Remove the clutch housing cover.
Unscrew the upper and lower toothed belt guards.
Set the piston of the first cylinder to TDC. To do this, put the gearbox in neutral and apply the handbrake. Place a bent wrench, an overhead wrench, or a socket wrench and a ratchet onto the center bolt of the engine crankshaft pulley. Rotate the crankshaft by hand clockwise until the top dead center marking on the flywheel (on right) and marking of the top dead center on the injection pump gear (left) do not match the corresponding markings.
Unscrew the camshaft housing.
Remove the vacuum pump.
Instead of a vacuum pump, install and block the camshaft using an Opel KM-537 tool.
Loosen the camshaft wheel mounting bolts, holding the shaft with a wrench inserted into the special flats on the camshaft. Ri S.V4700.
Loosen the water pump mounting bolts.
Loosen the timing belts by swinging the pump counterclockwise using the OPEL tool KM-509.
Separate the engine mount, front right, from the side member.
Move the engine away from the side member. Remove the toothed belt from the idler wheels and pull it out between the side member and the engine support.
Check the serviceability of the toothed belt guide wheels; replace damaged ones.
Check whether the markings match, as described in Fig. B4785.
Put on a new belt.
Secure the engine mount to the side member with a force of 40 Nm.
Tension the toothed belt.
Tighten the water pump bolts to 25 Nm.
Tighten the camshaft wheel bolts, but do not tighten them.
Check valve timing.
Tighten the camshaft wheel to 75 Nm and turn them not yet 60°. Attention: always replace bolts!
Check the start point of the injection pump.
Install the vacuum pump.
Install a new seal and tighten the camshaft cap evenly.
Screw on the lower and upper toothed belt guards.
Screw on the clutch cover.
Checking the tension and adjusting the timing belt
For diesel engines up to 8/86, check the toothed belt tension every 30,000 km. For gasoline and diesel engines with 9/86, check the toothed belt tension every 60,000 km or every 4th service.
Examination
To check the tension of the toothed belt, you need the OPEL device KM-510-A. The following special keys: 1.3-/1.6-liter engines; KM-421A: 1.6-/1.8 l engines and diesel engine: KM-509; engines 1.8-/2.0 l: KM-637. The tension can be done with a regular wrench, but to do this you need to remove the generator.
Proper tension increases belt life. Check the tension on a warm engine. The coolant temperature is about 80°C. If possible, a new belt should be installed and tensioned on a cold engine. The coolant temperature is below +25°C.
Attention! Do not check the belt tension by hand. Incorrect tension leads to increased noise.
The tension is checked on the driven branch of the belt drive "IN". The device is installed at the top of the belt.
Loosen the generator tension bar and remove the V-belt. Lower the generator down.
Unscrew the upper and lower toothed belt casings.
Place the piston of engine cylinder 1 at TDC. At the same time, rotate the engine crankshaft at least 90°so that the toothed belt is tensioned.
Attention! Do not check the belt by hand by bending or twisting.
Place the KM-510-A device in the working position and lock it.
Install the device on the timing belt at the point "IN", see fig. A7872. Carefully unlock the device.
Attention! Install the tester so that the belt passes between points A, B, C, and the tensioner should fit between the belt teeth.
Lightly press the device with your fingertips to unlock it and take readings, see table.
Value table for timing belt installation
Installation
Loosen the water pump mounting bolts.
Use a special wrench for the water pump to adjust the toothed belt; turning the pump up increases the tension and down decreases it. The tension can be adjusted with a regular wrench of the appropriate size, but to do this you need to remove the generator.
Designation | Special tools OPEL | Wrench motor size |
16N, 16SH, C18NE, 18E, 16D (Dieselmotor) OPEL | KI-509-AOPEL | 47.7 mm |
Screw the water pump mounting bolts to the torques shown in the table.
Engine designation | Torque value |
16N, 16SH, 1.8-2.0 l Diesel | 25 Nm |
Remove the device. Make a full revolution of the crankshaft. Check the tension again.
Attention! Install and check the timing belt until the device shows a constant value.
Install the upper and lower timing belt guards.
Diesel engine: check valve timing.
Diesel engine: check the starting point.
Install the generator. Put on the V-belt. Tension the V-belt.
Attention! If you do not have a tool at hand to check the timing belt tension (abroad, accident), then temporarily adjust the belt so that when you press it at the point "IN", Fig. A7872, it bent by about 10 mm. Avoid high speeds. Check with the device as soon as possible.
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