Opel

110395Timing Belt, Replace
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Timing Belt, Replace J462400

Remove 1. Disconnect battery negative lead 2. Raise vehicle 3. Remove engine and transmission undershield from vehicle 4. Remove right splash shield Remove 2x bolt, screw Release wash pipe (if installed) from 2x support clip
5. Remove blanking bolt (1) from cylinder block Note: To allow installation of Positioning Pin KM-6031.
6. Install Engine Support KM-6210-A see operation Engine Support KM-6210-A, Install and Remove
file://D:\tis2000\DATA\TMP\00110395.rtf.html
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7. Remove ribbed V-belt from engine Rotate tension roller clockwise, then lock using Locating Pin KM-6130 Note: Illustration shows vehicle with air conditioning. For vehicles without air conditioning the tension roller is rotated anti-clockwise.
8. Remove tension roller for ribbed V-belt from engine Remove bolt (1)
9. For vehicles with air conditioning, remove guide roller (1) for ribbed V-belt from support bracket Remove bolt
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10. Lower vehicle 11. Remove cylinder head trim cover Remove 3x bolt Release 3x clip 12. Release harness and fuel line (1) from bracket for engine damping block, then move to one side Release 2x clip
13. Release power steering reservoir from front panel Release clip
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14. Remove bracket with engine damping block, right side, and upper engine stabiliser Remove 12 mm bolt from engine stabiliser Remove 3x 10 mm bolt from bracket Remove 3x 10 mm bolt from engine damping block
15. Release timing belt cover from engine Remove 2x bolt (1)
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16. Raise vehicle 17. Install Positioning Pin KM-6031 (1) to crankshaft Note: To determine top dead centre (TDC). Rotate crankshaft clockwise until positioning locates fully into crankshaft recess
18. Lower vehicle 19. Check mark (1) on camshaft pulley is visible through hole in timing belt cover Note: If incorrectly aligned, remove Positioning Pin KM-6031, rotate the crankshaft 360 clockwise, and reinstall the positioning pin.
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20. Raise vehicle 21. Remove timing belt cover from engine Remove 2x bolt (1)
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22. Lower vehicle 23. Apply match mark (1) on rear cover, inline with mark (2) on camshaft pulley
24. Raise vehicle 25. Install Flywheel Locking Tool KM-911
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26. Remove Positioning Pin KM-6031 from crankshaft 27. Remove crankshaft pulley from engine Remove bolt (1)
28. Remove Flywheel Locking Tool KM-911 29. Install Positioning Pin KM-6031 to crankshaft 30. Remove timing belt from engine Release nut (1) from tensioner
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Install 31. Lower vehicle Important: Ensure the timing belt is installed with the direction arrows pointing clockwise. 32. Install new timing belt to camshaft pulley and fuel pump pulley Align mark (2) on timing belt with match mark (1) on rear cover and mark (3) on camshaft pulley
33. Raise vehicle 34. Install timing belt to tensioner, crankshaft timing belt pulley and coolant pump Align mark (1) on timing belt with mark (2) on crankshaft timing belt pulley
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35. Carry out final check of installation of timing belt around pulleys and tensioner
36. Install spacer (1) of Tensioning Tool KM6234 to crankshaft toothed pulley Install spacer with crankshaft bolt Note: Do not over tighten bolt.
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37. Install bolt (1) to tensioner Tighten bolt until tensioner pulley touches timing belt
38. Remove Positioning Pin KM-6031 from crankshaft
Adjust 39. Tension timing belt Install Timing Belt Tensioner KM6234 to crankshaft spacer Turn bolt of KM-6234 with torque wrench 11 Nm Remove Timing Belt Tensioner KM-
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6234 from crankshaft spacer
40. Adjust tension of timing belt Place pick up of Tester KM-6225 next to timing belt Turn bolt (1) until Tester KM-6225 indicates tension of 95 Hz 3 Hz
41. Pre-tighten tensioner nut (1) 10 Nm
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42. Rotate crankshaft 720 clockwise 43. Install Positioning Pin KM-6031 to crankshaft Note: To determine top dead centre (TDC). Rotate crankshaft clockwise until positioning pin enters recess in crankshaft 44. Remove Positioning Pin KM-6031 from crankshaft 45. Apply pre-tension to timing belt Install Tensioning Tool KM-6234 to crankshaft spacer Turn bolt of tensioning tool with torque wrench 11 Nm Remove tensioning tool from crankshaft spacer
46. Check tension of timing belt Place pick up of Tester KM-6225 next to timing belt and check whether timing belt now has tension of 90 Hz 3 Hz If not, correct adjustment and check
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again
47. Secure tensioner nut (1) for timing belt 50 Nm
48. Remove bolt (1) from timing belt tensioner
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49. Remove spacer (1) of Tensioning Tool KM-6234 from the crankshaft timing belt pulley
Install 50. Install timing belt cover to engine Install 2x bolt (1) 10 Nm
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51. Install Flywheel Locking Tool KM-911
52. Install crankshaft pulley to engine Install new bolt 20 Nm + 115 15
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53. Remove Flywheel Locking Tool KM-911 54. Lower vehicle 55. Install timing belt cover to engine Secure 2x bolt (1) 10 Nm
56. Install bracket with engine damping block, right side, and upper engine stabiliser Install 3x 10 mm bolt to engine damping block 44 Nm Install 3x 10 mm bolt to bracket 60 Nm in correct sequence Note: Ensure the washers move freely on the bolts.
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Install 12 mm bolt to engine stabiliser 100 Nm
57. Secure power steering reservoir to front panel Secure clip 58. Secure harness and fuel line (1) to bracket for engine damping block Secure 2x clip
59. Install cylinder head trim cover Secure 3x clip Install 3x bolt 60. Raise vehicle 61. Remove Engine Support KM-6210-A from vehicle 62. For vehicles with air conditioning, install new guide roller (1) for ribbed V-belt to support bracket
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Install bolt 21 Nm
63. Install new tension roller for ribbed V-belt to engine Install bolt (1)
64. Install new ribbed V-belt to engine Rotate tension roller clockwise, then remove Locating Pin KM-6130 Note: Illustration shows vehicle with air conditioning. For vehicles without air conditioning the tension roller is rotated anti-clockwise.
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65. Install blanking bolt (1) to cylinder block 20 Nm
66. Install right splash shield Secure 2x bolt, screw 8 Nm Secure wash pipe (if installed) to 2x support clip 67. Install engine and transmission undershield to vehicle
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68. Lower vehicle 69. Connect battery negative lead 70. Program all volatile memories
6/27/2011

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110395Timing Belt, Replace

Timing Belt, Replace J462400

110395Timing Belt, Replace

110395Timing Belt, Replace

110395Timing Belt, Replace

110395Timing Belt, Replace

110395Timing Belt, Replace

110395Timing Belt, Replace

24. Raise vehicle 25. Install Flywheel Locking Tool KM-911

110395Timing Belt, Replace

110395Timing Belt, Replace

110395Timing Belt, Replace

110395Timing Belt, Replace

38. Remove Positioning Pin KM-6031 from crankshaft

110395Timing Belt, Replace

6234 from crankshaft spacer

41. Pre-tighten tensioner nut (1) 10 Nm

110395Timing Belt, Replace

110395Timing Belt, Replace

47. Secure tensioner nut (1) for timing belt 50 Nm

48. Remove bolt (1) from timing belt tensioner

110395Timing Belt, Replace

110395Timing Belt, Replace

51. Install Flywheel Locking Tool KM-911

52. Install crankshaft pulley to engine Install new bolt 20 Nm + 115 15

110395Timing Belt, Replace

110395Timing Belt, Replace

Install 12 mm bolt to engine stabiliser 100 Nm

110395Timing Belt, Replace

110395Timing Belt, Replace

65. Install blanking bolt (1) to cylinder block 20 Nm

110395Timing Belt, Replace

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