Remove the clutch housing cover.
Unscrew the upper and lower timing belt shield.
Set the piston of the first cylinder to TDC. To do this, put the gearbox in neutral and tighten the handbrake. Place a bent, socket, wrench or socket wrench onto the center bolt of the engine crankshaft pulley. Turn the crankshaft clockwise by hand until the top dead center mark on the flywheel (right) and the top dead center mark on the injection pump gear (left) align with their corresponding markings.
Unscrew the camshaft housing cover.
Remove the vacuum pump.
Instead of the vacuum pump, install and lock the camshaft using the Opel KM-537 tool.
Loosen the camshaft wheel mounting bolts while holding the shaft with a wrench inserted into the special grooves on the camshaft. Ri S.V4700.
Loosen the water pump mounting bolts.
Loosen the timing belts by turning 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 timing belt guide wheels; replace damaged ones.
Check if the markings match as described in Figure B4785.
Put on a new belt.
Secure the engine support to the side member with a force of 40 Nm.
Tighten the timing belt.
Tighten the water pump bolts to 25 Nm.
Tighten the camshaft wheel bolts, but do not over tighten.
Check the valve timing.
Tighten the camshaft wheel to 75 Nm and turn them another 60°. Note: Always replace the bolts!
Check the moment the injection pump starts to feed.
Install the vacuum pump.
Install a new seal and tighten the camshaft cover evenly.
Screw on the lower and upper timing belt covers.
Screw on the clutch cover.
Checking the tension and adjusting the timing belt
For diesel engines up to 8/86, check the timing belt tension every 30,000 km. For petrol and diesel engines from 9/86, check the timing 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-l engines; KM-421A: 1.6-/1.8 l engines and diesel engine: KM-509; 1.8-/2.0 l engines: KM-637. Tensioning can also be done with a regular wrench, but to do this you need to remove the generator.
Correct tension increases belt life. Check the tension on a warm engine. Coolant temperature is about 80°C. If possible, install and tension the new belt on a cold engine. Coolant temperature below +25°C.
Caution! 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 "B". The device is installed in the upper part of the belt.
Loosen the generator tension bar and remove the V-belt. Lower the generator down.
Unscrew the upper and lower timing belt covers.
Set piston 1 of engine cylinder to TDC. At the same time, turn the engine crankshaft at least 90° so that the toothed belt is tensioned.
Caution! Do not check the belt by hand, bending or twisting it.
Place the KM-510-A device in the working position and lock it.
Place the device on the toothed belt at point "B", see figure A7872. Carefully unlock the device.
Attention! Install the test device so that the belt passes between points A, B, C, and the tensioner must fall between the belt teeth.
By lightly pressing your fingertips on the device, release it and take readings, see table.
Timing Belt Installation Value Table
Installation
Loosen the water pump mounting bolts.
Use a special key for the water pump to adjust the toothed belt; turning the pump up increases the tension, turning it down decreases it. The tension can be adjusted using a regular wrench of the appropriate size, but to do this you need to remove the generator.
| Designation | Special tool OPEL | Wrench Motor Size |
| 16N, 16SH, C18NE, 18E, 16D (Dieselmotor)OPEL | KI-509-AOPEL | 47.7 mm |
Tighten the water pump mounting bolts to the torques shown. table.
| Engine designation | Meaning of torques |
| 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 toothed belt until the device shows a constant value.
Install the upper and lower timing belt covers.
Diesel engine: check valve timing.
Diesel engine: check the start of delivery.
Install the generator. Put on the V-belt. Tighten the V-belt.
Attention! If you do not have a timing belt tension tester at hand (abroad, accident), then temporarily adjust the belt so that when you press it at point "B", figure A7872, it bends by about 10 mm. Avoid high speeds. Check with the device at the earliest opportunity.
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