Removal, installation and inspection of camshafts and valve lifters (Opel Vectra C)

1. The procedure for removing/checking/installing camshafts is fundamentally the same for all engines. It is described in most detail for petrol engines Z16XE/Z18XE. For the rest, the main attention is paid to the features of each specific engine.

2. When removing the bearing caps, follow the established sequence. The cap fasteners must be loosened evenly, in a spiral from the edges inward, in several steps, 1-0.5 turns per approach. On engines whose camshafts are installed on supports cast directly in the cylinder head, special care must be taken when loosening the fasteners and removing the bearing caps. Careless handling can damage the camshaft supports or the bearing cap. If at least one cap is broken, the entire cylinder head will have to be replaced - during manufacture, the caps are processed together with the head and individually on the spare parts market. are not supplied! Installation and tightening of the cap fasteners is carried out in the reverse order of their removal.

Engines Z16XE/Z18XE

Removal

3. On models with timing belt drives, to remove the camshafts, you must first remove the toothed belt

Before loosening the timing belt, move the engine out of TDC by turning the crankshaft at 60° counterclockwise so that neither piston is at TDC.

4. Before removing the cylinder head cover, first remove the ignition module. Disconnect all electrical wiring connectors and hoses. Unscrew the mounting bolts and remove the cover.



5. Remove the camshaft timing gears.



6. Remove the camshafts. First remove the exhaust camshaft: moving in a spiral from the edges inwards (in the sequence shown in the accompanying illustration), in several steps, evenly loosen the bolts securing the upper shaft covers, then completely unscrew the bolts.

7. When removing the upper camshaft covers, pay special attention to the numbering of the covers; during assembly, they must be installed strictly in their original places; the numbering of the camshaft support bearing covers is shown in the accompanying illustration. If for any reason the marks are missing, they must be applied independently using a marker.





8. Lift the camshaft and remove it from the engine, carefully remove the oil seal.

9. Proceeding in a similar manner, remove the intake camshaft - when installing the shafts must be installed only in their places.

10. 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

11. 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).

12. 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.

13. 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 must also be replaced if the valve mechanism has recently been accompanied by increased noise levels.

Installation

14. Before installation, lubricate the mating surfaces of the camshafts with molybdenum-containing grease (containing MoS2). Clean the mating surfaces of the guide (front) bearings (see illustration),apply fresh sealant (green color).





15. Install the intake valve shaft first and tighten the mounting bolts in the reverse order of loosening (see illustration 10.6), then install the exhaust valve shaft.



16. Press in new seals using the tool KM-422 (see illustration) or other suitable tool. Before installation, lubricate the outer surfaces of the seals with silicone grease (white color).

17. Before installing the cylinder head cover, clean all mating surfaces, replace the gaskets on the cover and apply fresh sealant (black color). Install the cover onto the cylinder head and tighten the mounting bolts to the required torque.





18. Install the camshaft sprockets/wheels.

19. Adjust the valve timing and install the timing belt (with appropriate equipment). Reinstall all removed components.

Features for Z22YH/Z22SE/Z20NET engines

Note: The difference of the Z20NET engine is the installation of a slightly different ignition system (see Chapter 5) and related operations for its dismantling. Otherwise, the procedure for removing/installing camshafts is similar to that described below.

20. Set the piston of the first cylinder to the TDC position, remove the upper timing chain guide (see Illustration 8.76 to Section 8) and loosen the timing chain by unscrewing the chain tensioner (see illustration 8.77).





21. Unscrew 3 bolts and remove the high pressure petrol pump (see illustration). Remove the camshaft sensor.

22. Hold the camshafts from turning with an open-end wrench on the hexagonal part of the shaft (see illustration), loosen the camshaft sprocket mounting bolts, install the special toolKM-6148 and completely unscrew the bolts securing the sprockets - the sprockets should remain on the guides of the installed device.



23. Please note that the exhaust shaft has 5 bearings, and the intake shaft has 6 (see illustrations). All upper camshaft bearing caps have their own number. Unscrew the mounting bolts of the exhaust camshaft bearing caps, remove the caps and remove the shaft. Then remove the intake camshaft.







24. Before installation, lubricate the mating surfaces of the camshafts and hydraulic tappets with molybdenum grease (containing MoS3). Install the intake valve shaft first, apply sealant strips (gray color) on mating surfaces (see illustration) under the installation of the guide bearing cover and tighten the mounting bolts in the reverse order of loosening, then install the exhaust valve shaft.



25. Install the camshaft sprockets and secure them with new bolts, adjust the valve timing and reinstall all components that were removed. Follow the instructions in Section 8 when installing the timing chain tensioner.

Features for the Z32SE engine

26. Remove the timing belt.

27. Relieve the pressure in the fuel supply system, disconnect the electrical wiring and lines of the fuel tank ventilation systems and the fuel supply line.

28. Disconnect the PCV hose from the throttle module and the engine coolant hose from the expansion tank. Disconnect the electrical connectors and disconnect the brake booster line.



29. Release the crankcase ventilation hose from the holder, unscrew the 6 mounting bolts (see illustration), disconnect the coolant hose and remove the pressure chamber. Close the air intake tract channels with suitable plugs.



30. Remove the ignition modules, then unscrew the bolts and remove the cylinder head covers.

31. Remove the camshaft sensor and, holding the shafts from turning by the hexagonal sections with an open-end wrench, remove the gears from them (see illustration).



32. Unscrew the cover mounting bolts and remove the camshafts first for cylinders 1-3-5, then for cylinders 2-4-6 (see illustration).

Note: The exhaust shafts must be removed first.

33. Apply sealant when installing (black color) on mating surfaces (see illustration 10.14) support (front) bearing caps, install the caps and tighten them in the reverse order of removal. Replace the camshaft seals, press them in using the KM-422 device and gear mounting bolts.

34. Install the gears on the shafts. When installing the gears, the engine crankshaft should be in a position where the piston of the first cylinder has not reached TDC by approximately 60' - the position of the gear marks is shown in the accompanying illustration.



35. Install the toothed belt and adjust the valve timing.

36. Further installation is carried out in the reverse order of removal.

Features for Y20DTH/Y22DTR engines

37. Remove the engine cover, separate the vacuum pump housing from the cylinder head, remove the multi-rib belt and belt tensioner. Set the TDC position for the piston of the first cylinder and fix it.

38. Remove the tensioner (see illustration) single-row chain, heat the 2 mounting bolts with hot air and unscrew them. Remove the upper guide of the single-row chain.



39. Remove the TDC checking tools, unscrew the mounting bolt and remove the camshaft sprocket.

40. Check availability of numbers (see illustration) on the camshaft bearing caps, if necessary, apply marks yourself. Gradually loosen and unscrew the mounting bolts in the order shown in the illustration, remove the caps.



41. Installation is carried out in the reverse order of removal. Apply sealant before installing the covers (green color) on the mating surfaces of the support bearing (see illustration).



42. After installing the upper chain guide, it is necessary to set the TDC position for the piston of the first cylinder, for which install the device KM-933 (see illustration), press the sprocket counterclockwise and secure it in this position using the locking bolt. Install the device KM-927 into the hole of the fuel injection pump drive sprocket. If the device is not installed, align the holes by loosening the locking bolt. Install the chain tensioner and tighten it to the required force.

Features for Y30DT engine

Note: The design feature of the timing belt of this engine is that the support bearings are made on a separate timing belt housing. If necessary, they can be replaced without changing the cylinder head.

Note: Preparatory work to gain access to the camshafts is quite labor-intensive, requiring the removal of a large number of small parts, hoses, lines and sensors. These operations are provided in abbreviated form, if necessary, contact an Opel service station.

43. Remove the top engine cover, disconnect and remove the battery with the tray, remove the air cleaner, remove the expansion tank cap.

44. Raise the vehicle on a lift, remove the engine crankcase protection and drain the coolant.

45. Remove the exhaust system and the catalytic converter mounting bracket (see illustration).



46. Remove the air cleaner, fuel filter and expansion tank.

47. Disconnect and remove all lines mounted on top of the engine such as coolant hoses, power steering vacuum lines, fuel lines, PCV lines, turbocharger oil lines, air intake and exhaust manifold components, vacuum pump, as well as the electronic engine control module and other sensors mounted on the engine heads. The mounting of some of the more important components is shown in the accompanying illustrations.







48. Install the special device KM-6352 and remove the right engine mount, then the timing belt. Remove the rear lifting eye.

49. Remove the 12 mounting bolts and remove the camshaft housing/cylinder head cover 1-3-5.

50. Disconnect and remove the lines (see illustration) lubrication system. Loosen the 3 nuts and remove the 2 mounting brackets and injectors.



51. Remove 13 screws and 3 bolts strictly following the established sequence (see illustration) and remove the camshaft housing together with the shafts.

Note: The bolts are of different lengths, please remember or mark their installation locations.

Remove 2 bolts and 2 nuts and remove the front camshaft housing cover.

52. Using special devices (see illustration) loosen and remove the camshaft drive gear mounting bolt. If necessary, use an assistant.



53. Unscrew 5 bolts and remove the gear mounting housing, unscrew 8 bolts, remove 4 covers (see illustration) support bearings and remove the camshafts.



54. If necessary, secure the exhaust camshaft in a vice and remove the retaining ring (see illustration), compensation washers and spring. Remove the compensation gear from the shaft.



55. The procedure for removing the camshafts of cylinders 2-4-6 is almost the same as described above. The difference is that the shafts have 5 bearing caps. It is necessary to first loosen the mounting bolts of all caps, then remove the front cover (2) (see illustration). Unscrew 2 bolts and remove the cover (1) of the additional bearing. Remove the remaining covers.



56. Installation is performed in the reverse order of removal. Before installation, clean all mating surfaces. Replace all gaskets, apply fresh sealant instead of the removed one. Tighten the mounting housing bolts of the camshaft drive gear for cylinders 1-3-5 (see illustration). The bolts for fastening the gear housing of cylinders 2-4-6 are tightened in mirror order. Do not forget to replace the camshaft drive oil seals, press in new oil seals using the appropriate device and gear mounting bolts.



57. If the exhaust camshaft was disassembled, install the spring in place, making sure it is seated correctly. Install the compensation washers so that the recess on the washer matches the installation hole (see illustration), and using a special device, turn the compensation gear until all the mounting holes are aligned and fix it from turning by installing a punch with a diameter of approximately 3 mm.



58. When installing the shafts into the housing, the marks on the gears must match (see illustration 10.58a). After installing the shafts, do not forget to remove the drift from the exhaust shaft gear. Tightening the camshaft housing screws/bolts should be done in the reverse order of their release (see illustration 10.51). The tightening sequence for the camshaft housing covers is shown in Illustration 10.58b.