Note: When installing, the toothed drive belt must be replaced. A two-pronged puller may be required to remove the crankshaft sprocket.
Removing
1. Disconnect the negative cable from the battery.
2. Disconnect the air filter fitting from the air flow meter, then remove the cover and filter element from the air filter. If required, the entire air cleaner assembly can be removed for improved access as described in Section 4B.
3. Remove the power steering pump drive belt as described in Section 10.
4. Remove the alternator drive belt as described in Section 5.
5. Turn off three screws of fastening, remove an external cover of a gear driving belt. Remove the rubber o-rings from the screw holes in the cover if they are free.
6. Rotate the crankshaft until the timing marks on the camshaft sprockets line up with the notch in the camshaft cover. The notch in the crankshaft pulley must also align with the pointer on the back cover of the toothed drive belt (see illustrations).
7. Unscrew the six mounting bolts, remove the crankshaft pulley (see illustration), If necessary, keep the crankshaft from rotating with the socket of the bolt and the crankshaft sprocket. If the engine is not removed from the vehicle, the crankshaft can be locked by engaging 1st gear and depressing the brake pedal. You can also use a large screwdriver, inserting it into the teeth of the flywheel ring. Before removing the pulley, make sure that the alignment marks have not shifted.
8. Loosen the fastening bolt, release the toothed belt tensioner pulley, then pull the belt off the sprockets and pulleys (see illustration).
9. If required, the sprockets, tensioner, idler pulleys and toothed drive belt rear cover can be removed as follows, otherwise go to step 27.
10. To remove the camshaft sprockets, first disconnect the breather hoses from the camshaft cover (see illustration).
11. Remove the two mounting bolts, and remove the spark plug cap (see illustration), then disconnect the high voltage wires from the spark plugs, unfasten them from the end of the camshaft cover. If necessary, mark the position of the wires to avoid confusion during installation.
12. Remove twenty mounting bolts, remove the camshaft cover (see illustration).
13. Remove the one-piece rubber pad (see illustration).
14. Holding the camshaft from rotation by the cam contour, unscrew the camshaft sprocket bolt (see illustration).
15. Remove the sprocket from the end of the camshaft, then repeat the procedure with the remaining camshaft sprocket.
16. Remove the crankshaft sprocket This will require preventing the crankshaft from rotating by attaching a metal rod to the sprocket with two crankshaft pulley bolts, or by pinching the flywheel ring gear. To unscrew the sprocket bolt, you will need a socket - take into account that the bolt is very tight. If necessary, use a two-legged puller to remove the sprocket. Remove the thrust washers from the end of the crankshaft and from under the head of the bolt.
17. To remove the belt tensioner pulley, simply unscrew the mounting bolt in the center of the pulley, then remove the pulley along with the mounting plate (see illustration). Remove the spacer from the pulley bolt.
18. To remove the belt tensioner pulley, unscrew the mounting bolt in the center of the pulley, then remove the pulley itself and the spacer from the pulley bolt
19. Now you can remove the back cover of the toothed drive belt by unscrewing the upper and middle racks for the screws securing the outer cover.
Please note that the top strut is simply unscrewed from the cylinder head, and the middle strut is attached with a bolt. Unscrew the two upper and one lower right bolts securing the rear cover of the belt, and remove the rear cover (see illustrations).
Installation
20. Installing the rear cover of the toothed drive belt is carried out in the reverse order of removal.
21. Install the tensioner pulleys, spacers are installed with a smaller diameter to the pulley (see illustration). Do not fully tighten the tensioner pulley bolts yet.
22. Install the thrust washer on the end of the crankshaft, then install the sprocket. Apply a little grease to the threads of the mounting bolt, tighten it in two stages with the tightening torque specified specifications. Make sure the thrust washer is in place under the head of the bolt, keep the crankshaft from rotating as you did when removing.
23. Install the camshaft sprockets. Make sure that the dowel pins on the ends of the camshafts fit into the holes in the sprockets, with the sprockets with the alignment marks facing forward. Then, in two stages, tighten the fastening bolts with a tightening torque regulated specifications. Hold the camshafts from rotating, as you did when removing.
24. Check up a condition of a rubber laying of a cover of a cam-shaft, replace if necessary. Then install the camshaft cover and tighten the mounting bolts (see illustration).
25. Install the high voltage wires to the spark plugs, then clip the wires to the end of the camshaft cover. Install the spark plug cap and tighten the mounting bolts.
26. Connect the breather hose to the camshaft cover.
27. Temporarily install the crankshaft pulley. Make sure that the alignment marks on the crankshaft pulley and camshaft sprockets are aligned as described in step 6. Then install the new toothed drive belt on the sprockets and pulleys, starting with the crankshaft sprocket.
28. Install the crankshaft pulley, tighten the fastening bolts with a tightening torque regulated specifications. If necessary, keep the crankshaft from rotating, as you did when removing it.
29. Adjust the tension of the toothed drive belt as described starting from point 35.
30. Install the outer timing belt cover. Make sure the rubber o-rings are in place in the screw holes, then tighten the mounting screws.
31. Install the alternator drive belt, adjust the drive belt tension as described in Section 5.
32. Install the power steering pump drive belt, adjust the drive belt tension as described in Section 10.
33. Install the air cleaner components according to Section 4B, if it is needed.
34. Connect the negative battery cable.
Adjustment
Note: Manufacturers recommend using a special Opel tool No. KM-666 to adjust the tension of the toothed drive belt. If this tool is not available, a rough adjustment can be made using the method described in this Chapter. However, it should be emphasized that after as soon as possible, it is still necessary to contact the dealer in order to carry out the correct tension adjustment using a special tool.
Approximate adjustment
35. Timing belt adjustment cannot be checked and the following adjustment procedure only applies to a newly installed belt (engine must be cold).
36. After removing the toothed drive belt cover and loosening the tensioner pulley bolts, check that the TDC marks on the camshaft sprockets and crankshaft pulley are aligned as described in step 6. If necessary, turn the crankshaft to achieve alignment.
37. Press the flint tensioner pulley until the belt can only be rotated 45°by applying moderate pressure with thumb and forefinger on the longest section of the belt between the exhaust camshaft sprocket and tensioner pulley.
38. Fix the tensioner pulley in this position, tighten the tensioner pulley bolt in two stages with the tightening torque regulated by the Specifications.
39. Turn the crankshaft clockwise two full turns, the TDC mark on the crankshaft pulley should again align with the pointer on the back cover of the toothed drive belt, and the TDC marks on the camshaft sprockets should line up with notches in the camshaft cover.
40. Then proceed as described in paragraphs 30-34 inclusive.
41. After that, contact your Opel dealer as soon as possible to adjust the belt tension.
Adjustment with a special Opel tool (KM-666)
42. Proceed as described in paragraphs 35 and 36.
43. Install the special tool KM-666 on the tensioner pulley mounting plate, according to the manufacturer's instructions.
44. Counterclockwise the TDC marks on the exhaust camshaft sprocket, count the seventh tooth (see illustration).
45. Turn the crankshaft clockwise until this tooth aligns with the TDC notch in the camshaft cover. The crankshaft must be rotated evenly, without jerking, to prevent the toothed drive belt from jumping off the sprockets and pulleys.
46. Tighten the idler pulley bolt in two stages with a tightening torque specified specifications.
47. Remove the special tool.
48. Turn the crankshaft clockwise until the TDC marks on the camshaft sprockets align with the notches in the camshaft cover, check that the TDC mark on the crankshaft pulley aligns with the pointer on the back cover of the toothed drive belt.
49. Proceed as described in paragraphs 30-34 inclusive.
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