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Home/Opel/Vivaro/Opel Vivaro A (2001-2011)/Repair manual/DOHC Petrol Engine/How to Replace the Guide Roller, Timing Belt
Contents Wiring diagrams Section: DOHC Petrol Engine All sections

How to Replace the Guide Roller, Timing Belt Opel Vivaro A

DOHC Petrol Engine 36 illustrations ~927 words

Remove

  1. 1. Disconnect battery negative lead
  2. 2. Raise vehicle
  3. 3. Remove right front wheel • Remove 5x bolt
  4. 4. Remove engine and transmission undershield from vehicle
  5. 5. Remove right splash panel • Release washer hose (if installed) from 2x clip • Remove 2x bolt , screw
  1. 6. 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.

  1. 7. Install Engine Support KM-6210-A from vehicle – see operation “Engine Support KM-6210-A, Install and Remove”
  2. 8. Lower vehicle
  3. 9. Release fluid reservoir (1) for power steering • Release clip • Move fluid reservoir to one side
  4. 10. Remove support bracket (2) • Remove 7x bolt • Move harness to one side
  1. 11. Release harness from timing belt cover, upper • Release clip (1) • Remove bolt (2)
  1. 12. Remove timing belt cover, upper • Remove 3x bolt (1), 2x nut (2)
  1. 13. Position No.1 cylinder at top dead centre • Move air intake ducting to one side • Remove, then discard 2x camshaft cap (1), taking care not to damage camshafts
  1. 14. Remove blanking bolt (1) for crankshaft positioning pin from cylinder block
  1. 15. Install Camshaft Positioning Tool KM-6233 • Rotate crankshaft to correct position
  1. 16. Install Crankshaft Positioning Pin KM-6031 (1) through cylinder block
  1. 17. Raise vehicle
  2. 18. Install Flywheel Locking Tool KM-911 to flywheel
  1. 19. Remove Crankshaft Positioning Pin KM-6031 (1) from cylinder block to prevent damage
  1. 20. Remove crankshaft pulley from engine • Remove bolt
  1. 21. Remove Flywheel Locking Tool KM-911 from flywheel
  2. 22. Install Crankshaft Positioning Pin KM-6031 (1) through cylinder block
  1. 23. Remove timing belt cover, lower • Remove 3x bolt (1)
  1. 24. Remove timing belt from engine • Remove timing belt tensioner (1) from cylinder block – Remove nut
  1. 25. Remove guide roller (1) from cylinder block • Remove bolt

Install

  1. 26. Install new guide roller to cylinder block • Install bolt 50 Nm

Important. Never install a used timing belt to engine.

  1. 27. Install new timing belt to engine • Remove grease from end surfaces of crankshaft • Install timing belt tensioner to cylinder block – Install nut – Align marks (2, 3) using 6 mm allen key at (1) • Install timing belt

Note. Rotate timing belt tensioner clockwise.

  1. 28. Loosen 2x camshaft pulley • Raise engine sufficient height to enable Camshaft Pulley Locking Tool KM-6244 to be installed • Lower vehicle • Install Camshaft Pulley Locking Tool KM-6244 – Install 3x nut, bolt • Loosen 2x nut • Remove Camshaft Pulley Locking Tool KM-6244 – Remove 3x nut, bolt

Note. Clearance between camshaft pulley and nut must be between 0.5 mm – 1 mm

  1. 29. Secure timing belt tensioner • Tighten nut 7 Nm
  2. 30. Rotate 2x camshaft pulley clockwise, 6 revolutions • Use Wrench KM-6245
  1. 31. Check alignment of marks (1, 2) of timing belt tensioner
  2. 32. Secure timing belt tensioner • Tighten nut 27 Nm
  1. 33. Raise vehicle
  2. 34. Install crankshaft pulley to engine • Install new bolt 40 Nm
  1. 35. Lower vehicle
  2. 36. Apply match mark to 2x camshaft pulley and cylinder head
  3. 37. Raise vehicle
  4. 38. Remove Crankshaft Positioning Pin KM-6031 (1) from cylinder block
  1. 39. Install Flywheel Locking Tool KM-911 to flywheel
  2. 40. Secure crankshaft pulley to engine using Angular Torque Wrench KM-470-B • Secure bolt 110°
  1. 41. Remove Flywheel Locking Tool KM-911 from flywheel
  2. 42. Install Crankshaft Positioning Pin KM-6031 (1) through cylinder block • Align match mark on 2x camshaft pulley with match mark on cylinder head
  1. 43. Lower vehicle
  2. 44. Secure 2x camshaft pulley • Install Camshaft Pulley Locking Tool KM-6244 • Secure 2x nut ( 30 Nm + 86° ± 6° ) • Remove Camshaft Pulley Locking Tool KM-6244
  1. 45. Remove Crankshaft Positioning Pin KM-6031 (1) from cylinder block
  1. 46. Check timing belt tension • Rotate crankshaft clockwise 720° • Install Crankshaft Positioning Pin KM-6031 through cylinder block • Check alignment of match mark on 2x camshaft pulley with match mark on cylinder head • Check alignment of marks (1, 2) of timing belt tensioner

Note. If adjustment is required, repeat step's 22 to 33.

  1. 47. Install timing belt cover, upper • Install 3x bolt (1), 2x nut (2) – M10: 38 Nm – M8: 18 Nm
  1. 48. secure harness to timing belt cover, upper • secure clip (1) – Push fit • Install bolt (2)
  1. 49. Install support bracket (1) • Position harness to original position • Install 7x bolt
  1. 50. Install 2x new camshaft cap (1) • Use 2x Installer KM-6231 and KM-6232
  1. 51. Install air intake ducting
  2. 52. Secure fluid reservoir for power steering • Secure clip
  3. 53. Raise vehicle
  4. 54. Remove Engine Support KM-6210 from vehicle
  5. 55. Install timing belt cover, lower • Install 3x bolt (1) – M8: 18 Nm – M6: 8 Nm
  1. 56. Remove Crankshaft Positioning Pin KM-6031 (1) from cylinder block
  1. 57. Install blanking bolt (1) for to cylinder block
  1. 58. Install ribbed V-belt to engine • Rotate tension roller clockwise, then remove Locating Pin KM-6130 (1)

Note. Illustration shows vehicle with air conditioning. For vehicles without air conditioning the tension roller is rotated anti-clockwise.

  1. 59. Install right splash panel • Install 2x bolt 8 Nm , screw 6 Nm • Secure washer hose (if installed) to 2x clip
  2. 60. Install engine and transmission undershield to vehicle
  1. 61. Install right front wheel • Install 5x bolt 140 Nm
  2. 62. Lower vehicle
  3. 63. Connect battery negative lead
  4. 64. Program all volatile memories

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