To correctly set the valve timing, you will need special Opel fixing devices, which you can make yourself (see Checking and adjusting the valve timing (engines 2.0 l). If none of these options is available, entrust this operation to car service specialists. If the problem has to be solved by improvised means, before removing the components, mark their installation position of the chains on the sprockets.
Scheme for laying chains and positioning sprockets of the timing drive on 2.0 l engines
1 - Crankshaft sprocket
2 - Asterisk of the lower chain of the injection pump
3 — an asterisk of the top chain TNVD
4 - Camshaft sprocket
Removing
Upper chain and sprockets
1. Disconnect the negative cable from the battery and remove the timing cover (see Removal and installation of a cover of the gas-distributing mechanism).
2. Set the piston of the first cylinder to the TDC position of the end of the compression stroke (see Bringing the piston of the first cylinder to the position of the top dead center of the end of the compression stroke (TDC). Lock the crankshaft in this position.
3. In order to provide free access to the injection pump sprocket cover, remove the air cleaner housing and the exhaust pipe of the exhaust system (see chapter Power and exhaust systems). Also remove the accessory drive belt (see chapter Current service). Mark the position of the right powertrain mount in relation to the cylinder head bracket. Turn out three bolts of fastening of a support to an arm of a head of cylinders and three bolts of fastening of its mudguard. Support the right side of the engine with a trolley jack, raising it as high as possible without excessively loading other supports and communication lines (hoses, cables, wiring harnesses).
4. Timing chain routing diagram on 2.0 l engines - see illustration Scheme for laying chains and positioning sprockets of the timing drive on 2.0 l engines.
5. Remove both tensioners (see Removal and installation of timing chain tensioners (engines 2.0 l)).
6. Turn out the bottom bolt of fastening of a rack of a tension roller of an auxiliary driving belt and a bolt of an axis of its base. Remove the tensioner assembly from the engine.
Installation will require a new camshaft sprocket bolt and new upper chain guide bolts.
Unless necessary, do not remove the rack from the tensioner assembly, as otherwise it will have to be lapped during installation.
7. Turn out fixing bolts.
8. Remove the injection pump sprocket cover from the timing chain cover.
9. Using special tools, block the sprockets of the injection pump and camshaft (see Removing and installing timing belt). If special tools are not available, mark the installation position of the chain on the sprockets, as well as the position of the sprockets relative to their mounting flanges.
10. Turn out fixing bolts.
11. Remove the upper chain guide from the top of the cylinder head.
The upper chain damper fastening bolts must be heated with a heat gun before removal (powerful hair dryer) in order to soften the sealant fixing the thread and greatly facilitate the task.
12. Holding the camshaft with an open-end wrench by the flats, unscrew the bolt securing its sprocket. In order to facilitate the task of aligning the marks during installation, tie the chain to the sprocket.
If locking devices were used, remove them before loosening the sprocket bolt, then reinstall.
13. If installed, remove the injection pump fixing rod, then unscrew the bolts securing the injection pump sprockets to the flange. Remove the injection pump sprocket for the top chain and the camshaft sprocket. Release the sprocket and remove the top chain.
Lower timing chain and sprockets
1. Remove the upper timing chain and sprocket (see above).
2. Remove the timing chain cover (see Removing and installing timing cover).
3. Mark the position of the chain on the sprockets and sprockets on the flanges.
4. Separate the injection pump sprocket from the flange and remove it together with the engine chain - try to remember the installation position of the components.
5. Remove the sprocket from the crankshaft stub.
6. Remove from the groove on the trunnion.
Examination
1. Inspect the sprocket teeth for chipping, wear, or other damage. If at least one of the sprockets is found to be defective, it must be replaced complete with its pair along the corresponding chain. Along with the sprockets, the chain is also replaced.
2. Check up a condition of cheeks and rollers of chains. The degree of wear is determined by the freedom of its stretching. The new chain should have almost no stretch. A worn chain must be replaced. The chain must also be replaced when overhauling the engine, prolonged use and excessive noise from the operation of the timing drive. Although this is not absolutely necessary, usually the chain is replaced complete with sprockets - an attempt to save on little sometimes turns into a subsequent expensive repair. If you are not sure about the assessment of the condition of the components, seek advice from car service specialists.
3. Also inspect chain guides and chain tensioner shoes. Damaged and worn components must be replaced.
Installation
Upper chain and sprockets
1. When installing new components, transfer the alignment marks from the old parts to them. Make sure the crankshaft is at TDC at the end of the compression stroke of the No. 1 cylinder and is locked from turning.
2. Put the chain on the camshaft sprocket and install the assembly in its original place.
3. Install the injection pump sprocket and engage it with the chain.
4. Achieve the alignment of the landing marks applied during the dismantling process and fix the sprockets on the flanges of the camshaft and high pressure fuel pump - if necessary, untie the camshaft sprocket from the chain.
5. Achieve the alignment of the timing mark of the injection pump sprocket with the hole in the flange, then screw in the sprocket mounting bolts, tightening them at this stage only by hand.
6. Install the NEW camshaft sprocket bolt finger-tight for now.
7. Install the lower chain tensioner (see Removal and installation of timing chain tensioners (engines 2.0 l).
8. Replace the upper chain guide (mounting lug up). Install NEW mounting bolts and tighten to specification.
9. If there are special tools, fix the camshaft, injection pump and crankshaft from turning, and also to make sure that the components are in the correct position. If there are no devices, make sure that the marks made during the dismantling process are aligned.
10. When using fixing devices, adjust the gas distribution mechanism (see Checking and adjusting the valve timing (engines 2.0 l), then remove the attachments.
11. If special adaptations were not used, achieve alignment of the labels put in the course of dismantle of components, then tighten bolts of fastening of asterisks of TNVD with the demanded effort. Tighten the camshaft sprocket bolt to stage 1 torque while holding the camshaft by the flats with an open end wrench. Make sure that the marks are not lost and tighten the bolt at the corners, stages 2 and 3 - use a goniometer nozzle, or apply reference marks with paint or marker.
12. Install the top chain tensioner (see Removal and installation of timing chain tensioners (engines 2.0 l).
13. Make sure that the mating surfaces of the injection pump sprocket cover and the chain cover are absolutely clean and dry. If the cover was installed with a gasket, be sure to replace the latter. Tighten the fixing bolts to the required torque. If there was no gasket, place a cushion of sealant about 2 mm thick into the groove of the cover, then press the cover, screw in the fixing bolts and tighten them with the required force.
14. Install the auxiliary drive belt tensioner on the engine - make sure that the axle bolts and the rack mounting bolts are tightened with the required force. When replacing the rack, or after the forced dismantling of the old one, grind the rack with reciprocating movements, grabbing the hexagonal part of the base with a replaceable socket head. After verifying that the rack is functioning properly, install the drive belt (see chapter Current service).
15. Install the right powertrain mount on the cylinder head, then lower the engine and remove the jack. Fix the support on the mudguard, - make sure that the landing marks applied during the dismantling process are aligned correctly and tighten the fixing bolts with the required force.
16. Install the timing cover (see Removal and installation of a cover of the gas-distributing mechanism).
17. Install the exhaust pipe, air cleaner housing and crankshaft position sensor (see chapter Power and exhaust systems). If camshaft locking tools were used, install a vacuum pump on the cylinder head (see chapter Brake system).
Lower chain and sprockets
1. If new components are installed, transfer installation marks from old parts to them.
2. Install the crankshaft key, then seat the sprocket on the trunnion - make sure the key enters the keyway.
3. Make sure that the injection pump flange is installed correctly (the cutout in the flange must align with the hole in the pump casing). The crankshaft must be set to the TDC position of the end of the compression stroke of the piston of the first cylinder and locked.
4. Seeking to match the marks made during dismantling, insert the pump sprocket into engagement with the chain and install the assembly on the engine. Put the chain on the crankshaft sprocket. Make sure that the marks are not lost and that the cutout in the pump flange is aligned with the hole in the sprocket.
5. Install the cover (see Removing and installing timing cover). Install the upper timing chain, (see above).
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