How to replace timing chain on Vauxhall/Opel Astra G 2.2i

Special tools

• Camshaft locking tool – No.KM-6148.
• Crankshaft pulley holder – No.KM-956-1/KM-J-38122-A.
• Tensioner locking tool – No.KM-6077.

General precautions

• Disconnect battery earth lead.
• Remove spark plugs to ease turning engine.
• Turn engine in normal direction of rotation (unless otherwise stated).
• Observe tightening torques.
• If fitted: Mark position of crankshaft position (CKP) sensor before removal.
• Do NOT turn crankshaft via camshaft or other sprockets.
• Do NOT turn crankshaft or camshaft with timing chain removed.

Valve timing procedures

Removal

• Ensure crankshaft at TDC on No.4 cylinder [1] & [2] .
• Install camshaft locking tool [3] . Tool No.KM-6148.
• Remove timing chain tensioner [4] .
• Check tensioner for identification marks [5] . If tensioner not marked: Replace tensioner and tensioner rail.
• Remove:
  • Camshaft locking tool.
  • Exhaust camshaft sprocket.
  • Inlet camshaft sprocket complete with timing chain.
  • Balancer shaft chain tensioner [6] .
  • Tensioner rail and chain guides.
  • Balancer shaft chain.

Installation

• Ensure crankshaft at TDC on No.4 cylinder.
• Install balancer shaft chain.
• Align copper coloured chain links with timing mark on each sprocket [7] , [8] & [9] .
• Install timing chain guides and tensioner rail.
• Lock balancer shaft tensioner before installation:
  • Turn plunger clockwise.
  • Press plunger into tensioner body.
  • Insert tensioner locking tool [10] . Tool No.KM-6077.
• Install balancer shaft tensioner [6] .
• Remove tensioner locking tool [10] .
• Install timing chain.
• Install inlet camshaft sprocket.

NOTE: Bolts for camshaft sprockets MUST only be used once.

• Align copper coloured chain link with camshaft sprocket timing mark [11] .
• Install upper timing chain guide.
• Install lower timing chain guide.
• Install exhaust camshaft sprocket.
• Align copper coloured chain link with camshaft sprocket timing mark [12] .
• Ensure copper coloured chain links aligned with timing marks on crankshaft sprockets [9] .
• Install timing chain tensioner rail. Apply Loctite to bolt threads.
• Lock timing chain tensioner before installation:
  • Remove tensioner plunger.
  • Turn inner plunger clockwise until locks.
  • Refit tensioner plunger.

  NOTE: Always renew tensioner ‘O’ rings.

• Press tensioner rail briefly against tensioner to unlock tensioner plunger.
• Ensure timing marks aligned [7] , [8] , [9] , [11] & [12] . If not, repeat installation procedures.
• Turn crankshaft two turns clockwise.
• Ensure crankshaft at TDC on No.4 cylinder [1] & [2] .
• Install camshaft locking tool [3] . Tool No.KM-6148.
• Remove camshaft locking tool [3] .

NOTE: Crankshaft pulley bolt MUST only be used once.