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Astra H

J Engine and Engine

Aggregates > DOHC Petrol
Engine > Cylinder Head >
Repair Instructions > Valve
Lash - Petrol Engine, Check and
Adjust

Valve Lash - Petrol Engine, Chec

  Remove

1.   Open bonnet

2.   Disconnect battery
•   Detach earth connection from earth te
– 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
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•   Turn crankshaft in the direction of
engine rotation by the bolt of the
Donate and help keep workshop torsional vibration damper to cylinder
manuals freely available. TDC of combustion stroke
•   Marking on torsional vibration damper
must align with the marking on the
lower part of the toothed belt cover (1

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9.   Cams at the intake side of cylinder no.2 (1
and the exhaust side of cylinder no.3 (2) a
Astra H Workshop Manual on top and tilted slightly towards the insid
General Vehicle Information to the same extent
A Maintenance, Body and Chassis
Sheet Metal Parts, Frame
B Paint
C Body Equipment
D Heating, Ventilation, Air
Conditioning (HVAC)
E Front Wheel Suspension,
Wheels and Tyres
F Rear Axle and Rear Wheel
Suspension
H Brakes
J Engine and Engine Aggregates
Repair Instructions
Component Locator
Other Information
10.   Check valve lash
•   Prescribed valve lash
– Intake valves 0.21 - 0.29 mm
– Exhaust valves 0.27 - 0.35 mm
11.   Check 4x valve clearance
•   Check valve lash with KM-6361

– 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

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 guarantee
•   Slacken 3x bolts (arrows) in adjusting
•   Insert KM-6001-A
– The journals (2) and (5) must sit
•   Tighten 3x bolts in adjusting rails
•   Adjust support bearings, front (4) and
– Raise support bearings up to the
Note:   The guide journals must

25.   Lower vehicle by its full height

26.   Remove engine damping block, right han
side
•   Unscrew 6x bolts (1)

27.   Remove engine damping block support

•   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 ke
(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
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 th
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
39.   Unscrew intake camshaft closure bolt
40.   Slacken exhaust camshaft adjuster
Note:   2 mechanics required
•   Counterhold against the camshaft he
(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 he
(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 insid
in steps of 1/2 up to 1 turn
•   Remove the camshaft bearing cover
from the cylinder head and take out t
camshaft
Note:   Note marking on the camshaf
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
•   Slacken camshaft bearing caps 5 - 8,
turn
•   Remove the camshaft bearing cover
Note:   Note marking on the camshaf
at bottom left before each number to
48.   Remove cup tappet with KM-845

49.   Determine cup tappet size

Example of determining the size
of a cup tappet, intake side:
Dimension of 3.20 (Identificati
fitted cup mm no. 20)
tappet
Valve + 0.35
clearance mm
measurement
between
cams and
cup tappets
= 3.55
mm
Required - 0.25
value, valve mm
lash, intake
side
Nominal 3.30 (Identificati
dimension of mm number 30X
the new cup
tappet
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 markin
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 markin
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 w
a suitable tool, e.g. plastic wedge
•   Free oil duct (arrow) from any sealan
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
- 4.

55.   Fit the camshaft adjuster for the intake c

•   Hand-tighten the bolt
56.   Fit the camshaft adjuster for the exhaust
•   Hand-tighten the bolt
Important:   If the actual value deviates from
the required value, these values must be note
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 directio
of engine rotation until the cams for
cylinder 1 are located in test position
(1)
•   Insert feeler gauge EN-6361
valve clearance
Note:   Required value, intake side
valve clearance: 0.25 mm

58.   Check the valve clearance at both intake

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

Note:   Required value, exhaust side

valve clearance: 0.30 mm

62.   Check the valve clearance at both exhau

•   Turn the exhaust camshaft to the cam
cams for cylinder 2 are located in tes
•   Insert feeler gauge EN-6361 and chec
Note:   Required value, exhaust side v
63.   Check the valve clearance at both exhau
•   Turn the exhaust camshaft to the cam
cams for cylinder 1 are located in tes
•   Insert feeler gauge EN-6361 and chec
Note:   Required value, exhaust side v
64.   Check the valve clearance at both exhau
•   Turn the exhaust camshaft to the cam
cams for cylinder 3 are located in tes
•   Insert feeler gauge EN-6361 and chec
Note:   Required value, exhaust side v
65.   Detach camshaft adjuster for intake cam
•   Counterhold against the intake camsh
66.   Detach camshaft adjuster for exhaust ca
•   Counterhold against the exhaust cam
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 surface
(arrows) of the camshaft bearing suppo
thinly and evenly

Note:   The grooves (1) adjacent to the

sealing surfaces must remain free from
sealant.

69.   Place the camshaft bearing support on t

cylinder head and hand-tighten the bolts
(approx. 2 Nm )
Note:   Note correct tightening sequence
- 4.
70.   Install 2x camshaft seal ring
•   Hoist the seal ring (3) using
(4) on the camshaft until this abuts
against the cylinder head
– To install, use camshaft sprocke
bolt (1) in conjunction with shim
(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 sequenc
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 compou
•   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 t
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 sprocket

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-L
during this process but must be somew
above as shown
The spot type marking (3) on the exhaus
camshaft adjuster must correspond to t
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 closu
•   Replace seal ring
82.   Tighten closure bolt, intake camshaft ad
•   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) a
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 tooth
pump module
•   Tighten bolt 20 Nm + 120° + 15°

90.   Remove fastening bolt with washer from

Important:   Use assembly tool.
91.   Insert toothed belt
92.   Release tension on toothed belt tensione
•   Apply preliminary tension clockwise t
– 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
Note:   Note marking, camshaft sproc
•   Insert KM-6340 into camshaft sprock
100.   Check camshaft positions
Insert KM-6628-A into camshafts
Note:   If KM-6628-A cannot be inserte
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 co
105.   Install support for engine damping bloc
•   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 tensi
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
– Tighten nut

119.   Program volatile memories

120.   Close bonnet

J Engine and Engine

Aggregates > DOHC Petrol
Engine > Cylinder Head >
Repair Instructions > Valve
Lash - Petrol Engine, Check and
Adjust

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