How to Replace the Timing Belt Opel Vivaro A

Remove

1. 1. Disconnect battery negative lead
2. 2. Raise vehicle
3. 3. Remove engine and transmission undershield from vehicle
4. 4. Remove right splash shield • Remove 2x bolt, screw • Release wash pipe (if installed) from 2x support clip

5. 5. Remove blanking bolt (1) from cylinder block

Note. To allow installation of Positioning Pin KM-6031 .

6. 6. Install Engine Support KM-6210-A – see operation “Engine Support KM-6210-A, Install and Remove”
7. 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. 8. Remove tension roller for ribbed V-belt from engine • Remove bolt (1)

9. 9. For vehicles with air conditioning, remove guide roller (1) for ribbed V-belt from support bracket • Remove bolt

10. 10. Lower vehicle
11. 11. Remove cylinder head trim cover • Remove 3x bolt • Release 3x clip
12. 12. Release harness and fuel line (1) from bracket for engine damping block, then move to one side • Release 2x clip

13. 13. Release power steering reservoir from front panel • Release clip

14. 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. 15. Release timing belt cover from engine • Remove 2x bolt (1)

16. 16. Raise vehicle
17. 17. Install Positioning Pin KM-6031 (1) to crankshaft • Rotate crankshaft clockwise until positioning locates fully into crankshaft recess

Note. To determine top dead centre (TDC).

18. 18. Lower vehicle
19. 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.

20. 20. Raise vehicle
21. 21. Remove timing belt cover from engine • Remove 2x bolt (1)

22. 22. Lower vehicle
23. 23. Apply match mark (1) on rear cover, in-line with mark (2) on camshaft pulley

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

26. 26. Remove Positioning Pin KM-6031 from crankshaft
27. 27. Remove crankshaft pulley from engine • Remove bolt (1)

28. 28. Remove Flywheel Locking Tool KM-911
29. 29. Install Positioning Pin KM-6031 to crankshaft
30. 30. Remove timing belt from engine • Release nut (1) from tensioner

Install

31. 31. Lower vehicle

Important. Ensure the timing belt is installed with the direction arrows pointing clockwise.

32. 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. 33. Raise vehicle
34. 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

35. 35. Carry out final check of installation of timing belt around pulleys and tensioner

36. 36. Install spacer (1) of Tensioning Tool KM-6234 to crankshaft toothed pulley • Install spacer with crankshaft bolt

Note. Do not over tighten bolt.

37. 37. Install bolt (1) to tensioner • Tighten bolt until tensioner pulley touches timing belt

38. 38. Remove Positioning Pin KM-6031 from crankshaft

Adjust

39. 39. Tension timing belt • Install Timing Belt Tensioner KM-6234 to crankshaft spacer • Turn bolt of KM-6234 with torque wrench 11 Nm • Remove Timing Belt Tensioner KM-6234 from crankshaft spacer

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

42. 42. Rotate crankshaft 720° clockwise
43. 43. Install Positioning Pin KM-6031 to crankshaft • Rotate crankshaft clockwise until positioning pin enters recess in crankshaft

Note. To determine top dead centre (TDC).

44. 44. Remove Positioning Pin KM-6031 from crankshaft
45. 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. 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 again

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

48. 48. Remove bolt (1) from timing belt tensioner

49. 49. Remove spacer (1) of Tensioning Tool KM-6234 from the crankshaft timing belt pulley

Install

50. 50. Install timing belt cover to engine • Install 2x bolt (1) 10 Nm

51. 51. Install Flywheel Locking Tool KM-911

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

53. 53. Remove Flywheel Locking Tool KM-911
54. 54. Lower vehicle
55. 55. Install timing belt cover to engine • Secure 2x bolt (1) 10 Nm

56. 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 • Install 12 mm bolt to engine stabiliser 100 Nm

Note. Ensure the washers move freely on the bolts.

57. 57. Secure power steering reservoir to front panel • Secure clip
58. 58. Secure harness and fuel line (1) to bracket for engine damping block • Secure 2x clip

59. 59. Install cylinder head trim cover • Secure 3x clip • Install 3x bolt
60. 60. Raise vehicle
61. 61. Remove Engine Support KM-6210-A from vehicle
62. 62. For vehicles with air conditioning, install new guide roller (1) for ribbed V-belt to support bracket • Install bolt 21 Nm

63. 63. Install new tension roller for ribbed V-belt to engine • Install bolt (1)

64. 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.

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

66. 66. Install right splash shield • Secure 2x bolt, screw 8 Nm • Secure wash pipe (if installed) to 2x support clip
67. 67. Install engine and transmission undershield to vehicle

68. 68. Lower vehicle
69. 69. Connect battery negative lead
70. 70. Program all volatile memories