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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

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

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.

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