The timing belt must be removed on a cold engine!
Do not turn the engine with the timing belt removed!
A new camshaft timing gear bolt will be required
Removal
1. Disconnect the negative cable from the battery.
2. Remove the air filter with the supply hose.
3. On 1.7 l engine remove the engine mounts as a set.
4. Remove the accessory drive belt (see Chapter Vehicle settings and routine maintenance).
5. Unscrew the mounting bolts and remove the upper timing belt cover.
6. Set the piston of the first cylinder to the TDC position (see section Procedures for repairing diesel engines without removing them from the vehicle).
7. If the removed belt is to be reinstalled later, mark the direction of rotation of the engine on it with a felt-tip pen (clockwise).
8. Loosen the tension roller fastening (arrows) and disconnect its spring
Tension roller mounting
9. Remove the toothed belt from the fuel injection pump pulley.
10. Remove the crankshaft pulley. To do this, hold the crankshaft by the central mounting bolt with a spanner and unscrew the mounting bolts.
Crankshaft pulley mounting bolts
11. Unscrew the mounting bolts and remove the lower timing belt cover.
12. Remove the timing belt.
Removal and installation engine mounts (1.7L engine)
1. Raise the engine using the KM-263-V device and a chain. Instead of the specified device, you can use a suitable pipe, installing it on wooden blocks on the wing protrusions.
Using a special device to lift the engine
Original posted on the website OpelBook.ru
2. Unscrew the bolts securing the engine damping support to the holder.
Engine damper mount to bracket mounting bolts
3. Unscrew the bolts securing the engine damper support to the front frame longitudinal beam. After this, clean the threads with a wire brush from any remaining sealant.
4. Remove the bolts securing the engine mount bracket from the engine block.
5. Installation is performed in the reverse order of component dismantling. Tighten the fasteners with the required force. Pre-lubricate the threads with a sealant, for example, OPEL-15 10 177.
Installation
Before installing the timing belt, check whether the mark on the crankshaft pulley matches the pointer on the cylinder block. The fixing bolts in the camshaft and fuel injection pump gears should be screwed in at the same time. The crankshaft pulley can be temporarily installed for checking.
1. Put on the timing belt in accordance with its routing diagram.
Drive Belt Routing Diagram
If the old belt is installed, observe the direction of its movement.
2. Tighten the lower timing belt cover mounting bolts with force 10 Nm.
3. Install the crankshaft pulley and tighten its mounting bolts with force 20 Nm.
4. Remove the TDC position lock bolts.
5. Hook the tension roller spring, thereby tensioning the timing belt.
The crankshaft must be in a position corresponding to the TDC position of the piston of the first cylinder.
6. Install the tension roller and tighten its fasteners with force 20 Nm. In this case, first tighten the bolt (A) and then the nut (B).
Tension roller fastener
7. Turn the crankshaft two full turns in the direction of engine rotation so that the piston of the first cylinder stops at the TDC position.
Rotate the crankshaft smoothly to prevent the belt teeth from jumping. Temporarily insert the bolts for fixing and check the TDC position.
8. Check the fuel injection timing (see Chapter Fuel, exhaust and emission control systems).
9. Further installation is carried out in the reverse order of dismantling the components.
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