Camshafts (Opel Frontera B)

Removal

Set the piston of the 1st cylinder to TDC in the compression stroke (see the relevant chapter).

Remove the vacuum pump (see the relevant chapter).

Mark the installation position and remove the single-row chain tensioner (1).



Heat the bolts (2) for fastening the single-row chain guide with a hair dryer and unscrew them.

Mark the installation position and remove the single-row chain guide by lifting it upwards.

Remove the measuring tool KM-932 from the cylinder head and remove the thrust pin KM-927 from the hole in the fuel injection pump pulley.

Remove the camshaft sprocket mounting bolt, holding the shaft by the hexagon with a wrench to prevent it from turning.



Remove the camshaft sprocket from the single row chain. To facilitate assembly, secure the single-row chain to the timing case.

Warning: Before removing the camshaft bearing caps, mark their mounting position.

Loosen the camshaft bearing cap bolts by turning them half a turn or a full turn in a spiral motion in the sequence shown in the illustration. Then, in the same sequence, unscrew the bolts, remove the bearing caps, and then the camshaft.

Warning! If the camshaft is to be replaced, the valve rocker arms must also be replaced.

Installation

Clean the mating surfaces of the camshaft bearing cap and remove any remaining sealant.

Check the condition of the camshaft and bearing caps for wear and mechanical damage and, if necessary, replace damaged parts with new ones.

When replacing the camshaft, install new rocker arms, using the installation marks located on the ends adjacent to the fuel rail.

Apply a thin layer of sealant to the areas indicated by arrows in the figure.



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Inspect the working surfaces of the camshaft and cam bearings for scratches and wear. If such damage is found, replace the camshaft. If the cylinder head running surfaces are excessively worn, replace the cylinder head.

Lubricate the contact surfaces of the tappets and camshaft with grease MoS2 and carefully install the camshafts back into place in the cylinder head.

Warning! When installing, the identification numbers on the camshaft bearing caps must match the numbers on the cylinder head.

Install the camshaft bearing caps and tighten their mounting bolts in a spiral pattern, following the sequence shown in the figure. First tighten all bolts by half a turn or a full turn, and then tighten them in the same sequence to a torque of 15 Nm.



Place a single row chain on the camshaft sprocket and secure the sprocket to the camshaft by screwing in and hand tightening a new bolt.

Warning! The sprocket must fit snugly on the shaft.

Install the guide (1) of the single-row chain in accordance with the previously applied marks.



Using new bolts (2), secure the single-row chain guide and tighten the bolts to 8 Nm.





Make sure that the arrow (1) on the sprocket of the single-row high-pressure fuel pump (HPFP) drive chain matches the slot on the HPFP flange and the corresponding hole (2) in the fuel pump.



Fix the fuel injection pump in this position by inserting the KM-927 stop pin (3) into the fuel injection pump hole.

Install the thrust shoe (1) of the adjusting device (4) KM-933 into the hole of the camshaft sprocket. Secure the KM-933 tool to the cylinder head.



Insert the handle (2) into the hole in the stop shoe and gently push it in the direction of the arrow (in the direction opposite to the direction of rotation of the engine parts) and fix the shoe in this position with the clamping bolt (3).





Make sure that the KM-927 thrust pin moves freely in the hole, otherwise, relieve the pressure on the thrust shoe by loosening the bolt.

Tighten the new camshaft sprocket bolt as follows:;

• 1st pass: 90 Nm;
• 2nd pass; turn to an angle of 60°;
• 3rd pass: turn to an angle of 30°.

Install the single-row chain tensioner (4) into the cylinder head with the closed side of the chain tensioner facing the tensioner guide. Screw on the cover (2) with a new sealing ring (3) and tighten it to a torque of 60 Nm.

Warning! After installing a new single-row chain tensioner, disengage the tensioning mechanism by separating the pin (1). The pin will snap into place when you hear a distinctive click.

Remove all special adjustment devices.



Using the vibration damper mounting bolt, turn the crankshaft in the direction of engine rotation so that the TDC mark of the 1st cylinder piston (3) on the vibration damper is positioned opposite the mark (2) on the rear casing of the timing drive.



Make sure that in this position of the piston of the 1st cylinder, the camshaft cams (1) are directed upwards.

To prevent the crankshaft from turning, insert the KM-929 stop pin (1) into the hole for the crankshaft position sensor. If necessary, carefully turn the crankshaft in the direction of engine rotation until the thrust pin is fully seated in the corresponding hole.



Make sure that after fixing the crankshaft, the timing marks (3) are opposite each other.





Install the measuring tool KM-932 (3) on the cylinder head. The pin (2) must be located in the hole (1) of the camshaft.



Install all previously removed parts, then set the piston of the 1st cylinder to TDC in the compression stroke.