Auto Repair Manual Free Download and ReviewsFree download ebook pdf files automotive manual

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1. Back out the tensioner bolt four (4) full turns and position the tensioner so the locating tab is at approximately the 4 o’clock position. Line up the hex key slot in the tensioner adjusting washer with the pointer that is located behind the pulley (Figure 1). 2. Working counterclockwise from the crank sprocket, install the liming belt. 3. Rotate the tensioner locating tab counterclockwise and insert the locating tab into the slot in the rear timing cover (Figure 2). 4. Position the hex key slot in the tensioner adjusting washer to the 4 o’clock position (Figure 2). 5. Tighten the attaching bolt enough to seat the tensioner firmly against the rear timing cover, but still allow the tensioner adjusting washer to be rotated using a 6 mm hex key (Figure 2). 6. Using the hex key, rotate the adjusting washer counterclockwise until the notch in the pointer is centered over the index line on the locating tab. (The pointer will move in a clockwise direction during adjustment) (Figure 3). 7. While holding the adjusting washer in position, torque the attaching bolt to 25 +/- 3 N.m (18 +/- 2 lb-ft) (Figure 4). NOTE IF THE POINTER DOES NOT REMAIN CENTERED OVER THE INDEX LINE DURING FINAL TIGHTENING, LOOSEN THE BOLT AND REPEAT THE PROCEDURE BEGINNING WITH STEP 4. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 490000, 499000

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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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Special Precautions Special Precautions Disconnect battery earth lead. DO NOT turn crankshaft or camshaft when timing belt removed. Remove glow plugs to ease turning engine. Turn engine in normal direction of rotation (unless otherwise stated). DO NOT turn engine via camshaft or other sprockets. Observe all tightening torques. Check diesel injection pump timing after belt replacement. Removal Removal 1. Support engine. 2. Remove: Air filter and air intake hoses. Auxiliary drive belts. RH engine mounting. Vacuum pipe bracket. Timing belt upper cover [1]. 3. Turn crankshaft clockwise to TDC on No.1 cylinder. Ensure crankshaft sprocket timing marks aligned [2]. 4. Insert M6 x 1,00 bolt in camshaft sprocket and M8 x 1,25 bolt in injection pump sprocket to lock sprockets in position [3]. NOTE: If locating holes not aligned: Turn crankshaft one turn. 5. Remove: Crankshaft pulley (4 bolts). Timing belt lower cover [4]. 6. Slacken tensioner bolts [6]. Remove tensioner spring [5]. 7. Move tensioner pulley away from belt. Lightly tighten bolts. 8. Remove timing belt. Installation Installation 1. 2. 3. 4. 5. Use crankshaft pulley to check TDC marks aligned [2]. Ensure locking bolts located correctly [3]. Fit timing belt in clockwise direction, starting at crankshaft sprocket. Ensure belt is taut between sprockets. Temporarily fit crankshaft pulley. Ensure timing marks aligned [2]. Fit tensioner spring [5]. Corsa-B/Corsavan/Combo: Slacken tensioner bolts [6]. Allow tensioner to operate. Remove locking bolts [3]. Tighten tensioner bolts to 19 Nm [6]. Turn crankshaft slowly two turns clockwise. Ensure timing marks aligned [2]. 6. Astra-F/Vectra/Cavalier: Slacken tensioner bolts [6]. Temporarily fit crankshaft pulley. Remove locking bolts [3]. Turn crankshaft 60° anti-clockwise (against normal direction of rotation) [7]. Tighten tensioner bolts to 19 Nm [6]. Turn crankshaft slowly two turns + 60° clockwise until timing marks aligned [2]. 7. 8. 9. 10. 11. Ensure timing marks aligned [2]. Ensure locking bolts can be inserted in sprockets [3]. If not: Repeat tensioning procedure. Remove crankshaft pulley. Fit timing belt lower cover [4]. Fit crankshaft pulley. Tighten bolts to 20 Nm. Install components in reverse order of removal.

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Due to the knocking noise and slow leaking of antifreeze, I decided to bite the bullet and replace the timing belt, tensioner arm and water pump. The following is information and photos regarding the repair procedure as well as replacing idler bearings for the timing belt and accessory belts. TIMING BELT (Loosen Crank / Water Pump Bolts) Before jacking the car up, MTX and ATX PGT’s should turn their wheel to the left and pop out the rubber plug in the splash well. The crank bolt is accessible directly inline with this hole pictured here……… Put the MTX in forth gear and set the parking brake firmly. The bolt can easily be broken loose with a breaker bar. ATX trannys will have to brace the breaker bar against the frame rail and tap the starter to crank the engine and pop the bolt loose. Next, while the car is still on the ground with all the belts still on, take a 10 mm combination wrench and crack the four water pump pulley bolts loose. It’s much easier now with the driveline and belts holding the pulley(s) still.

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Removal 1. Disconnect negative battery cable. Rotate crankshaft counterclockwise until cylinder No. 1 is at TDC of compression stroke. While rotating crankshaft, check water pump for signs of seal leakage. Remove accessory drive belts. Remove alternator terminal and connector. Raise and support vehicle. Remove wheelwell splash shield. Use a jack, with cushion between oil pan and jack, to support engine. Remove side engine mount. 2. Remove cylinder head cover. See Fig. 1 . Remove crankshaft pulley. Remove upper and lower timing belt covers. See Fig. 2 . Loosen timing belt tensioner adjuster nut 145-180 degrees. See Fig. 3 . Push tensioner to release belt tension from timing belt and balancer belt. Retighten tensioner adjuster nut. Mark rotation direction of timing belt if it is to be reused. Remove timing belt from pulleys. Installation Ensure cylinder No. 1 is at TDC of compression stroke. See Fig. 4 and Fig. 5 . Install timing belt in sequence shown. See Fig. 6 . Tighten bolts to specification. See TORQUE SPECIFICATIONS . To complete installation, reverse removal procedure. Adjust drive belts to proper tension.