Contents: Removal ⬇ Installation ⬇
Camshaft pulley for 1.8 and 2.0 L engines
Removal
1. Remove the timing belt.
Camshaft pulleys
2. To unscrew the camshaft pulley mounting bolt, secure the camshaft before turning either by the camshaft pulley or by the camshaft grooves with a wrench.
3. Remove the bolt and pulley from the end of the camshaft. On 1.6L engines, the intake and exhaust camshaft pulleys are different. The camshaft pulley that controls the exhaust valves should be identified by the lugs that activate the camshaft position sensor. On 1.8L and 2.0L models, both pulleys are the same.
Crankshaft pulley model 1.6L
4. Remove the pulley from the end of the crankshaft.
Crankshaft pulley for 1.8 and 2.0L models
Warning: A new bolt must be used to secure the crankshaft pulley.
5. Loosen the crankshaft pulley mounting bolt. To prevent the crankshaft from turning, have an assistant engage any gear and apply the brake.
6. Remove the bolt and pulley from the end of the crankshaft.
Timing Belt Tensioner Mechanism
7. Remove the bolts and remove the belt tensioner assembly from the engine.
Idle pulley
8. Remove the bolt and remove the idler pulley from the engine. On 1.8L and 2.0L models, if necessary, remove the bolt from the idler pulley mounting bracket or remove the idler pulley and bracket.
Installation
Camshaft pulleys
Warning: When installing the camshaft pulleys, new bolts must be used.
1. Before installing the pulleys, check the oil seal ring for wear or damage and replace if necessary.
2. Check that the timing pulley is in the camshaft seat.
3. On 1.6L models, align the groove on the pulley with the locating pin and secure the pulley with the bolt.
4. On 1.8L and 2.0L models, the pulleys have two dowel pin grooves. If the pulley is installed on an intake camshaft, the dowel pin is located in the groove marked IN. And if the pulley is installed on an exhaust camshaft, the dowel pin is installed in the groove marked EX.
5. Correctly install the pulleys on the camshafts and secure them with bolts, tightening them to the required torque. At the same time, secure the camshaft with a wrench to prevent it from turning.
6. Install the timing belt and install the cylinder head cover.
Crankshaft pulley model 1.6L
7. Install the pulley onto the crankshaft. The timing mark should align with the pointer.
8. Install the timing belt.
Crankshaft pulley for 1.8 and 2.0L models
9. Install the crankshaft pulley. The timing mark should align with the pointer.
10. Secure the crankshaft from turning and tighten the pulley mounting bolt.
11. Install the timing belt.
Timing Belt Tensioner Mechanism
12. Install the tensioner with the protrusion on the support plate positioned in the hole in the oil pump housing. Pre-tighten the tensioner mounting bolt. Using a hex key, turn the tensioner lever clockwise until it stops and finally tighten the mounting bolt.
13. Install the timing belt.
Idle pulley
14. On 1.8L and 2.0L models, install the idler pulley hanger to the cylinder block and secure with bolts, tightening them to the specified torque.
[Original source on the website OpelBook.ru]
15. On all models, install the idler pulley and secure with the bolt, tightening it to the specified torque.
16. Install the timing belt.
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