Removal and installation the timing belt/chain (Opel Corsa C)

General information

The main purpose of the toothed belt/chain is to drive the gas distribution mechanism (GRM), while it ensures coordinated opening/closing of the valves depending on the current stroke of the working cycle in each of the engine cylinders. In addition, on various engine models, some auxiliary units, such as the high-pressure fuel pump, are driven by means of a toothed belt/chain (diesel models), water pump and some other units.

Checking and replacing the timing belt must be carried out in strict accordance with the Maintenance Schedule (see Chapter 1). A whistling or whining toothed belt when the engine is running indicates that it is too tight, while if the tension is too low, the belt hits the cover. A toothed belt failure can cause serious damage to the engine, so it is recommended to replace the belt each time it is removed. If you plan to reuse the belt, mark the toothed wheels with a marker before removing it (in the form of an arrow) to determine the direction of rotation during subsequent installation. Note: The belt rotates clockwise when viewed from the belt drive side of the engine. It is recommended to draw a diagram of its tension before removing the belt.

The chain requires virtually no maintenance throughout its entire service life. When troubleshooting or replacing units driven by the chain, it may be necessary to remove and sometimes replace the chain. After each chain removal, the valve timing must be adjusted. These operations can only be performed using special tools - take care of purchasing them in advance.



During operation, due to weakening of the belt/chain, increase in length or some damage to the belt, it/she may jump one or more teeth on the gear wheels/sprockets of the camshafts, which will lead to a violation of the timing phase coordination, a decrease in engine efficiency, and in some cases to failure of the valves or pistons of the cylinders. Adjustment of the timing phases is carried out with the toothed belt/chain removed by aligning the marks/installing the devices when setting the TDC position for the corresponding piston (see Section 6).

Caution: When turning the camshafts with the timing belt/chain removed, none of the pistons should be in the TDC position - otherwise the valves will rest against the piston, which may damage the valves and/or pistons. It is necessary to turn the engine crankshaft approximately 60° from the TDC position! The crankshaft may not be turned if only a small displacement of the camshafts is required - in this case, choose the shortest path to the TDC position.

Note: After replacing the timing belt, it is recommended to stick a label on the upper timing belt cover indicating the current mileage and replacement date.

Engines Z14XE/Z16XE/Z18XE

Removal

1. Disconnect the cable from the negative terminal of the battery (see Chapter 5) and remove the top engine cover (see Section 2).

2. Remove the air cleaner (see Chapter 4) and the right front wheel.

3. Remove the multi-rib belt (see Section 7).

4. Remove the locking pin and loosen the multi-rib belt tensioner. Remove the mounting bolt (see accompanying illustration) and remove the device from the engine.





5. Set the piston of the first cylinder to the TDC position of the compression stroke (see Section 6).

6. Remove the crankshaft pulley (see Section 5), then reinstall the mounting bolt and secure the timing belt drive wheel with it.

7. Unscrew the mounting bolt (see accompanying illustration) and remove the lower timing belt cover.



8. Remove the right engine mount (see Section 5).

9. Remove the 3 screws securing the upper timing belt cover (see accompanying illustration) and remove the lid.





10. Disconnect the camshaft sensor wiring connector, on the Z16XE engine, unscrew the 2 bolts and remove the sensor from the cylinder head.

11. Check the TDC position for the piston of the first cylinder of the engine, check that all marks match (see illustration 8.11, I and III) and fix the position of the camshafts using a special device (see illustration 8.11, II).

Note: If the marks on the gears do not match, there is no need to fix the camshafts.

12. Loosen the mounting bolt and use a hex key to turn the timing belt tension roller clockwise by the adjusting eccentric (see accompanying illustration) until the tension roller indicator is positioned in front of the left stop, tighten the bolt. If necessary, mark the direction of rotation of the belt and remove it. A belt that has characteristic signs of wear, kinks and damage must be replaced without fail.



13. If, when checking the valve timing adjustment, the marks on the timing gear do not match, it is necessary, after removing the belt, to turn the camshafts, set the marks to the required position and fix them with a special device (see illustration 8.11, II).

Caution: Do not change the position of the crankshaft when the belt is removed.

14. If necessary, unscrew the mounting bolt and remove the timing belt tension roller (see accompanying illustration). The guide roller is removed in the same way.

Installation

15. Install (if they were filmed) guide and tension rollers of the toothed belt. The tension roller locking lever must be installed in the guide on the oil pump housing (see accompanying illustration).

Note: The tensioner mounting bolt is only fully tightened to the required torque after adjustment (see below).

16. Install the belt on the wheels and rollers so that the pulling branch (right - if you look at the engine from the timing drive side) was tensioned, do not forget to check the direction of rotation of the belt. Check the alignment of all timing marks.

17. After replacing/removing the belt, it is necessary to adjust its tension by loosening the fastening bolt (if the video was not filmed) and turn the timing belt tension roller (see accompanying illustration) by the adjusting eccentric in the direction of the arrow so that the tension roller indicator is in front of the right stop, tighten the bolt.

Note: On the Z16XE engine, this operation is performed from under the engine. To check the position of the tension roller indicator, it is necessary to use a special inspection mirror.

18. Remove the KM-852 device, smoothly turn the crankshaft 2 full turns clockwise and set the piston of the first cylinder to the TDC position. To check the position, reinstall the KM-852 device; if no adjustment is required, remove it. If the marks do not match, (see illustration 8.11) remove and reinstall the timing belt.

19. Slightly loosen the timing belt tension roller mounting bolt, turn the adjusting eccentric clockwise so that the position of the pointer corresponds to that shown in the accompanying illustration. Tighten the tension roller mounting bolt to the required torque.



20. Once again, smoothly turn the crankshaft by 2 full revolutions and set the TDC position. If after turning the crankshaft the timing marks do not match, reinstall the belt; if the tension roller indicator deviates from the standard position, repeat the toothed belt tensioning procedure.



21. Install the remaining removed components in the reverse order of removal. On the Z16XE engine, lubricate the camshaft position sensor mounting bolts with a fixing compound.

Z16SE Engine

Note: On these models, the timing belt removal procedure is almost the same as on the Z14XE/Z16XE/Z18XE engines. The description below only indicates the differences.

Caution: When the timing belt is loosened/tightened on these engines, the water pump housing shifts, which may result in a loss of tightness of its seal. It is recommended that when replacing the timing belt, the water pump is also removed to replace its seal (see Chapter 3).

Removal

22. Remove 3 bolts and the upper timing belt cover (see accompanying illustration).



23. Remove the crankshaft pulley (see Section 5), then reinstall the mounting bolt and secure the toothed belt drive wheel with it. Unscrew the mounting bolts (see accompanying illustration) and remove the lower timing belt cover.



24. Remove the right engine mount (see Section 5).

25. Check the TDC position for the piston of the first engine cylinder (see Section 6), - the position of the marks with the crankshaft pulley removed is shown in the accompanying illustration.



26. Drain the coolant (see Chapter 3) and unscrew the 3 bolts securing the water pump (see accompanying illustration).



27. Overcoming the spring force, press the timing belt tension roller upwards, align the holes and fix the roller in the pressed position using a suitable mandrel (see accompanying illustration).



28. Turn the water pump with a wrench or a special device KM-421-A in the direction indicated by the arrow (see accompanying illustration) and loosen the timing belt tension.



29. Remove the toothed belt. If necessary, mark its direction of rotation beforehand.

Caution: Do not change the position of the crankshaft when the belt is removed.

Installation

30. Install the water pump (if it was filmed) with a new sealing ring, but do not tighten the fastening screws.

31. Install the toothed belt on the wheels so that the pulling branch (right - if you look at the engine from the timing drive side) was tensioned, do not forget to check the direction of rotation of the belt. Check the position of the TDC of the compression stroke for the piston of the first cylinder - all marks must match. Otherwise, turn the corresponding shaft by the required amount.

32. Lightly press the timing belt tension roller, remove the mandrel and release the tension roller.

33. Using the special device KM-421-A, turn the pump in the direction indicated by the arrow and set the tensioner indicator in front of the upper stop (see accompanying illustration). In this position, tighten the water pump mounting bolts.



34. Smoothly turn the crankshaft 2 full turns clockwise and set the piston of the first cylinder to the TDC position - the water pump should not move.

35. Loosen the water pump mounting bolts, turn the pump counterclockwise so that the position of the pointer corresponds to that shown in the accompanying illustration. Tighten the water pump mounting bolts to the required torque.



36. Once again, smoothly turn the crankshaft by 2 full revolutions and set the TDC position. If after turning the crankshaft the timing marks do not match, reinstall the belt; if the tension roller indicator deviates from the standard position, repeat the toothed belt tensioning procedure.

37. Reinstall all components that were removed. Fill the system with coolant and make any necessary adjustments (see Chapter 1).

Engines Y17DT(L)/Z17DTH)

Note: In general, the procedure for removing/installing the timing belt on these models is the same as on gasoline engines. The description below only indicates the differences.

Removal

38. Disconnect the electrical wiring from the generator (see Chapter 5).

39. Disconnect the cable channel box and vacuum lines in front of the upper timing belt cover.

40. On the Z17DTH engine, disconnect the camshaft sensor and boost pressure sensor wiring connectors. Remove the camshaft sensor.

41. Remove the upper timing belt cover (see accompanying illustration).

Note: The cover is secured with bolts of different lengths, please remember or mark the installation position of the bolts.

42. Remove the right engine mount and dismantle the right engine mount mounting bracket (see Section 5).

43. Loosen the water pump drive pulley mounting bolts (see accompanying illustration). Remove the multi-rib belt, then completely remove the bolts and pulley.



44. On the Z17DTH engine, disconnect the electrical wiring from the starter (see Chapter 5).

45. Remove 4 bolts and crankshaft pulley (see Section 5).

46. Loosen the mounting bolts and remove the lower timing belt cover (see accompanying illustration).



47. Set the engine to TDC position (see Section 6).

48. On Y17DT/Y17DTL engines, secure the tension roller with an M10 bolt by screwing it through the lower hole of the roller into the cylinder block. Loosen the roller mounting bolt and remove the tension spring (see accompanying illustration).



49. On the Z17DTH engine, loosen the timing belt tension roller mounting bolt (see accompanying illustration), turn the tension roller at an angle of 90° with a socket wrench(1/4 turn) counterclockwise and fix the roller in this position by tightening the mounting bolt.



50. Remove the toothed belt. If necessary, mark its direction of rotation.

Installation

51. Install the toothed belt, observing the direction of rotation, on the drive gears in the following sequence: crankshaft drive gear, oil pump wheel, fuel injection pump wheel and camshaft wheel (see accompanying illustration).

Note: The fuel injection pump and timing drive wheels must be secured with bolts; the marks on the crankshaft mounting flange and the oil pump housing must match.

52. Install the tension spring, loosen the tension roller mounting bolt and release the roller - the belt will tighten. Unscrew the fixing bolts from the fuel injection pump gears and the camshaft.

53. Turn the crankshaft by the central bolt at an angle of 60° against the direction of engine rotation (counterclockwise) and tighten the tension roller mounting bolt to the required torque.

54. Smoothly turn the crankshaft 2 full turns clockwise and set the piston of the first cylinder to the TDC position of the compression stroke (see Section 6), - the marks on the crankshaft flange and the oil pump housing must match (see illustration 8.51). Screw the adjusting bolts into the fuel injection pump and timing belt drive gears - if at least one of the bolts does not screw in (the holes on the wheel and engine housing did not match), reinstall the timing belt.

55. Installation of removed and disconnected components is carried out in the reverse order of dismantling. When installing the crankshaft pulley, it is necessary to align the axis of the mounting flange with the hole in the pulley, do not forget to replace the pulley mounting bolts. Tighten all fasteners with the required force (see Specifications). The water pump mounting bolts are finally tightened after installing the multi-rib belt. After completing the work, check the coolant level and make the appropriate adjustments if necessary.

56. Instructions for installing the toothed belt tension roller on the Z17DTH engine: install the spring and screw in the roller mounting bolt. Turn the tension roller approximately 180° counterclockwise and tighten the mounting (clamp) bolt to approximately 40 Nm.

Engines Z10XE(P)/Z12XE/Z14XEP

Note: The procedure for removing/installing the timing chain for the Z10XEP engine equipped with an air conditioning system is described below. For other engines, this procedure is almost completely similar, but some additional operations may be required due to the specifics of the assembly of the units.

Removal

57. Disconnect the cable from the negative terminal of the battery (see Chapter 5), drain the coolant (see Chapter 3) and remove the air cleaner (see Chapter 4).

58. Disconnect the heating system hoses and disconnect the electrical wiring connectors shown in the accompanying illustration.



59. Disconnect the upper and lower coolant hoses from the water pump assembly (see Chapter 3).

60. Remove the ignition module (see Chapter 5), unscrew the mounting bolts and remove the cylinder head cover.

61. Remove the right front wheel (see Chapter "Introduction"), remove the multi-rib belt cover (see Section 5) and drain the oil from the engine crankcase (see Chapter 1).

62. Remove the exhaust system (see Chapter 4).

63. Disconnect the generator wiring (see Chapter 5), secure the tension roller and remove the multi-rib belt from the crankshaft pulley (see Section 7).

64. Press the tension roller, remove the locking device KM-6130 and release the roller. Unscrew the tensioner mounting bolts (see accompanying illustration).

Caution: The tensioner must be in a vertical position (the arrow on the device points upwards), otherwise the shock absorber fluid may leak out and the tensioner may fail!

65. Remove the generator (see Chapter 5) and remove the engine oil pan (see Section 12).

66. Install the special tool kit for removing the right engine mount (see Section 5) and loosen the support fasteners.

67. Remove 3 bolts (see accompanying illustration), separate the air conditioning compressor and set it aside or tie it to the supporting parts of the body.

Caution: Proceed with caution - the air conditioning system must not be compromised! Safety precautions when working with refrigerant are given in Chapter 3. If you are unsure of your abilities, seek help from specialists!

68. Remove the right engine mount (see Section 5) and remove the multi-rib belt.

69. Remove the 3 mounting bolts and remove the water pump drive pulley.

Note: The bolts must be loosened beforehand with the multi-rib belt installed.

70. Remove the mounting bolt and remove the multi-rib belt tensioner from the engine.

71. Unscrew 3 bolts and remove the connecting pipe of the cooling system (see accompanying illustration).



72. Set the piston of the first cylinder to the TDC position of the compression stroke (see Section 6). Remove the 6 crankshaft pulley mounting bolts, holding the pulley from turning by the central bolt (see Section 5), and remove the pulley.

Note: When removing the pulley, the crankshaft locking device must be removed.

73. Holding the crankshaft from turning using the KM-956-1/-2 device (see accompanying illustration), loosen the central bolt securing the crankshaft mounting flange - use the help of an assistant.

Note: On other engines, a special device KM-6013 may be additionally required, which is installed on the flange during this operation. The KM-952 device must be removed from the mounting hole.

74. Reinstall the KM-952 device, completely unscrew the central bolt and remove the mounting flange.

75. Unscrew 2 bolts M10 and 14 lower bolts MB fastening the timing belt cover (see accompanying illustration). Lower the car, remove the 4 mounting bolts and remove the water pump. Then remove the 4 more upper mounting bolts and remove the timing belt cover from the engine.

Note: Bolts of different lengths are used for fastening - remember or mark their installation position.

76. Pull back and secure the chain tensioner using the KM-955-1 tool (see accompanying illustration). Remove the guides (alternately - (3), (5), (7)) and remove the chain from the crankshaft drive sprocket. Remove the timing cover gasket, clean the mating surfaces.



77. Using a suitable tool, carefully remove the front crankshaft oil seal from the timing cover seat - do not damage the seating surfaces.

Note: The seal must be replaced every time the timing chain is replaced/removed.

Installation

78. Lubricate the outer surfaces of the new seal with silicone grease (white) and install the seal using the KM-960 tool (see accompanying illustration) into the seat of the timing belt cover.



79. Remove any remaining old gasket from the timing belt cover and install a new water pump gasket on the cleaned surface - make sure the guide bushings are installed correctly (see accompanying illustration) Install the water pump onto the drive cover, securing it with 3 short bolts.



80. Remove the elastomer gaskets (see accompanying illustration) the joints of the cylinder head with the cylinder block and replace them with new ones, having previously lubricated them with silicone sealant (gray color), applying a strip of sealant approximately 2 mm thick. In the absence of elastomeric gaskets, the joints of the mating surfaces can be filled with sealant without installing gaskets.

Caution: Installation of the timing belt cover must be completed within 10 minutes after applying the sealant!

81. Install a new timing cover gasket onto the engine - make sure the guide bushings are installed correctly (see illustration 8.76).

82. Install the crankshaft drive sprocket onto the shaft and install the timing chain onto the camshaft sprockets - the pull (right) side of the chain should be taut. Install the guides in the reverse order of their removal (see paragraph 76).

83. Install the timing belt cover and tighten the mounting bolts one by one, in accordance with the numbers shown in the accompanying illustration.



84. Remove the adjusting devices KM-952 and KM-953 from the engine. Using special devices (see above), install the crankshaft mounting flange.

85. Check and adjust the valve timing (see Section 6) and install the remaining removed components in the reverse order of their removal. Fill the lubrication system with oil and coolant into the engine cooling system; check the systems for leaks.

Z13DT Engine

Removal

86. Disconnect the cable from the negative terminal of the battery (see Chapter 5), remove the multi-rib belt cover (see Section 5) and drain the coolant (see Chapter 3).

87. Remove the air cleaner (see Chapter 4) and set the piston of the first cylinder to the TDC position of the compression stroke (see Section 6).

88. Remove the exhaust system (see Chapter 4).

89. Loosen the 4 crankshaft pulley mounting bolts (see Section 5) and remove the multi-rib belt (see Section 7). Then completely unscrew the mounting bolts and remove the pulley.

90. Loosen the mounting bolt and remove the multi-rib belt tension roller (see accompanying illustration).



91. Drain the oil from the engine crankcase (see Chapter 1).

92. Lower the vehicle and remove the turbocharger boost air pipe (see accompanying illustration), and then the heat exchanger tube and the oil feed line - be careful not to burn yourself on the exhaust manifold heat shield.



93. Remove 4 bolts and oil filter heat exchanger (see accompanying illustration).



94. Bend back the retaining plate tabs. Remove the 3 bolts and separate the catalytic converter (see accompanying illustration).



95. Install the KM-662-C device on the crankshaft flange (see accompanying illustration). Using a device to hold the crankshaft from turning, loosen the central mounting bolt - use an assistant to help.

Attention: The bolt has a left-hand thread!

96. Block the engine flywheel from turning by installing the KM-46785 device into the hole on the clutch dome - be careful when installing the device.

97. Remove the engine oil pan (see Section 12). Install the special tool and remove the right engine mount (see Section 5), and then the bracket for mounting the right support.

98. Remove the crankcase ventilation system (PCV) hose, loosen the 4 nuts and remove the cooling system water pump (see Chapter 3).

99. Remove the bolt and the wiring harness mounting bracket from the timing belt cover (see accompanying illustration). Unscrew 14 bolts, loosen 3 fastening nuts and remove the timing belt cover assembly with the oil intake from the engine.



100. Release the hydraulic timing chain tensioner (see accompanying illustration), fix it with the KM-955 device, unscrew 2 bolts and remove the tensioner. Unscrew the bolt and remove the tensioner bar. Remove the timing chain from the sprockets.

Installation

101. Installation is carried out in the reverse order of removal. Before installing the timing belt cover, remove the remains of the old sealant and apply a layer of fresh sealant (e.g. Loctite 5900) on the mating surfaces. When installing, center the cover on the crankshaft using the special device KM-4677 5 (see accompanying illustration). Tighten the fasteners in the order shown.



102. Before securing the crankshaft flange, using a suitable tool, carefully remove the front shaft seal from the mounting seat - do not damage the mounting surfaces. Lubricate the outer surfaces of the new seal with fresh engine oil and install the seal using the EN-46776 tool (see illustration 8.101) into the seat of the timing belt cover.