Replacing the camshaft drive belt of a 16-valve engine (Opel Kadett E)

Warning: If the timing belt has been removed, it must always be replaced with a new one.

Removal

Disconnect the wire from the negative terminal of the battery.

Remove the air filter and the air duct connecting it to the mass air flow meter.

Remove the alternator drive belt and the power steering pump drive belt (if it is installed).

Remove the front timing belt cover by unscrewing the three mounting bolts.

Turning the crankshaft clockwise using a ratchet wrench and a TORX E20 head, set the piston of the 1st cylinder to the TDC position at the end of the compression stroke and check the alignment of the timing mechanism drive installation marks (see above).

Loosen the bolts securing the side bracket for the oil radiator inlet and outlet pipes and move the pipes to the side.

Lock the crankshaft using a TORX E20 head wrench.

Loosen the six crankshaft pulley mounting bolts using the KM 312A tip.

Check the alignment of the timing drive installation marks again.

Remove the crankshaft pulley.

Warning: After removing the crankshaft pulley, do not turn the crankshaft or camshafts.

Loosen the timing belt tension roller mounting bolt, loosen the belt tension and remove it.

Installation

Place a new timing belt on the pulleys.

Install the crankshaft pulley, tighten the six bolts securing it to a torque of 20 kgf·m.

Warning: Timing belt tension is adjusted at ambient temperature with the engine cold.

Install a special device KM 666 to adjust the belt tension.



Turn the crankshaft 120° clockwise relative to the TDC position of the piston of the 1st cylinder, which corresponds to turning the camshaft pulleys by seven teeth. The turn should be done slowly to prevent the teeth of the toothed belt from jumping.

Tighten the tension roller mounting bolt to the required torque.

Remove the KM 666 belt tension adjustment tool.

Turning the crankshaft clockwise, set the piston of the 1st cylinder to the TDC position and check the alignment of the timing mechanism drive installation marks.

Install the removed parts in the reverse order of removal, ensuring that the rubber bushings of the three bolts securing the front toothed belt cover are in the correct position.