GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2009 🢒 Astra 🢒 Engine 🢒 Engine Mechanical - 1.6L (LDE or LLU) and 1.8L (2H0) 🢒 Camshaft Installation

Special Tools

    • KM-422 Installer
    • KM-845 Suction Device
    • MK-6340 Locking Tool
    • MK-6628 Locking Tool

For equivalent regional tools, refer to Special Tools.


    Object Number: 1947353 Size: SH
  1. Lightly coat the sliding surfaces with oil.
  2. Using the KM-845 device , insert the 16 cup tappets.

    3. Note: Note the identification marking on the camshaft bearing cover.

  3. Tighten the camshaft bearing caps 2-5 in a spiral from the inside to the outside. Tighten the camshaft bearing caps to 8 N·m (71 lb in).
  4. Install the intake camshaft.

    5. Specification
    Coat the intake camshaft with MoS 2 lubricating paste.

  5. Install the camshaft bearing cover.

    6. Object Number: 1947354 Size: SH

    Note: Note the identification marking on the camshaft bearing cover.

  6. Tighten the camshaft bearing caps 2-5 in a spiral from the inside to the outside. Tighten the camshaft bearing caps 8 N·m (71 lb in).
  7. Install the exhaust camshaft.

    8. Specification
    Coat the exhaust camshaft with MoS 2 lubricating paste.

  8. Install the camshaft bearing cover.

    9. Object Number: 1947413 Size: SH

    Note: Sealing surfaces must be free from oil and grease.

  9. Using a suitable tool, such as a plastic wedge, clean the 1st camshaft bearing support sealing surfaces and the cylinder head sealing surfaces.

    10. Clean the oil duct, arrow, from any sealant residue.


    Object Number: 1947417 Size: SH

    Note: 

       • It is essential to ensure that no sealant is applied outside the marked sealing areas.
       • The grooves (1) adjacent to the sealing surfaces must remain free from sealant.

  10. Apply green surface sealant, thinly and evenly, to the 1st camshaft bearing support sealing surfaces, arrows.

    11. Caution: Refer to Fastener Caution in the Preface section.

  11. Position the camshaft bearing bridge on the cylinder block and tighten the bolts hand-tight, approximately 2 N·m (18 lb in).

    12. Object Number: 1945794 Size: SH
  12. Install the 2 camshaft seal rings.
    13. 12.1. Using the KM-422 installer  (4), tighten the seal ring on the camshaft until this is in contact with the cylinder head.
    12.2. To install, use camshaft sprocket bolt (1) in conjunction with shims (2) with a total thickness of approximately 10 mm (0.39 in).
    12.3. Remove the KM-422 installer .
    12.4. Remove the bolt.

    Object Number: 1947415 Size: SH

    Note: 

       • Ensure no sealant reaches the camshafts.
       • Note the installation sequence 1-4.

  13. Install the 1st camshaft bearing support and the 4 bolts. Tighten the 4 bolts to 8 N·m (71 lb in).
  14. Insert the MK-6628 tool .
  15. Turn the intake camshaft against the direction of engine rotation
  16. Insert the MK-6628 tool .
  17. Turn the exhaust camshaft in the direction of rotation of the engine.
  18. Insert the MK-6628 tool .

    19. Object Number: 1944922 Size: SH

    Note: Screw in the bolt, but do not tighten.

  19. Attach the intake camshaft adjuster or exhaust camshaft adjuster.
  20. Insert the MK-6340 tool in the camshaft adjuster.

    21. Note: 

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

  21. Insert the MK-6340 tool -Left (1) and the MK-6340 tool -Right (2) in the camshaft adjuster, as shown.

    22. Note: A second person is required.

  22. Counterhold at camshaft hexagon.
  23. Install the intake camshaft adjuster or exhaust camshaft adjuster and bolt. Tighten the bolt to 65 N·m (48 lb ft ) + 120 degrees + 15 degrees.
  24. Replace the seal ring and tighten the closure bolt. Tighten the bolt to 30 N·m (22 lb ft).