How to replace timing chain on Vauxhall/Opel Astra J 1.4i Turbo

Special tools

• Camshaft locking tool – No.KM-953-A.
• Camshaft position (CMP) sensor disc setting tool – No.EN-49977-100.
• Crankshaft locking pin – No.KM-952.
• Crankshaft pulley holding tool – No.EN-49979.
• Crankshaft pulley holding tool handle – No.KM-956-1.
• Inlet camshaft adjuster locking tool – No.EN-49977-200.
• Timing chain tensioner locking pin – No.KM-955-1.

General precautions

• Disconnect battery earth lead.
• Remove spark plugs to ease turning engine.
• Turn engine in normal direction of rotation (unless otherwise stated).
• DO NOT use special tools listed above to lock engine when slackening sprocket or pulley bolts.
• 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/installation of timing chain requires:
  • Sump removal.
• Turn crankshaft until just before TDC mark on No.1 cylinder [1] .
• Remove blanking plug from cylinder block.
• Slowly turn crankshaft clockwise until crankshaft locking pin can be inserted in crankshaft [2] .
• Insert camshaft locking tool in rear of camshafts [3] .
• Lock timing chain tensioner in retracted position [4] :
  • Push tensioner rail against chain tensioner [5] .
  • Insert timing chain tensioner locking pin [6] .
• Remove timing chain tensioner [4] .
• Remove tensioner rail, chain guides and timing chain.
• Fit timing chain.

NOTE: Ensure timing chain is taut between sprockets on non-tensioned side.

• Install tensioner rail and chain guides.
• Install timing chain tensioner [4] .
• Remove timing chain tensioner locking pin [6] .
• Remove special tools [2] & [3] .
• Turn crankshaft two turns clockwise until just before TDC on No.1 cylinder [1] .
• Slowly turn crankshaft clockwise until crankshaft locking pin can be inserted in crankshaft [2] .
• Insert camshaft locking tool in rear of camshafts [3] .

NOTE: If camshaft locking tool cannot be fitted valve timing is incorrect.

• Adjust camshafts as follows:
  • Turn crankshaft until just before TDC mark on No.1 cylinder [1] .
  • Remove blanking plug from cylinder block.
  • Slowly turn crankshaft clockwise until crankshaft locking pin can be inserted in crankshaft [2] .
  • Remove blanking plug from timing chain front cover [7] .
  • Turn inlet camshaft slowly clockwise to compress the timing chain tensioner.
  • Insert timing chain tensioner locking pin [6] .
  • Slacken inlet camshaft adjuster bolt [8] .
  • Slacken exhaust camshaft adjuster bolt [9] .

  NOTE: Camshaft rotation can be prevented using spanner on hexagon.

  • Turn camshafts until camshaft locking tool can be inserted correctly [3] .
  • Remove upper timing chain guide [10] .
  • Remove timing chain tensioner locking pin [6] .
  • Install inlet camshaft adjuster locking tool [11] .
  • Install camshaft position (CMP) sensor disc setting tool [12] .
  • Ensure camshaft position (CMP) sensor disc setting tool abuts cylinder head.
  • Secure camshaft position (CMP) sensor disc setting tool to cylinder head.
  • Tighten inlet camshaft adjuster bolt [8] . Tightening torque: 50 Nm + 60°.
  • Tighten exhaust camshaft adjuster bolt [9] . Tightening torque: 50 Nm + 60°.

  NOTE: Camshaft rotation can be prevented using spanner on hexagon.

  • Remove special tools [2] , [3] , [11] & [12] .
  • Turn crankshaft to TDC on No.1 cylinder [1] .
  • Check valve timing.