9.Cams at the intake side of cylinder no.2 (1) and the exhaust side of cylinder no.3 (2) are o n 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 ) –
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11. Check 4x valve clearance Check valve lash with KM-6361 (1) •
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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 •
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13. Check 4x valve clearance Check valve lash with KM-6361 •
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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 •
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15. Check 4x valve clearance Check valve lash with KM-6361 •
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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 •
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17. Check 4x valve clearance Check valve lash with KM-6361 •
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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 •
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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. •
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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 Valve clearance measurement between cams and cup tappets
3.20 (Identification mm no. 20) + 0.35 mm
= 3.55 mm Required value, valve - 0.25 lash, intake side mm Nominal dimension of the 3.30 (Identification new cup tappet mm 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 i n 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 cam s 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 cam s 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 c ylinder 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 •
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•
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 •
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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-6340Right
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 •
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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 –
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•
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°
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96. Remove KM-6625
Detach screwed connection Tighten screwed joint 40 Nm
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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
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•
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 –
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Fasten engine damping block
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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 Cigueñal-Árbol de lévas Astra 1.8 2002 USUARIOS SMDA Les dejo unas imagenes de la graficación de dos sensores que algunas veces nos dan problemas. Línea verde es el se nsor de cigüeñal y línea amarilla representa el árbol de levas. A pie de cada imagen estan las referencias de la medición. 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 gráficas nos ayudan a saber la condición de los sensores, pero tambien de las ruedas reluc toras o dentadas, esto es, cuantos dientes, cuantos espacios sin diente, simetria de la rueda y sincronización entre sensores ruedas. Espero les sirva y ayuden a generar información similar 2 cosas más 1. Este post originalmente es del ingeniero Antonio Villegas 2. en los enlaces de sus imágenes no usen acentos o caracteres especiales como (ñ) Saludos
