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9.Cams at the intake side of cylinder no.

2 (1) and the


exhaust side of cylinder no.3 (2) are on top and tilted
slightly towards the inside to the same extent


10. Check valve lash
Prescribed valve lash
Intake valves 0.21 - 0.29 mm (nominal value 0.25 mm )
Exhaust valves 0.27 - 0.35 mm (nominal value 0.30 mm )

11. Check 4x valve clearance
Check valve lash with KM-6361 (1)
Note down result




12. Rotate crankshaft on torsional vibration damper bolt
by 180
In direction of engine rotation.
Pairs of cams (1) and (2) point upwards at an
angle




13. Check 4x valve clearance
Check valve lash with KM-6361
Note down result

14. Rotate crankshaft on torsional vibration damper bolt
by 180
In direction of engine rotation.
Pairs of cams (1) and (2) point upwards at an
angle




15. Check 4x valve clearance
Check valve lash with KM-6361
Note down result

16. Rotate crankshaft on torsional vibration damper bolt
by 180
In direction of engine rotation.
Pairs of cams (1) and (2) point upwards at an
angle




17. Check 4x valve clearance
Check valve lash with KM-6361
Note down result

18. Rotate crankshaft on torsional vibration damper bolt by 180, to TDC of combustion stroke of cylinder 1
19. Raise vehicle by its full height
20. Immobilise crankshaft via starter ring
Attach KM-6625
Detach screwed connection (1)
Insert KM-6625 (2)
Tighten screwed connection (3)




21. Remove torsional vibration damper
Unscrew bolt
22. Remove front toothed belt cover (bottom)
Unscrew 4x bolts
23. Insert KM-6173 (3)
Slacken 4x bolts (arrows) and hand-tighten
Align KM-6173 at front axle body
Wind up the support bearing (1)
Journal (2) must sit in mount at cylinder block
Tighten 4x bolts




24. Attach KM-6001-A (1)
Note: Attaching KM-6001-A guarantees perfect alignment of the drive unit with the front axle body.
Slacken 3x bolts (arrows) in adjusting rails
Insert KM-6001-A
The journals (2) and (5) must sit in the guide holes of the front axle body
Tighten 3x bolts in adjusting rails
Adjust support bearings, front (4) and rear (3)
Raise support bearings up to the stop on the guide journals
Note: The guide journals must be seated free from play in the support bearings.



25. Lower vehicle by its full height
26. Remove engine damping block, right hand side
Unscrew 6x bolts (1)



27. Remove engine damping block support (1)
Unscrew 3x bolts (2)



28. Remove front toothed belt cover (centre) (1)
Unclip 2x from rear of toothed belt cover



29. Stop toothed belt tensioner
Apply tension to toothed belt tension roller (2)
clockwise using an Allen key (1), and fix
using KM-6333 (3)



30. Remove toothed belt
31. Remove toothed belt tensioner (2)
Note: Do not remove locking using KM-6333 (3).
Unscrew bolt (1)



32. Raise vehicle by its full height
33. Attach fastening bolt with washer to the torsional vibration damper of the crankshaft. Tighten by hand.
34. Remove KM-6625
Detach screwed connection
35. Turn the crankshaft 60 against the direction of
engine rotation to the fastening bolt of the torsional
vibration damper
Note: Check using the TDC marks on the toothed
belt drive gear (1) and oil pump housing (2)


36. Lower vehicle by its full height
37. Place collecting basin underneath.
38. Unscrew closure bolt, exhaust camshaft adjuster
39. Unscrew intake camshaft closure bolt
40. Slacken exhaust camshaft adjuster
Note: 2 mechanics required
Counterhold against the camshaft hex (2) using
an open-ended spanner socket (1)



41. Detach exhaust camshaft adjuster
Unscrew bolt
42. Slacken intake camshaft adjuster
Note: 2 mechanics required
Counterhold against the camshaft hex (2) using
an open-ended spanner socket (1)



43. Detach intake camshaft adjuster
Unscrew bolt
44. Remove rear toothed belt cover
Unclip wiring trough cover
Unscrew 4x bolts
45. Remove camshaft bearing support
Unscrew 4x bolts
Note removal sequence 1 - 4
Release bearing support by striking it gently with
a plastic hammer



46. Remove intake camshaft
Note: Mark the camshaft bearing caps before
removing them.
Slacken camshaft bearing caps 1 - 4, working in
spiral from outside to inside in steps of 1/2 up to 1
turn
Remove the camshaft bearing cover from the
cylinder head and take out the camshaft
Note: Note marking on the camshaft bearing
cap with stamped numbers from 1 to 8 (there is a
dot at bottom left before each number to avoid
mistakes).




47. Remove exhaust camshaft
Note: Mark the camshaft bearing caps before removing them.
Slacken camshaft bearing caps 5 - 8, working in spiral from outside to inside in steps of 1/2 up to 1 turn
Remove the camshaft bearing cover from the cylinder head and take out the camshaft
Note: Note marking on the camshaft bearing cap with stamped numbers from 1 to 8 (there is a dot at bottom
left before each number to avoid mistakes).


48. Remove cup tappet with KM-845 (1)


49. Determine cup tappet size
Example of determining the size of a cup tappet,
intake side:
Dimension of fitted cup
tappet
3.20
mm
(Identification
no. 20)
Valve clearance
measurement between
cams and cup tappets
+ 0.35
mm

= 3.55
mm

Required value, valve
lash, intake side
- 0.25
mm

Nominal dimension of the
new cup tappet
3.30
mm
(Identification
number 30X)
Note: The identification number (arrow) is on the
inside of the cup tappet
Now use a cup tappet with this dimension or one
that is nearest to it
Currently available cup tappet sizes




Install
50. Insert cup tappet with KM-845
Lightly coat sliding surfaces with oil
51. Install intake camshaft
Coat with MoS 2 lubricating paste
Insert camshaft
Note: Note the identification marking on the
camshaft bearing cover.
Install camshaft bearing cover
Tighten camshaft bearing caps 1 - 4 in a
spiral from the inside outward 8 Nm
Note: Note correct tightening sequence 1 -
4.




52. Install exhaust camshaft
Coat with MoS 2 lubricating paste
Insert camshaft
Note: Note the identification marking on the
camshaft bearing cover.
Install camshaft bearing cover
Tighten camshaft bearing caps 1 - 8 in a
spiral from the inside outward 8 Nm
Note: Note correct tightening sequence 1 -
4.




53. Clean sealing surfaces of 1st camshaft bearing
support and the cylinder head with a suitable tool,
e.g. plastic wedge
Free oil duct (arrow) from any sealant residue



54. Place the camshaft bearing cap on the cylinder head
without sealant and hand-tighten the bolts (approx. 2
Nm )
Note: Note correct tightening sequence 1 - 4.


55. Fit the camshaft adjuster for the intake camshaft to the intake camshaft
Hand-tighten the bolt
56. Fit the camshaft adjuster for the exhaust camshaft to the exhaust camshaft
Hand-tighten the bolt
Important: If the actual value deviates from the required
value, these values must be noted and the adjustment
procedure repeated
57. Check the valve clearance at both intake valves for
cylinder 1
Turn the intake camshaft to the camshaft adjuster
bolt in the direction of engine rotation until the
cams for cylinder 1 are located in test position (1)
Insert feeler gauge EN-6361 and check valve
clearance
Note: Required value, intake side valve
clearance: 0.25 mm



58. Check the valve clearance at both intake valves for cylinder 3
Turn the intake camshaft to the camshaft adjuster bolt in the direction of engine rotation until the cams for
cylinder 3 are located in test position
Insert feeler gauge EN-6361 and check valve clearance
Note: Required value, intake side valve clearance: 0.25 mm .
59. Check the valve clearance at both intake valves for cylinder 4
Turn the intake camshaft to the camshaft adjuster bolt in the direction of engine rotation until the cams for
cylinder 4 are located in test position
Insert feeler gauge EN-6361 and check valve clearance
Note: Required value, intake side valve clearance: 0.25 mm .
60. Check the valve clearance at both intake valves for cylinder 2
Turn the intake camshaft to the camshaft adjuster bolt in the direction of engine rotation until the cams for
cylinder 2 are located in test position
Insert feeler gauge EN-6361 and check valve clearance
Note: Required value, intake side valve clearance: 0.25 mm .
Important: If the actual value deviates from the required
value, these values must be noted and the adjustment
procedure repeated
61. Check the valve clearance at both exhaust valves for
cylinder 4
Turn the exhaust camshaft to the camshaft
adjuster bolt in the direction of engine rotation
until the cams for cylinder 4 are located in test
position (1)
Insert feeler gauge EN-6361 and check valve
clearance
Note: Required value, exhaust side valve
clearance: 0.30 mm



62. Check the valve clearance at both exhaust valves for cylinder 2
Turn the exhaust camshaft to the camshaft adjuster bolt in the direction of engine rotation until the cams for
cylinder 2 are located in test position
Insert feeler gauge EN-6361 and check valve clearance
Note: Required value, exhaust side valve clearance: 0.30 mm
63. Check the valve clearance at both exhaust valves for cylinder 1
Turn the exhaust camshaft to the camshaft adjuster bolt in the direction of engine rotation until the cams for
cylinder 1 are located in test position
Insert feeler gauge EN-6361 and check valve clearance
Note: Required value, exhaust side valve clearance: 0.30 mm
64. Check the valve clearance at both exhaust valves for cylinder 3
Turn the exhaust camshaft to the camshaft adjuster bolt in the direction of engine rotation until the cams for
cylinder 3 are located in test position
Insert feeler gauge EN-6361 and check valve clearance
Note: Required value, exhaust side valve clearance: 0.30 mm
65. Detach camshaft adjuster for intake camshaft
Counterhold against the intake camshaft hex
66. Detach camshaft adjuster for exhaust camshaft
Counterhold against the exhaust camshaft hex
67. Detach camshaft bearing support
Important: It is necessary to ensure that no sealant is
applied outside the designated sealing surfaces.
68. Apply surface sealant to sealing surfaces (arrows) of
the camshaft bearing support thinly and evenly
Note: The grooves (1) adjacent to the sealing
surfaces must remain free from sealant.


69. Place the camshaft bearing support on the cylinder
head and hand-tighten the bolts (approx. 2 Nm )
Note: Note correct tightening sequence 1 - 4.


70. Install 2x camshaft seal ring
Hoist the seal ring (3) using KM-422 (4) on the
camshaft until this abuts against the cylinder head
To install, use camshaft sprocket bolt (1) in
conjunction with shims (2) with a total
thickness of approx. 10 mm
Remove KM-422
Unscrew bolt




71. Tighten the camshaft bearing support
Important: No sealant may reach the camshafts.
Tighten 4x bolt 8 Nm
Note correct tightening sequence 1-4




72. Clean 4x thread, rear toothed belt cover
73. Install rear toothed belt cover
Tighten 4x new bolt 6 Nm
Coat 4x bolt with locking compound
Clip in wiring trough cover
74. Attach exhaust camshaft adjuster
Insert new sealing sleeve in adjuster
Screw in new bolt
75. Attach intake camshaft adjuster
Insert new sealing sleeve in adjuster
Screw in new bolt
76. Insert KM-6328-A (1) into camshafts
Note: Align camshafts horizontally by the hexagon
until KM-6328-A (1) can be inserted in the grooves
(arrows)


77. Prepare KM-6340-Right for use on engines A16XER,
Z16XER, A18XER and Z18XER
Detach front panel (1) from KM-6340-Right
Unscrew 2x bolts (2)




78. Insert KM-6340 into camshaft sprockets
Insert KM-6340-Left (1) and KM-6340-Right (2) in
the camshaft adjuster as shown
Note: The spot-type marking (4) on the intake
camshaft adjuster does not correspond to the groove
of KM-6340-Left during this process but must be
somewhat above as shown
The spot type marking (3) on the exhaust camshaft
adjuster must correspond to the groove on KM-6340-
Right


79. Fasten exhaust camshaft adjuster
Note: 2 mechanics required
Tighten bolt 65 Nm+125+15
Counterhold at camshaft hexagon
80. Fasten intake camshaft adjuster
Note: 2 mechanics required.
Tighten bolt 65 Nm+125+15
Counterhold at camshaft hexagon
81. Tighten exhaust camshaft adjuster closure bolt 30 Nm
Replace seal ring
82. Tighten closure bolt, intake camshaft adjuster 30 Nm
Replace seal ring
83. Remove KM-6628-A
84. Raise vehicle by its full height
85. Rotate the crankshaft about 60 in the direction of
engine rotation against the torsional vibration damper
bolt
Marking, toothed belt drive gear (1) and oil pump
housing (2) must align



86. Block crankshaft.
Insert KM-6625
Install bolted connection

87. Lower vehicle by its full height
88. Clean thread, toothed belt tensioner

89. Intake toothed belt tensioner
Insert toothed belt tension roller
Use new bolt
Free leg of spring (1) of the toothed belt tension roller must engage in the cut-out (arrow) of the pump
module
Tighten bolt 20 Nm + 120 + 15


90. Remove fastening bolt with washer from the torsional vibration damper of the crankshaft
Important: Use assembly tool.
91. Insert toothed belt
92. Release tension on toothed belt tensioner
Apply preliminary tension clockwise to toothed belt tension roller
Remove KM-6333

93. Raise vehicle by its full height
94. Install front toothed belt cover (lower)
Tighten 4x bolt 6 Nm
95. Install torsional vibration damper
Important: Use new bolt.
Tighten bolt 95 Nm + 45 + 15
96. Remove KM-6625
Detach screwed connection
Tighten screwed joint 40 Nm
97. Lower vehicle by its full height
98. Remove KM-6340
99. Check position of camshaft sprockets
Turn crankshaft 720 in the direction of engine rotation by the bolt on the torsional vibration damper
Note: Note marking, camshaft sprockets.
Insert KM-6340 into camshaft sprockets
100. Check camshaft positions
Insert KM-6628-A into camshafts
Note: If KM-6628-A cannot be inserted in the camshafts, the timings must be set
101. Raise vehicle by its full height
102. Check crankshaft position
Marking on torsional vibration damper must align
with the marking (1) on the lower part of the
toothed belt cover



103. Lower vehicle by its full height
104. Insert front toothed belt cover (centre)
Clip 2x onto the rear toothed belt cover
105. Install support for engine damping block
Tighten 3x bolt 50 Nm
106. Install engine damping block
Fasten engine bracket adapter
Tighten 3x bolt 55 Nm
Fasten engine damping block
Tighten 2x bolt 55 Nm
Tighten nut 55 Nm

107. Raise vehicle by its full height
108. Remove KM-6001-A
Slacken 3x screwed connections
109. Remove KM-6173
Undo 4x bolts
110. Clean thread of bolt, ribbed V-belt tensioner
111. Install ribbed V-belt tensioner
112. Lower vehicle by its full height
113. Remove KM-6628-A
114. Install cylinder head cover
115. Remove KM-6340
Attach bracket
Tighten 2x bolts

116. Install front toothed belt cover (top)
117. Install air cleaner housing
A 16 XER, Z 16 XER
A 18 XER, Z 18 XER
118. Connect battery
Attach ground connection to ground terminal
Tighten nut

119. Program volatile memories
120. Close bonnet










Valve Lash - Petrol Engine, Check and Adjust
Remove
1. Open bonnet
2. Disconnect battery
Detach earth connection from earth terminal
Slacken nut

3. Remove air cleaner housing
A 16 XER, Z 16 XER
A 18 XER, Z 18 XER
4. Remove front toothed belt cover (top)
5. Remove cylinder head cover
6. Raise vehicle by its full height
7. Remove ribbed V-belt tensioner
8. Set engine to TDC
Turn crankshaft in the direction of engine rotation
by the bolt of the torsional vibration damper to
cylinder 1 TDC of combustion stroke
Marking on torsional vibration damper must align
with the marking on the lower part of the toothed
belt cover (1)


































Sensor Cigueal-rbol de lvas Astra 1.8 2002
USUARIOS SMDA
Les dejo unas imagenes de la graficacin de dos sensores que algunas veces nos dan problemas. Lnea verde es el sensor de
cigeal y lnea amarilla representa el rbol de levas.
A pie de cada imagen estan las referencias de la medicin.
http://www.scanator.com.mx/descarga/Astra-2002MT-z18xe-ciguenal-arbol.png
http://www.scanator.com.mx/descarga/Astra-2002MT-z18xe-ciguenal-arbol-arranque.png
Como ustedes deben de saber, estas grficas nos ayudan a saber la condicin de los sensores, pero tambien de las ruedas reluctoras
o dentadas, esto es, cuantos dientes, cuantos espacios sin diente, simetria de la rueda y sincronizacin entre sensores ruedas.
Espero les sirva y ayuden a generar informacin similar
2 cosas ms
1. Este post originalmente es del ingeniero Antonio Villegas
2. en los enlaces de sus imgenes no usen acentos o caracteres especiales como ()
Saludos