Gasoline engines and 1.7L diesel engines
Attention! Special instructions for 16-valve and diesel engines are given at the end of the section.
Removing
Disconnect wire "masses" from the battery.
Remove the air filter and (if there) suction hose.
Remove the alternator drive belt, power steering pump and air conditioning compressor.
Vehicles with V-ribbed belt: Remove belt, pulley and power steering pump.
Remove the front toothed belt cover by opening the clips.
Set the piston of the 1st cylinder to TDC. To do this, shift the transmission to neutral and apply the parking brake. Place a ring wrench or ratchet on the center bolt of the crankshaft pulley and turn the crankshaft clockwise until the mark on the pulley aligns with the pointer on the engine block (see bottom of figure C4459).
At the same time, the marks on the camshaft pulley and the engine block must match (see top of picture). If not, turn the crankshaft one more turn.
Attention! Do not turn the crankshaft by the camshaft pulley bolt, as this can overload the toothed belt.
Loosen the coolant pump mounting bolts (see arrows in fig. P0510).
For all engines except 1.4 and 1.6 liter engines from June 1990: Turn the coolant pump until the toothed belt is released.
Attention! Due to the lack of sufficient space to perform this operation with an ordinary key, it is recommended to use a special Opel key: for engines with a volume of 1.4 and 1.6 liters - KM-421 A; for engines with a volume of 1.8 and 2.0 liters - KM-637. If there is no such key, you can use a regular wrench, but you must first remove the generator.
Remove toothed belt from camshaft drive gear.
For engines with a volume of 1.4 and 1.6 liters of production since June 1990. (with automatic toothed belt tensioner): Press on the tensioner pulley and remove the toothed belt.
Attention! Do not change the position of the pulleys with the toothed belt removed!
Remove the belt pulley from the crankshaft, first engaging 1st gear and the parking brake. In this case, the crankshaft is blocked, and the bolt (bolts) pulley fasteners can be unscrewed (pic. A - pulley mounting bolt for engines with a volume of 1.4 and 1.6 liters; pic. B - pulley bolt for engines with a volume of 1.8 and 2.0 liters).
Installation
Attention! Before installing the belt, check that the mark on the camshaft drive gear matches the mark on the engine housing. In addition, the mark on the crankshaft pulley must match the pointer on the engine housing. To check, install and remove the pulley.
Install toothed belt.
Attention! For engines with a volume of 1.4 and 1.6 liters of production since June 1990. (with automatic belt tensioner) after installing the toothed belt and before installing the crankshaft pulley, install the tensioner roller.
Install the crankshaft pulley and secure it with bolts. For engines with a volume of 1.8 and 2.0 liters, four bolts are tightened with a torque of 25 Nm; for engines with a volume of 1.4 and 1.6 liters, the central bolt with a thread length of 23 mm is tightened with a torque of 55 Nm, a bolt with a thread length of 30 mm - with a torque of 55 Nm, and then both bolts are tightened to an angle of 45-60°.
Attention! Use only new bolts.
Engines without automatic tensioner: Tighten the belt.
Attention! After tensioning the belt, it is necessary to check the coincidence of the marks again. If necessary, loosen the belt and align the marks.
Install the coolant pump mounting bolts.
Rotate the crankshaft one full turn and check the belt tension again.
Tighten the coolant pump mounting bolts:
- for engines with a volume of 1.4 and 1.6 liters - a torque of 8 Nm;
- for engines with a volume of 1.8 and 2.0 liters - a torque of 25 Nm.
Install the front toothed belt cover and secure it.
Install and tighten the V-belt.
Vehicles with V-ribbed belt: Install belt, pulley and pump.
Install the air filter and (if there) suction hose.
Connect wire "masses" to the battery.
16 valve engines
The following are guidelines for 16-valve engines. Basically, the procedure for installing a belt on them is the same as for 8-valve engines.
Attention! The removed toothed belt must be replaced.
Set the piston of the 1st cylinder to the ignition position before TDC. To do this, first place the transmission in neutral and apply the parking brake. Then slowly turn the crankshaft by the pulley clockwise using the Opel MKM-6-4-21 or Hazet 900M-E20 key until the mark on the pulley matches the pointer on the engine housing (see bottom of fig.C8374).
At the same time, the marks on the camshaft drive gears must match the marks on the cylinder head cover (see top of fig.C8374). If this is not the case, then it is necessary to turn the crankshaft one more complete revolution.
Attention! Do not turn the crankshaft by the camshaft pulley bolt, as this can overload the toothed belt.
Remove the oil cooler line holders.
Remove the crankshaft pulley using an 8mm Allen key.
Attention! Before removing the pulley, once again check the correspondence of the ignition marks.
Loosen the tension roller and remove the toothed belt.
Attention! Do not turn the crankshaft and camshafts with a loose tension roller, as the toothed belt may jump onto the adjacent tooth.
Tighten the crankshaft pulley bolts to 20 Nm.
Install and tension the toothed belt.
Install the oil cooler line brackets.
Diesel engines
The following instructions are for diesel engines only. The installation procedure for a diesel engine is basically identical to that for a gasoline engine.
Removing
Remove the top and bottom timing belt covers.
Remove the clutch housing cover.
Set the piston of the 1st cylinder to TDC. To do this, turn the crankshaft in the direction of rotation until the marks on the flywheel match (see right figure in Fig. B4785) and on injection pump (see left figure fig.B4785).
Remove the camshaft housing cover.
Remove vacuum pump (it is mounted on the flange of the camshaft housing).
Loosen the camshaft mounting bolts.
Unscrew the bolts of the cooling system pump, move the pump with the Opel KM-509 tool (47.7 mm) and loosen the timing belt.
Detach engine mount at front right.
Press the engine off the support. Remove toothed belt from pulleys.
Installation
Check pulleys for damage, replace if necessary.
Check the match of the TDC marks, as shown in Figure B4785.
Install a new toothed belt.
Fasten the engine support to the longitudinal beam with a torque of 40 Nm.
Pull on toothed belt.
Tighten the coolant pump bolts to 25 Nm.
Screw in the camshaft pulley bolt without tightening it.
Check ignition setting (label matching).
Tighten the camshaft pulley bolt to 75 Nm, then tighten by 60-65°.
Install a new gasket under the camshaft taper cover and tighten the cover bolts crosswise.
Attach the lower and upper toothed belt covers.
Tighten the clutch housing bolts.
1.7L turbocharged diesel engine
Removing
Disconnect wire "masses" from the battery.
Remove air filter.
Remove the power steering pump and alternator V-belts.
Remove the top toothed belt cover.
Set the piston of the 1st cylinder to TDC. To do this, put the gearbox in neutral and apply the parking brake. Attach a ring wrench to the center bolt of the crankshaft pulley. Turn the crankshaft clockwise until the mark on the pulley aligns with the pointer on the engine housing.
At the same time, it is necessary to insert the fixing bolts into the camshaft pulleys and the injection pump. If this fails, rotate the crankshaft one full revolution. As fixing bolts, you can use ordinary M6x1 bolts (camshaft) and M8x1.25 (injection pump).
Attention! Do not change the position of the camshaft with the toothed belt removed.
Install the lifting device KM-263-B and tension the chain.
If the specified device is not available, place a suitable pipe over the engine compartment, resting it on the wings through wooden blocks. Do not lay the pipe directly on the fenders!
Remove right engine mount.
Remove the tension roller mount, remove the tension spring (see arrows in fig. D5906).
Loosen the crankshaft pulley mounting bolts and remove the pulley.
Loosen the camshaft pulley mounting bolts and remove the pulley. Loosen the camshaft drive gear bolt.
Remove toothed belt together with camshaft pulley.
Installation
Attention! Before installing the toothed belt, check that the mark on the camshaft drive gear matches the mark on the engine housing.
Install the toothed belt together with the camshaft pulley.
Install the fixing bolt and the camshaft pulley bolts. Tighten bolts to 10 Nm.
Install the tensioner spring and tighten its fastening bolts to 20 Nm.
Attach the lower toothed belt cover.
Install the camshaft pulley and tighten its fastening bolts to 20 Nm.
Install the right engine mount and remove the engine lift from the fenders.
Loosen the fixing screw.
Attention! Once again check the location of the marks with the toothed belt tensioned. If necessary, loosen the belt and achieve the correct relative position of the marks.
Check injection start timing.
Install the upper toothed belt cover.
Install V-belt.
Connect wire "masses" to the battery.
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