Engines 1.4 and 1.6 liters
Removing
Disconnect the negative battery terminal.
Remove the outer belt covers as previously noted. The power steering pump must be completely removed.
Check crankshaft. to bring piston No. 1 to TDC.
Insert a tool into the hole in the belt tension indicator lever, then turn the lever clockwise until it stops and lock into position.
Loosen the three bolts on the coolant pump with a socket wrench, then turn the pump to loosen the belt tension.
Remove the belt from the sprockets.
Install the belt on the sprockets (starting from crankshaft sprocket), making sure. that piston no. 1 is at TDC. The arrow on the sprocket should line up with the mark on the cap.
Adjust the belt tension, replace the covers, install the power steering pump. Connect the negative battery terminal.
Adjustment
Note: The engine must be cold when checking and adjusting the distributor belt tension.
After removing the outer belt covers, do the following:
Turn the crankshaft to bring the No. 1 piston to TDC. To facilitate turning the crankshaft, remove the spark plugs.
Loosen the coolant pump bolts with a socket wrench. Turn pump clockwise to increase belt tension until until the tension indicator lever reaches the stop (the holes in the lever and the back plate will match). To turn the coolant pump, there is a special tool from Vauxhall / Opel KM-421-A and an equivalent tool.
Tighten the coolant pump bolts to prevent the pump from turning during the next operation.
Using a wrench and a crankshaft pulley bolt, turn the crankshaft pulley clockwise two full turns until the No. 1 piston is in the TDC position.
Carefully turn the coolant pump counterclockwise to loosen the belt until the tension gauge needle is in the center of the fork "V" — (see picture), then tighten the bolts.
Turn the crankshaft clockwise two full turns and check if the tension indicator needle is in the position indicated in the previous paragraph - if it is not, repeat the sequence of operations.
Replace the spark plugs and install the outer belt covers.
Engines 1.8 and 2.0 l
Note: An appropriate crankshaft sprocket puller may be required.
Disconnect the negative battery terminal.
Remove the outer belt covers.
Turn the crankshaft so that in cylinder No. 1 the piston is at TDC, using a wrench and a crankshaft sprocket bolt. Remove the crankshaft pulley.
Loosen the three coolant pump mounting bolts with a socket wrench, then turn the pump to loosen the belt tension.
Remove the belt from the sprockets.
Make sure that in cylinder No. 1 the piston is still at TDC.
Put a belt on the sprockets, starting with the crankshaft sprocket. Adjust belt tension.
Install the pulley on the crankshaft.
Install the outer covers. Connect the negative lead to the battery.
Adjustment with an Opel instrument
A special company device for adjusting the belt tension is in the auto repair shop. The device is accompanied by instructions explaining the procedure for performing operations.
Rough adjustment
If a special device is not available, the belt tension can be checked by twisting the belt between the thumb and forefinger in the middle. It should only turn 90°with medium pressure on it.
2.0L twin cam engines
Disconnect the negative battery terminal, remove the outer belt cover and rotate the crankshaft so that the piston of cylinder No. 1 is at TDC.
Remove the crankshaft pulley, loosen the tightening bolt as shown in the figure, and release the belt tensioner pulley, then remove the belt from the sprockets and pulleys.
Install the new belt on the sprockets and pulleys, starting with the crankshaft sprocket. Install the crankshaft pulley.
Adjust belt tension.
Install its outer cover and connect the negative battery terminal.
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