Vauxhall Workshop Service and Repair Manuals

Engine Timing Side  

Toothed Belt, Remove and Install  

  Remove, Disconnect   

Remove air cleaner or air resonator with air intake hoses. Remove upper toothed belt cover (note different bolt lengths).  

  Inspect   

Turn crankshaft in direction of engine rotation until the 1st cylinder piston is at "Ign. TDC". The 1st cylinder piston is at "Ign. TDC" when the oil pump pin aligns with the identification mark on the crankshaft V-belt pulley and the 1st cylinder cams point upwards.

  Remove, Disconnect   

Suspend engine on Engine Bridge KM-263-B or MKM-883-1. Remove fastening bolts (1) from engine damping block (2).   Remove fastening bolts for engine damping block (3) from cylinder block bracket and remove engine damping block. Remove cylinder block bracket (4) from cylinder block.   Remove V-belt from power steering pump and alternator. Remove flywheel cover plate and lock flywheel with KM-517-B. Remove crankshaft pulley from toothed belt drive gear. Remove lower toothed belt cover.

  Remove, Disconnect   

Install TDC fixing bolts (1) in camshaft drive gear and injection pump drive gear.  

Bolt, camshaft drive gear	M6 x 1.00
Bolt, injection pump drive gear	M8 x 1.25

Loosen fastening bolts of toothed belt tension roller (3) and detach tension spring (4). Press toothed belt tension roller with bracket (2) to the right and remove toothed belt.  

  Install, Connect   

Install toothed belt and attach tension spring (4). Remove TDC fixing bolts and KM-517-B.   To tension toothed belt, turn crankshaft approx. 60 ° against engine rotational direction. Install lower toothed belt cover. Install KM-517-B.

  Tighten (Torque)   

Toothed belt tensioning roller to cylinder block - 19 Nm/14 lbf. ft. Crankshaft pulley (1) to toothed belt drive gear - 20 Nm/15 lbf. ft.   Fit the cylinder block holder on the cylinder block - tightening torque 45 Nm. Insert the engine damping block and fit to holder - tightening torque 35 Nm. Fit the engine damping block to the side member - tightening torque 65 Nm.   Remove Engine Bridge KM-263-B or MKM-883-1. Install upper toothed belt cover (note different bolt lengths). Install air cleaner or air resonator.   Notice:  Document the replacement of the toothed belt on the provided sticker.