Operation CHARM: Car repair manuals for everyone.
Home >> Saturn >> 2008 >> Astra L4-1.8L >> Repair and Diagnosis >> Engine, Cooling and Exhaust >> Engine >> Service and Repair >> Overhaul >> Repair Instructions >> 1. Timing Belt Inspection and Adjustment >> Adjustment

Adjustment



Timing Belt Inspection and Adjustment (Adjustment)


Special Tools
* KM-6009 Remover/Installer
* KM-6333 Fixing Rod
* MK-6340 Locking Tool
* KM-6349 Fixing Rod
* KM-6625 Flywheel Locking Device
* MK-6628 Locking Tool



Removal Procedure

1. Open the hood.
Caution: Refer to Battery Disconnect Caution (Battery Disconnect Caution) .
2. Disconnect the battery.

* Detach the ground connection from ground terminal.
* Loosen the nut.

3. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (Service and Repair) .
4. Remove the drive belt cover upper section.
Remove the 2 bolts.
5. Raise the vehicle by its full height.
6. Remove the drive belt tensioner. Refer to Drive Belt Tensioner Replacement (Service and Repair) .
7. Lower the vehicle by its full height.
8. Detach the engine management wiring harness from the intake manifold, cylinder head cover.
Release 2x from bracket.
9. Remove the cover of the ignition module.
Release the cover in the direction of the arrow.




10. Remove the ignition module.

* Disconnect the wiring harness connector.
* Unscrew the 2 bolts.
* Screw in 2 KM-6009 .
* Take out the ignition module.

11. Detach the engine management wiring harness from the intake manifold, cylinder head cover.

* Remove the wiring trough.
* Release 3x.
* Release the wiring harness from the guide.

12. Remove the engine venting pipe.
Disconnect the 2 quick-release fittings.




13. Remove the cylinder head cover.
Remove the 11 bolts.





Important: Recognizable from the lettering "Right" (arrow).


14. Prepare the right half of MK-6340 for use on the U 18 XER engine.

* Detach the front panel (1) from MK-6340 .
* Unscrew the 2 bolts (2).






Important: The spot-type marking (4) on the intake camshaft adjuster does not correspond to the groove of MK-6340 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 MK-6340 .


15. Insert MK-6340 into the camshaft timing gears.
Insert MK-6340 (1, 2) in the camshaft adjuster as shown .




16. Stop the drive belt tensioner.
Apply tension to the drive belt tensioner (2) in the direction of the arrow, using an Allen key (1). Fix using KM-6333 (3).
17. Mark the drive belt direction of rotation.
18. Raise the vehicle by its full height.




19. Block the crankshaft.

* Attach KM-6625 .
* Detach the screwed connection (1).
* Insert KM-6625 (2).
* Tighten the screwed connection (3).





20. Remove the torsional vibration damper (1).
Remove the bolt (2).
21. Remove the front drive belt cover (bottom) (3).
Remove the 4 bolts (4).




22. Remove the drive belt guide roller.
Remove the bolt.
23. Clean the thread, drive belt guide roller.
24. Lower the vehicle by its full height.
25. Remove the drive belt.
26. Raise the vehicle by its full height.
27. Remove KM-6625 .
Detach the screwed connection.




28. Turn the crankshaft 60 degrees against the direction of engine rotation.
29. Lower the vehicle by its full height.
30. Place the collecting basin underneath.
31. Unscrew the closure bolt, exhaust camshaft adjuster.
32. Unscrew the intake camshaft closure bolt.
33. Loosen the exhaust camshaft adjuster.
Counterhold at camshaft hexagon.
34. Loosen the intake camshaft adjuster.
Counterhold at camshaft hexagon.





Important: If MK-6628 cannot be inserted, the timing must be set.


35. Insert MK-6628 (1) into the camshafts.
Align the camshafts horizontally by the hexagon (arrows) until MK-6628 can be inserted in both camshafts.



Installation Procedure


Notice: Refer to Fastener Notice (Fastener Notice) .

1. Tighten the exhaust camshaft adjuster.

Tighten the exhaust camshaft adjuster to 65 N.m (48 lb ft) plus 125 degrees plus 15 degrees.
Counterhold at camshaft hexagon.
2. Tighten the intake camshaft adjuster.

Tighten the intake camshaft adjuster to 65 N.m (48 lb ft) plus 125 degrees plus 15 degrees.
Counterhold at camshaft hexagon.
3. Tighten the exhaust camshaft adjuster closure bolt.

Tighten the exhaust camshaft adjuster closure bolt to 30 N.m (22 lb ft).
Replace the seal ring.
4. Unscrew the intake camshaft closure bolt.
Replace the seal ring.
5. Remove MK-6628 .
6. Raise the vehicle by its full height.




7. Set the crankshaft to cylinder number 1 ignition TDC (1).
Marking, drive belt drive gear and oil pump housing must align.
8. Block the crankshaft.

* Insert KM-6625 .
* Install the bolted connection.

9. Lower the vehicle by its full height.

Important: Use the assembly tool.


10. Insert the drive belt.
11. Fit the drive belt guide roller.

Tighten the new bolt to 25 N.m (18 lb ft).

12. Release the tension on the drive belt tensioner.

* Apply preliminary tension clockwise to the drive belt tension roller.
* Remove KM-6333 .

13. Raise the vehicle by its full height.
14. Install the drive belt cover lower section.

Tighten the 4 bolts to 6 N.m (53 lb in).


Important: New bolt must be coated with screw locking compound (red).


15. Install the torsional vibration damper.

Tighten the new bolt to 95 N.m (70 lb ft) plus 30 degrees plus 15 degrees.

16. Remove KM-6625 .

* Detach the screwed connection.
* Tighten the bolted connection.
* Use new nuts.

17. Lower the vehicle by its full height.
18. Remove MK-6340 .
19. Check the position of the camshaft sprockets.


Important: Note marking, camshaft sprockets.


* Turn the crankshaft 720 degrees in the direction of engine rotation by the bolt on the torsional vibration damper.
* Insert MK-6340 into camshaft timing gears.

20. Check camshaft positions.
21. Raise the vehicle by its full height.
22. Check crankshaft position.
Insert MK-6628 in the camshafts, align the camshafts by hexagon until MK-6628 can be inserted in both camshafts, marking on torsional vibration damper must align with marking on lower part of drive belt cover.
23. Clean the thread of the bolt, drive belt tensioner.
24. Install the drive belt tensioner.

Tighten the new bolt to 50 N.m (37 lb ft).

25. Insert the drive belt.

* Observe the direction of rotation.
* Apply tension to the tensioner at projection counterclockwise in the direction of the arrow.
* Remove KM-6349 .

26. Install the lower engine compartment cover or the right engine splash guard.
27. Lower the vehicle by its full height.
28. Remove MK-6628 .
29. Install the cylinder head cover.
Replace the cylinder head gasket.

Tighten the 11 bolts to 8 N.m (71 lb in).

30. Install the engine venting pipe.
Connect the 2 quick-release fittings.
31. Attach the engine management wiring harness to the intake manifold.

* Attach the wiring trough.
* Clip on 3x.
* Clip the wiring harness into the guide.

32. Install the ignition module.

* Insert the ignition module.
* Unscrew the 2 KM-6009 .
* Tighten the 2 bolts.

Tighten the 2 bolts to 8 N.m (71 lb in).

* Fix the wiring harness plug.

33. Install the cover of the ignition module.
34. Attach the engine management wiring harness to the intake manifold.
Clip 2x in bracket.
35. Remove MK-6340 .
Attach the bracket.

Tighten the 2 bolts to 5 N.m (44 lb in).

36. Install the front drive belt cover (top).

Tighten the 2 bolts to 6 N.m (53 lb in).

37. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (Service and Repair) .

* Attach the air intake hose to the throttle valve module.
* Attach the resonator air intake housing to the air cleaner housing.
* Connect the mass air flow meter wiring harness plug.
* Fasten the clamp.

38. Connect the battery.
Attach the ground connection to the ground terminal.

Tighten the nut to 5 N.m (44 lb in).

39. For programming procedures, refer to Control Module References (Programming and Relearning) .
40. Close the hood.


pro multis · About Operation CHARM