How to Replace the Timing Belt Opel Vivaro A

Remove

1. 1. Disconnect battery negative lead
2. 2. Release resonance chamber (1) with ducting hose from air cleaner assembly, then move to one side • Release coolant hose from resonance chamber – Release from clip • Release strap (2) from bracket (3)

Important. Take care not to damage camshaft or housing.

3. 3. Remove 2x camshaft sealing cap (1) from cylinder head • Prise out using suitable tool

4. 4. Raise vehicle
5. 5. Remove engine and transmission undershield from vehicle
6. 6. Remove splash panel, right side • Release washer hose (if installed) from 2x clip • Remove 2x bolt , screw

7. 7. Remove blanking bolt (1) from cylinder block for installation of Positioning Pin KM-6031

8. 8. Position No. 1 cylinder at top dead centre (TDC) • Install Crankshaft Positioning Pin KM-6031 (1) into cylinder block and crankshaft – Rotate crankshaft clockwise, simultaneously apply inward pressure to Crankshaft Positioning Pin KM-6031 to ensure full installation into crankshaft

Note. It is possible to incorrectly insert the crankshaft positioning pin in a crankshaft balancing hole. Check the slots in the end of the camshaft are horizontal and offset below the horizontal line.

9. 9. Lower vehicle
10. 10. Ensure 2x off-set slot (2) at rear of 2x camshaft (1) are positioned downward. If 2x off-set slot are positioned upward remove Crankshaft Positioning Pin KM-6031 , rotate crankshaft 180°, then reinstall Crankshaft Positioning Pin KM-6031

11. 11. Raise vehicle
12. 12. 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.

13. 13. Remove Crankshaft Positioning Pin KM-6031 from cylinder block and crankshaft
14. 14. Install Flywheel Locking Tool KM-911 to flywheel

15. 15. Remove pulley from crankshaft • Remove bolt

16. 16. Remove Flywheel Locking Tool KM-911 from flywheel
17. 17. Install Crankshaft Positioning Pin KM-6031 into cylinder block and crankshaft
18. 18. For vehicles with F4R 720 engine, release fuel pipe and breather pipe from lower cover for timing belt • Release 2x clip
19. 19. Remove lower cover for timing belt • Remove 3x bolt (1)

20. 20. Install Engine Support KM-6210-A to vehicle – see “Engine Support KM-6210-A, Install and Remove”
21. 21. Lower vehicle
22. 22. Release reservoir for power steering fluid from upper front panel, then move to one side • Release clip, then slide off

Note. To prevent fluid loss ensure reservoir remains in vertical position.

23. 23. Remove bracket (4) with upper stabiliser from vehicle • Release engine damping block (5) from bracket – Remove bolt (1) • Release bolt (2) • Remove 4x bolt (3)
24. 24. Remove engine damping block from inner wing • Remove 3x bolt

25. 25. Release front engine harness from cylinder head, then move to one side • Release clip (1) • Remove bolt (2)

26. 26. Disconnect harness connector (1) from vacuum sensor (2)

27. 27. Remove upper cover for timing belt from cylinder head • Remove 3x bolt (1), 2x nut (2), 2x spacer

28. 28. Raise vehicle
29. 29. Lower engine using Engine Support KM-6210-A (1) • Turn bolt (2)

30. 30. Release timing belt tensioner (1) from cylinder head • Release nut (2)

31. 31. Raise engine using Engine Support KM-6210-A
32. 32. Lower vehicle
33. 33. Remove 2x camshaft pulley • Install Camshaft Pulley Locking Tool KM-6244 to 2x camshaft pulley – Use bolt and nut removed from timing belt cover – Secure 2x locking gear against 2x camshaft pulley • Release 2x camshaft pulley nut • Remove Camshaft Pulley Locking Tool KM-6244 • Remove 2x camshaft pulley with timing belt – Remove 2x nut

34. 34. Remove timing belt tensioner from cylinder head • Remove nut
35. 35. Remove guide roller for timing belt from cylinder block • Remove bolt

Install

36. 36. Align 2x camshaft • Install 2x camshaft pulley – Use 2x nut removed during removal procedure – Secure 2x nut 15 Nm • Install Camshaft Positioning Tool KM-6233 to 2x off-set slot of 2x camshaft – Turn 2x camshaft pulley, using Wrench KM-6245 inserted into intake camshaft pulley, if required – Install bolt to camshaft positioning tool • Remove 2x camshaft pulley – Remove 2x nut

Important. It is essential to ensure there is no grease or oil on the contact faces of the timing gear, the pulleys and their shafts. This is to prevent the gear or pulleys slipping on their shafts, which could damage the engine.

37. 37. Degrease the contact faces of 2x camshaft pulley • Degrease 2x camshaft (timing end) • Degrease 2x pulley bore and contact face
38. 38. Install 2x camshaft pulley to 2x camshaft • Install 2x new nut; do not tighten at this stage – Allow a clearance of 0.5 mm - 1 mm between camshaft pulley and nut

39. 39. Raise vehicle
40. 40. Lower engine using Engine Support KM-6210-A (1) • Turn bolt (2)

Important. Before installing new components it is necessary to thoroughly clean timing end of crankshaft and inside of crankshaft sprocket . Use clean lint-free cloths and thinners to remove dust and oil/grease deposits. Allow sufficient time for components to dry. Failure to clean end of crankshaft and inside of crankshaft sprocket could cause timing belt to slip, resulting in serious damage to engine.

41. 41. Remove timing belt pulley (1) from crankshaft (2) • Pull off • Clean mating surfaces
42. 42. Install timing belt pulley to crankshaft • Push on

43. 43. Install new guide roller for timing belt to cylinder block • Install bolt 45 Nm
44. 44. Install new timing belt tensioner (1) with new timing belt to engine • Observe arrow marking of timing belt to ensure correct rotation • Ensure lug on rear of timing belt tensioner locates into groove of cylinder head • Install nut (2); do not tighten at this stage

Note. Ensure correct route of timing belt.

45. 45. Install crankshaft pulley (1) to engine • Install new bolt (2); do not tighten at this stage

46. 46. Raise engine using Engine Support KM-6210-A
47. 47. Lower vehicle
48. 48. Tension timing belt • Rotate tensioner clockwise, until marks (2) and (3) are aligned – Use allen key at (1) • Secure timing belt tensioner when marks aligned – Secure nut (4) 7 Nm

49. 49. Rotate timing belt 6 revolutions • Use Wrench KM-6245 inserted into intake camshaft pulley

Note. Only the belt and pulleys rotate during this procedure. The shafts are locked in position. Be careful that the nuts and bolt do not tighten themselves when the pulleys rotate.

50. 50. Check alignment marks on tensioner • If necessary, release nut (4) then rotate tensioner clockwise, until marks (2) and (3) are aligned – Use allen key at (1)
51. 51. If necessary, secure timing belt tensioner when marks aligned • Secure nut 28 Nm

52. 52. Apply match marks (1) to 2x camshaft pulley and cylinder head cover

53. 53. Raise vehicle
54. 54. Remove Crankshaft Positioning Pin KM-6031 (1) from cylinder block and crankshaft

55. 55. Install Flywheel Locking Tool KM-911 to flywheel

56. 56. Secure pulley (1) to crankshaft • Secure bolt (2) 40 Nm + 110°

57. 57. Remove Flywheel Locking Tool KM-911 from flywheel
58. 58. Lower vehicle
59. 59. Secure 2x camshaft pulley to 2x camshaft • Install Camshaft Pulley Locking Tool KM-6244 to 2x camshaft pulley – Use bolt and nut removed from timing belt cover – Secure 2x locking gear against 2x camshaft pulley • Secure 2x camshaft pulley nut 30 Nm + 86° • Remove Camshaft Pulley Locking Tool KM-6244

60. 60. Remove Camshaft Positioning tool KM-6233 • Remove bolt

61. 61. Raise vehicle
62. 62. Rotate crankshaft 2 revolutions (720°)
63. 63. Install Crankshaft Positioning Pin KM-6031 to cylinder block and crankshaft
64. 64. Lower vehicle
65. 65. Check alignment of match marks (1) on 2x camshaft pulley and cylinder head cover

66. 66. Check alignment marks on tensioner • If necessary, release nut (4) then rotate tensioner clockwise, until marks (2) and (3) are aligned – Use allen key at (1)
67. 67. If necessary, secure timing belt tensioner when marks aligned • Secure nut 28 Nm

68. 68. Check timing • Install Camshaft Positioning Tool KM-6233 to 2x off-set slot of 2x camshaft – Install bolt • Remove Camshaft Positioning Tool KM-6233 – Remove bolt

Note. If timing is correct, the Camshaft Positioning Tool should fit without rotating camshafts or using force.

69. 69. If timing incorrect, release 2x camshaft pulley, then repeat adjustment procedure
70. 70. Install upper cover for timing belt to cylinder head • Install 2x spacer, 3x bolt (1), 2x nut (2) – M10: 38 Nm – M8: 18 Nm

71. 71. Secure front engine harness (2) to cylinder head • Install clip (1), bolt (3)

72. 72. Connect harness connector (1) to vacuum sensor (2)

73. 73. Install engine damping block (5) to inner wing • Install 3x bolt 44 Nm
74. 74. Install bracket (4) with upper stabiliser to vehicle • Install 4x bolt (3) 60 Nm • Secure bolt (2) 100 Nm
75. 75. Adjust engine position using Engine Support KM-6210-A
76. 76. Secure engine damping block to bracket • Install bolt (1) 44 Nm

77. 77. Secure reservoir for power steering fluid to upper front panel • Slide on to secure clip
78. 78. Install 2x new camshaft sealing cap (1) • Use Installer KM-6231 for 57 mm diameter cap • Use Installer KM-6232 for 43 mm diameter cap

79. 79. Secure resonance chamber (1) with ducting hose to air cleaner assembly • Secure strap (2) to bracket (3) • Secure coolant hose to resonance chamber – Secure clip

80. 80. Raise vehicle
81. 81. Remove Engine Support KM-6210-A from vehicle
82. 82. Install lower cover for timing belt • Install 3x bolt (1) – M8: 18 Nm – M6: 8 Nm

Note. The crankshaft pulley is shown removed for clarity.

83. 83. For vehicles with F4R 720 engine, secure fuel pipe and breather pipe to lower cover for timing belt • Secure 2x clip
84. 84. Install 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.

85. 85. Remove Crankshaft Positioning Pin KM-6031 from cylinder block and crankshaft
86. 86. Install blanking bolt (1) to cylinder block • Apply sealant to bolt thread – see “Sealants, Lubricants and Locking Compounds”

87. 87. Install right splash shield • Install 2x bolt 8 Nm , screw 6 Nm • Secure washer hose (if installed) to 2x clip
88. 88. Install engine and transmission undershield to vehicle

89. 89. Lower vehicle
90. 90. Connect battery negative lead
91. 91. Program all volatile memories