Removal
1. Loosen the mounting bolts and remove the cylinder head cover.
2. Remove the timing belt from the camshaft timing gear (see section Removal and installation the timing belt).
3. Remove the camshaft timing gear (see section Removal and installation the oil pan).
4. Remove the upper bolts securing the rear timing belt cover.
5. Loosen the mounting bolts and remove the camshaft bearing caps. In doing so, unscrew all the bolts in the specified on the accompanying illustration sequence first by 1/2, then by 1 turn and then completely unscrew them. Remove the bearing caps.
The order of loosening the bolts securing the camshaft bearing caps
6. Remove the camshaft by separating it evenly from its mounting seats.
7. Carefully remove the camshaft oil seal.
Examination
1. Carefully examine the condition of the bearing journals and camshaft cams. If scoring or scratches are detected, replace the shaft. Also check the condition of the working surfaces of the plain bearings in the camshaft housing supports. Damaged and worn supports can be replaced.
2. Having placed the camshaft in the prisms, determine the value of its radial runout (by bearing journals) using a plunger-type dial gauge. If the measurement results are outside the permissible range (see Specifications in Chapter Engines) the camshaft must be replaced.
3. The camshaft oil seal must also be replaced.
4. Assess the degree of wear and the general condition of the working surfaces of the valve drive levers that contact the camshaft cams. If cracks, cavities, grooves, and scoring are detected, the levers should be replaced.
5. Check the condition of the camshaft thrust plate and replace it if necessary.
If the axial play of the shaft is increased, the plate must also be replaced.
Installation
1. Before installing the camshaft, set all pistons to the same height. To do this, turn the crankshaft 90 degrees forward or backward from the position corresponding to the TDC of the piston of the first cylinder.
2. Lubricate the sliding surfaces of the plate tappets with MoS2 grease.
3. Lubricate all bearing surfaces on the camshaft and cylinder head with engine oil.
4. Install the camshaft, making sure the pin faces up.
The camshaft pin must be facing upwards when installed
5. Lubricate the mating surfaces of the first camshaft bearing (from the toothed belt side) on the cylinder head with a sealant, for example, OPEL 15 03 294. Make sure that the sealant does not get on the cams.
Mating surfaces of the first camshaft bearing
6. Install the camshaft bearing caps.
7. Tighten the bearing cap mounting bolts in several steps in the reverse order indicated in the illustration with effort 15 Nm.
In this case, the piston of the first cylinder should not be in the TDC position, otherwise there is a risk of damage to the camshaft.
8. Install a new seal using a drift, after lubricating it with engine oil.
9. Install the camshaft gear.
10. Set the crankshaft to the position corresponding to the TDC of the piston of the first cylinder (see section Procedures for repairing diesel engines without removing them from the vehicle).
11. Install the timing belt (see section Removal and installation the timing belt).
12. Check the valve clearance (see Chapter Vehicle settings and routine maintenance).
13. Install the cylinder head cover with a new sealing gasket and tighten the mounting bolts with force 8 Nm.
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