover.
22. The numbering of the camshaft support bearing caps is shown in the accompanying illustration.
23. Before installing the camshaft support bearing caps, clean the mating surfaces of the guide (front) bearings (see accompanying illustration), apply fresh sealant (green color) and install the covers.
24. Before installing the cylinder head cover, clean all mating surfaces, replace the gaskets on the cylinder head cover (see accompanying illustration) and apply fresh sealant (black color). Install the cover onto the cylinder head and tighten the mounting bolts to the required torque.
Features for Z20LE(L/R/H) engines
25. Before removing the cylinder head cover, disconnect all electrical wiring connectors and hoses. Unscrew the mounting bolts and remove the cover.
26. The numbering of the camshaft support bearing caps is shown in the accompanying illustration.
27. Before installing the camshaft support bearing caps, clean the mating surfaces of the guide (front) bearings (see illustration 10.23), apply fresh sealant (green color) and install the covers.
28. The camshaft gears are different from each other (see accompanying illustration), install them in their places with the adjustment marks facing out.
29. Apply sealant (black color) at the joints, replace the gaskets on the cylinder head cover (see accompanying illustration). Install the cover and tighten the mounting bolts to the required torque.
Features for the Z14XEP engine
30. Set the piston of the first cylinder to the TDC position and loosen the timing chain by pulling the chain tensioner and fixing it using the device (see Section 6).
Note: If the timing belt cover has not been removed, to install the KM-955-1 device, you must first unscrew the chain tensioner cover.
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31. After unscrewing the 2 mounting bolts, remove the guide (see accompanying illustration) timing chains. Holding the camshafts from turning with an open-end wrench on the hexagonal part of the shaft, unscrew the mounting bolts and remove the camshaft sprockets.
32. Please note that all upper camshaft bearing caps have their own number (see accompanying illustration): 1, 3, 5, 7, 9 — exhaust valve shaft and 2, 4, 6, 8, 10 — intake valve shaft. Unscrew the fastening bolts of the exhaust camshaft support bearing caps, remove the caps and remove the shaft. Then remove the intake camshaft.
33. Before installation, lubricate the mating surfaces of the camshafts and hydraulic tappets with molybdenum grease (with MoS ₂ content). Install the intake valve shaft first and tighten the mounting bolts in the reverse order of loosening, then install the exhaust valve shaft.
Attention: When installing the shafts, the piston of the first cylinder must be at TDC.
34. Install the camshaft sprockets and secure them with new bolts, adjust the valve timing and reinstall all removed components (see Section 6).
Diesel engines
Z17DT(L/H) Engines
Removal
35. Disconnect the battery (see Chapter 5) and remove the fuel injection nozzles (see Chapter 4).
36. Remove the timing belt (see Section 8).
37. Turn the engine 60° counterclockwise and remove the camshaft timing gear (see Section 5).
Note: The wheel is mounted on the intake camshaft and drives the exhaust camshaft via a gear transmission.
38. Lock the exhaust camshaft together with the compensating gear from turning (see accompanying illustration), for which remove the support bearing cover closest to the shaft gears and install the KM-6092-10 device.
39. Moving in a spiral from the edges inwards (in the sequence shown in the accompanying illustration), in several steps, 1-0.5 turns per approach, evenly loosen the bolts securing the upper bearing caps of the shafts, then completely unscrew the bolts. Before removing the caps, mark them so that they can be installed in the same place later. Carefully remove the shafts - when removing the exhaust valve shaft, in addition to the KM-6092-10 device, install the KM-6092 device to securely fix the compensation gear on the camshaft gear (see ibid).
40. Carefully, so as not to damage the seating surfaces, remove the intake camshaft oil seal (see accompanying illustration).
Examination
41. The procedure for checking the timing components is the same as for petrol models (see above).
Installation
42. Lubricate the mating surfaces of the shafts with clean engine oil. Before installing the shafts, engage their gears and install the shafts on the engine so that the mark on the gear of the exhaust shaft is between the marks on the intake shaft (see accompanying illustration), and the marks should be approximately at the level of the upper edge of the camshaft housing. Apply sealant (green color) for sealing the joint of the first cover of the support bearings.
43. Replace the four front covers and hand tighten the bolts and nuts securing them.
Note: The arrows on the bearing caps must point towards the timing drive. Remove the KM-6092-10 tool and install the fifth support bearing cap.
44. Tighten 10 fastening nuts and 5 nuts to the required torque in several stages, one at a time, half a turn per approach, in the numbering order shown in the accompanying illustration.
45. Lubricate the outer surface of the new camshaft seal and install it using the KM-656 tool (see accompanying illustration).
46. Install the camshaft timing gear (see Section 5), adjust the valve timing (see Section 6), install the toothed belt (see Section 8) and check and adjust the thermal clearances of the valves (see Section 9). The installation of the remaining removed components is carried out in the reverse order of removal (see the relevant sections and chapters).
Removal/installation of the timing belt housing (using the example of an engine with a compressor drive K/V)
47. The design feature of the timing system of this engine is that the support bearings are made on a separate timing system housing. If necessary, they can be replaced without changing the cylinder head.
48. On models with an air conditioning system, before performing work, it is necessary to remove the refrigerant from the system using special service equipment (contact the Opel company service station) and first drain the coolant (see Chapter 3).
49. When removing attachments, in addition to the operations for removing the injectors (see Chapter 4) it is necessary to remove the throttle body, disconnecting all supply lines from it (see accompanying illustration).
50. Before removing the injectors, it is necessary to disconnect the cooling system pipes from the compressor, the electrical wiring connector, unscrew the 3 mounting bolts and remove the compressor, and then the compressor mounting bracket, the EGR radiator and the right lifting eye (see accompanying illustrations).
51. After removing the gears (see Section 5) disconnect the rear timing belt cover (see illustration 10.40), unscrewing 2 mounting bolts.
52. Unscrew 17 timing case fastening elements in order from 1 to 17 (see accompanying illustration) in several steps, releasing each element by 1-0.5 turns per approach, and remove the housing from the engine.
53. Installation, including tightening the timing case fastening, is carried out in the reverse order of removal - do not forget to replace the gasket under the timing case.
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