Removal and installation the timing belt (Opel Kadett D)

Removal

Disconnect the ground cable from the battery.

Remove the air filter, see paragraph 4.44.

Remove the cover from the clutch housing, see item 9.

Remove the V-belt, see item 22.3.

Remove the upper and lower timing belt covers, see item 6.7.



Remove the torsional vibration damper (four screws).

Remove the cover from the camshaft housing.

Remove the vacuum pump, see item 7.14.

Rotate the crankshaft in the direction of engine rotation until the top dead center mark on the flywheel coincides with the top dead center mark on the high-pressure fuel pump. To do this, engage fourth gear and push the car, or set the gearbox to idle and, accordingly, turn the crankshaft (place the socket wrench on the crankshaft pulley).

The crankshaft is at TDC for the first cylinder if the valves of the fourth cylinder are overlapped. In this position, the KM-537 tool can be used instead of a vacuum pump.

Using the KM-537 tool, lock the camshaft, see item 7.15.

Unscrew the camshaft gear mounting screws. At the same time, use a wrench to hold the camshaft from turning, see p. 1.6.





Unscrew the water pump mounting screws (arrow).



Move the water pump counterclockwise using the KM-509 wrench, which loosens the V-belt tension. You can also use a 41 mm wrench. However, the generator must first be removed.



Disconnect the engine mount to the right of the side member.

Press the engine off the side member. Remove the toothed belt from the drive gears and pull it between the side member and the engine mount.

Installation

Check if the TDC marks match.

Pull a new toothed belt between the side member and the engine mount.

Secure the engine mount to the side member.

Tighten the toothed belt, see p. 6.6.

Tighten the coolant pump screws to 25 Nm.

Tighten the vibration damper screws to 50 Nm (4 pcs).

Check, if necessary, whether the TDC marks match.

Tighten the camshaft gear mounting screws to 90 Nm, using a wrench to prevent the camshaft from turning.

Check the valve timing, see item 7.15.

Check the moment of fuel supply by the high-pressure fuel pump, see item 7.11.

Install the vacuum pump.

Install the camshaft housing cover and tighten the screws.

Install the upper and lower timing belt covers.

Install and tension the V-belt, see item 22.3.

Install the clutch dome cover.

Install the air filter.

Connect the ground cable to the battery.