Replace Toothed Belt — Opel Vectra C (2002-2008)

Replace Toothed Belt Opel Vectra C

DOHC Diesel Engine 10 illustrations ~731 words

1. Remove air cleaner housing
2. Raise vehicle by its entire height
3. Detach engine compartment cover and right-hand engine splash guard if present
4. Detach wiring harness, oil temperature sensor (1) • Disconnect wiring harness connector. – Unclip 2x wiring harness and lay aside

5. Install KM-6352 (1) • Insert base plate • Insert support with bracket • Screw in 2x bolt • Adjust support • Tighten 2x bolt

Note. Turn spindle until the bracket is in contact. The two bolts of the upper part of the oil pan must sit in the bracket (arrows).

8. Unclip 2x wiring harness (1) • Disconnect AC pressure sensor wiring harness plug • Lay both wiring harnesses aside

Note. Note dissimilar bolt lengths

Note. Note guide bushings, O-rings and differing bolt lengths.

12. Remove camshaft sensor (2) • Remove bolt (1) • Disconnect wiring harness plug (3).

13. Set cylinder 1 to TDC of combustion stroke • Marking on toothed belt drive wheel (5) must align with lug (6) on cover of timing case • Marking on torsional vibration damper (7) must align with lug (8) on cover of the timing case • Marking LH on camshaft sprocket - cylinders-2-4-6 (4) must align with lug (3) on camshaft cover • Marking RH on camshaft sprocket - cylinders-1-3-5 (2) must align with lug (1) on camshaft cover

Note. Use mirror. Turn crankshaft evenly in the direction of rotation of the engine.

14. Tension toothed belt tension roller (1) • Fix toothed belt tensioning roller with KM-6349 (2)

Note. Tension toothed belt tensioning roller anticlockwise. Do not cover fixing bore in toothed belt tensioning roller.

Note. Remove tensioning roller from toothed belt and mark direction of rotation.

16. Check 1st cylinder TDC of combustion stroke • Marking on toothed belt drive wheel must align with lug on cover of timing case • Marking on torsional vibration damper must align with lug on cover of the timing case • Marking LH on camshaft sprocket - cylinders-2-4-6 must align with lug on camshaft cover • Marking RH on camshaft sprocket - cylinders-1-3-5 must align with lug on camshaft cover

Note. Use a mirror.

17. Install toothed belt • Tighten tensioning roller anticlockwise as far as the stop.

Note. A second person is required. Note direction of rotation and markings.

Note. Lastly, place toothed belt on tensioning roller

Note. Tension anticlockwise on internal hexagon.

19. Timing, Check • Turn crankshaft evenly 720° in the direction of rotation of the engine. • Marking on toothed belt drive wheel (5) must align with lug (6) on cover of timing case • Marking on torsional vibration damper (7) must align with lug (8) on cover of the timing case • Marking LH on camshaft sprocket - cylinders-2-4-6 (4) must align with lug (3) on camshaft cover • Marking RH on camshaft sprocket - cylinders-1-3-5 (2) must align with lug (1) on camshaft cover

Note. Use mirror. Turn crankshaft evenly in the direction of rotation of the engine.

Note. Note guide bushings and O-rings

22. Install right hand engine transport shackle • Tighten 2x bolts 50 Nm
23. Install right engine damping block adapter • Tighten 2x new bolts M10 40 Nm + 90° • Tighten 2x bolt-M12 64 Nm

Note. Note differing bolt lengths. Insert bracket with the two rear bolts.

24. Clip in 2x wiring harness • Connect AC pressure sensor wiring harness plug
25. Install right engine damping block • Tighten 5x bolt 55 Nm • Tighten nuts 55 Nm
26. Raise vehicle by its entire height
27. Remove KM-6352
28. Attach wiring harness, oil temperature sensor • Connect wiring harness plug – Clip in 2x wiring harness
29. Attach engine compartment cover and right-hand engine splash guard if removed
30. Lower vehicle by its entire height
31. Install air cleaner housing

Replace Toothed Belt Opel Vectra C