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Removal/refitting requires: Engine removal. NOTE: Refer to Technical Data module for tightening torques. Sump removal. Align coloured chain links with timing mark on each sprocket [1], [2], [3] & [4] . NOTE: Timing chain marks on injection pump sprocket maybe difficult to see. Remove: Upper timing chain and tensioner. Lower timing chain tensioner. Injection pump sprocket and timing chain. Refit: Ensure crankshaft sprocket keyway at 12 o’clock position [5] . Install injection pump sprocket and timing chain. Insert injection pump sprocket locking tool [6] . Tool No.KV11106030. Align blue or silver coloured chain link with injection pump sprocket timing mark [2] . Align yellow coloured chain link with crankshaft sprocket timing mark [4] . Align blue or silver coloured chain links with timing mark on each camshaft sprocket [1] . Align yellow coloured chain link with injection pump sprocket timing mark [3] . Reset timing chain tensioners: Push plungers into tensioner housings and lock with retaining clips. Refit timing chain tensioners. Remove retaining clips.

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1. Disconnect negative battery cable. Remove engine undercover. Place wooden block between jack and oil pan, and raise engine slightly. Remove engine mount assembly near timing belt cover. 2. Remove clamp for power steering return hose near timing belt cover. Remove all drive belts and tensioner pulley bracket. See Fig. 1 . Remove power steering and water pump pulleys. Rotate crankshaft clockwise so that No. 1 cylinder is at TDC of compression stroke. Remove crankshaft pulley. CAUTION: DO NOT rotate crankshaft counterclockwise. Ensure timing marks are aligned. If reusing timing belts, mark timing belts for direction of rotation. 3. Remove upper timing belt cover and gasket. Remove stub bolt of engine support bracket, and remove center timing belt cover. Remove lower timing belt cover. NOTE: Camshaft sprocket dowel pins will be in 12 o’clock position when timing marks are correctly aligned. 4. Ensure camshaft, crankshaft and oil pump sprocket timing marks are aligned. See Fig. 2 or Fig. 3 . Loosen tensioner pulley center bolt. Move tensioner to relieve timing belt tension. Remove timing belt. Remove timing belt auto tensioner. See Fig. 1 . 5. Remove plug from left side of cylinder block. Install a .31″ (8.0 mm) diameter Phillips screwdriver into the hole against balance shaft. See Fig. 4 . Screwdriver must go in at least 2.36″ (60 mm) or more. If screwdriver will only go in about .79-.98″ (20-25 mm) before striking balance shaft, turn sprocket one revolution and align timing mark. Keep screwdriver in place until timing belt is installed. This ensures balance shaft driven by oil pump sprocket remains in correct position. 6. To remove timing belt “B” (balance shaft belt), hold crankshaft sprocket stationary with a spanner wrench. Remove crankshaft sprocket bolt. Using gear puller, remove outer crankshaft sprocket. 7. Remove crankshaft sensing blade (if equipped). See Fig. 5 . Loosen timing belt “B” tensioner bolt. If reusing timing belt “B”, mark direction of belt rotation for reassembly reference. Remove timing belt “B”.

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CAUTION: When removing water pump assembly, be careful not to get coolant on drive belt. Water pump cannot be disassembled and should be replaced as a unit. After Installing water pump, connect hose and clamp securely, then check for leaks using radiator cap tester. 1. Drain coolant from drain plugs on radiator and both sides of cylinder block. 2. Remove drain plug on cylinder block. 3. Remove right side engine mounting, mounting bracket and nuts. 4. Remove drive belts and idler pulley bracket. 5. Remove chain tensioner cover and water pump cover.6. Pushing timing chain tensioner sleeve, apply a stopper pin so it does not return. Then remove the chain tensioner assembly. 7. Remove the 3 water pump fixing bolts. Secure a gap between water pump gear and timing chain, by turning crankshaft pulley 2O° backwards. 8. Put M8 bolts to two M8-threaded holes out of 3 water pump fixing bolt holes.9. Tighten M8 bolts by turning half turn alternately until they reach timing chain rear case. In order to prevent damages to water pump or timing chain rear case, do not tighten one bolt continuously. Always turn each bolt half turn each time. 10. Lift up water pump and remove it. When lifting up water pump, do not allow water pump gear to hit timing chain. INSPECTION 1. Check for badly rusted or corroded body assembly. 2. Check for rough operation due to excessive end play. INSTALLATION

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The above application is prone to the timing belt teeth lifting off the belt in service due to operating the belt with insufficient tension. The following instructions have been produced to assist in the fitting of your new timing belt, giving simple hints and tips, which should help avoid problems caused by adopting an incorrect fitting / adjustment procedure. For instructions for the removal of the engine components required to gain access to the timing belt, please refer to the vehicle workshop manual. Note:- Incorrect tension of the timing belt, can lead to the teeth lifting from the belt, resulting in belt failure, and subsequent major engine damage. Special Tools Required: 1) Timing belt tension gauge, (accurately calibrated), Part No’s: either Rover KM4088 or Borroughs BT33-86F 2) Two 8mm Allen keys (for tensioner adjustment) 3) Short length of round steel bar (for flywheel timing location) Fitting Procedure: 1) Before the old timing belt is removed, the crankshaft should be rotated clockwise to align the timing mark on the crankshaft pulley with the edge of the metal bracket, which forms part of the lower timing belt cover (See I). To lock the crankshaft in this position, which is 90 degrees before top dead centre, insert a steel rod of the correct diameter into the hole on the gearbox / engine adaptor plate, positioned on the front facing lower edge of the cylinder block (See diagram B), and locate with the corresponding hole in the flywheel. The timing marks on the camshaft gears should now be aligned at the 3 o’clock position for the left hand gear, and the 9 o’clock position for the right hand gear (See II). Undo the timing belt tensioner Allen bolt and remove tensioner. The old timing belt can now be removed (See III). Check the condition of the geared teeth on the camshaft, crankshaft, and water pump drives. Check the tensioner, water pump, and idler bearings. Fit the new timing belt over the drive gears, ensuring the timing marks set at ‘I’and‘II’ have not moved. Refit the tensioner using the anti-slip washer ‘IV’ supplied with the new timing belt. The anti-slip washer should be fitted between the tensioner and the backplate, with the abrasive side facing towards the tensioner. Note: A new anti-slip washer must always be fitted. Non modified vehicles will not have the anti-slip washer fitted. Rotate the tensioner, using the Allen key drive to set the initial pre-load tension, sufficient to prevent the timing belt from slipping over the toothed drives, then tighten the Allen bolt to 45Nm.

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T] EXHAUST CAMSHAFT (RIGHT) T| INTAKE CAMSHAFT (RIGHT) T] SECONDARY TIMING BELT IDLER PULLEYS T) INTAKE CAMSHAFT (LEFT) 7] EXHAUST CAMSHAFT (LEFT) T] COOLANT PUMP T] INTERMEDIATE SHAFT BELT SPROCKET T] SERPENTINE BELT TENSIONER T| SECONDARY TIMING BELT TENSIONER PULLEY ??] GENERATOR ??] SECONDARY TIMING BELT TENSIONER ?2? SECONDARY TIMING BELT NOTE: START AT #7 AND INSTALL COUNTERCLOCIOMBE A LOCATION OF TIMING MARKS WITH CAM HOLD DOWN TOOLS J 38813 INSTALLED B FRONT COVER TIMING MARK C LOCATION OF TIMINS MARKS WITH DRIVE BELT IN- STALLED D LOCATION WHERE CAM HOLD DOWN TOOLS ARE INSTALLED RH EXHAUST CAMSHAFT SPROCKET RH INTAKE CAMSHAFT SPROCKET LH INTAKE CAMSHAFT SPROCKET LH EXHAUST CAMSHAFT SPROCKET PERMANENT MARKS PAINTED DOTS REMOVE PREVIOUS MARKS IF TIMING IS BEINS CHANGED AND MARK AGAIN IN THESE LOCATIONS TORSIONAL DAMPER INTERMEDIATE SHAFT SPROCKET NOTE: THIS TDC #1 EXHAUST. INTtRMEDlATE »HAFT BELT sprocket twno mark» at » o’clock (powtmo towards drain notch) NOTE : GM does not provide a timing mark diagram for belt installation without using the special tool(s) listed below. TOOLS REQUIRED: A J 38613 CamHold Down Tool A J 38614 Cam Sprocket Holding Tool NOTICE: If only one (1) bank is to be timed, make sure bank to bank earn timing relationship is one (1) revolution apart. Timing flats should be 180 degrees opposite (right bank versus left bank) when finally timed. 1. Remove all spark plugs. 2. Remove all camshaft sprockets. IMPORTANT: Remove oil from cam hold down tool bolt hole in carrier before installing and tightening bolt. 3. Rotate camshaft flats “up” and install J 38613. Tighten cam hold down tool bolt to 30 Nm (22 lb. ft). 4. Install all camshaft sprockets. 5. Timing belt by routing it around the idlers and sprockets. DO NOT bend, kink, or pry on belt as damage may occur. A. Start at intermediate cam sprocket and work counterclockwise. B. Make sure the belt is installed in direction of rotation. C. Engage teeth into all sprockets, place rubber hose behind belt at intermediate sprocket and accumulate slack at tensioner location. 6. Tensioner pulley to mounting base. A Use flat magnet, tape or cup plug to hold pivot tube in pulley during this step. Otherwise, pivot tube may fall out. A After starting pivot bolt, rotate arm counterclockwise to position square lug at 6 o’clock