1988 OPEL CALIBRA Service Repair Manual

28Air inlet temperature control
check (carburettor models
only)
2
Refer to Chapter 4A for details.
29Fuel filter renewal
3
Fuel filters are fitted in various locations
throughout the range. Some may be ‘in-line’ in
the fuel tank itself, or fitted into the
carburettor.
Refer to Chapters 4A or 4B, as appropriate.
30Spark plug renewal (SOHC)
2
1The correct functioning of the spark plugs is
vital for the correct running and efficiency of
the engine. It is essential that the plugs fitted
are appropriate for the engine. Refer to the
specifications in Chapter 5. If this type is used
and the engine is in good condition, the spark
plugs should not need attention between
scheduled service replacement intervals.
Spark plug cleaning is rarely necessary and
should not be attempted unless specialised
equipment is available, as damage can easily
be caused to the firing ends.
2Identify each HT lead for position so that the
leads can be refitted to their correct cylinders.
Then disconnect the leads from the plugs by
pulling on the connectors, not the leads.
3Clean the area around each spark plug
using a small paintbrush, then using a plugspanner (preferably with a rubber insert),
unscrew and remove the plugs (see
illustration). Cover the spark plug holes with
a clean rag to prevent the ingress of any
foreign matter.
4The condition of the spark plugs will tell
much about the overall condition of the
engine.
5If the insulator nose of the spark plug is
clean and white, with no deposits, this is a
sign of a weak mixture, or too hot a plug (a hot
plug transfers heat away from the electrode
slowly -a cold plug transfers heat away
quickly).
6If the tip and insulator nose is covered with
hard black-looking deposits, then this is
indicative that the mixture is too rich. Should
the plug be black and oily, then it is likely that
the engine is fairly worn, as well as the mixture
being too rich.
7If the insulator nose is covered with light tan
to greyish brown deposits, then the mixture is
correct, and it is likely that the engine is in
good condition.
8The spark plug gap is of considerable
importance, because if it is either too large or
too small, the size of the spark and its
efficiency will be seriously impaired. The spark
plug gap should be set to the figure given in
the Specifications, in Chapter 5.
9To set it, measure the gap with a feeler
blade and then bend open, or close, the outer
plug electrode until the correct gap is
achieved. The centre electrode should never
be bent, as this may crack the insulation and
cause plug failure, if nothing worse (see
illustrations).10Before fitting new spark plugs check that
their threaded connector sleeves are tight.
11Screw in the plugs by hand, then tighten
them to the specified torque. Do not exceed
the torque figure.
12Push the HT leads firmly onto the spark
plugs, ensuring that they are connected to
their correct cylinders.
31Distributor cap and HT lead
check
3
1Remove the distributor cap and HT leads,
and wipe them clean.
2Also wipe clean the coil connections.
Remove the rotor arm, then visually check the
distributor cap, rotor arm and HT leads for
hairline cracks, and signs of arcing.
1•14Every 18 000 miles or 24 months
30.9A Tools required for spark plug
removal, gap adjustment and refitting30.9C Measuring the spark plug gap with
feeler blade30.9B Measuring the spark plug gap with
wire gauge
30.3 Removing a spark plugWarning: Before carrying out
the following operation, refer to
the precautions given in “Safety
first!” at the beginning of this
manual, and follow them implicitly. Petrol
is a highly dangerous and volatile liquid,
and the precautions necessary when
handling it cannot be overstressed.
It is very often difficult to insert spark
plugs into their holes without cross-
threading them. To avoid this, fit a
short length of 8 mm (internal
diameter), rubber hose over the end of
the spark plug. The flexible hose acts
as a universal joint to help align the
plug correctly. Should the plug begin to
cross-thread, the hose will slip on the
spark plug, preventing damage to the
thread in the cylinder head.
Number the HT leads before
removal to ensure correct
refitting.

3When refitting the distributor cap, check
that the ends of the HT leads are fitted
securely to the cap, plugs and coil. Also make
sure that the spring-tensioned carbon brush
in the centre of the distributor cap moves
freely, and that the HT segments are not worn
excessively.
4Inspect the electrical and vacuum
connections of the ignition/engine
management systems, and make sure that
they are clean and secure.
32Clutch cable check
2
Check the clutch cable adjustment, as
described in Chapter 6.
Check also, the condition of the cable.
Inspect the cable strands for fraying, and
ensure that the cable is correctly routed, to
avoid chafing against surrounding
components. Renew the cable, as described
in Chapter 6, if excessive wear or damage is
evident.
33Manual transmission fluid
check
2
Note:Models built after 1994 it is no longer
necessary to check levels.
1Ensure that the vehicle is on level ground.
2Unscrew the transmission oil level plug,
which is located in the rear left of the
differential housing on F10 and F13
transmissions, and in the rear right of the
differential housing on F16 and F20
transmissions (see illustrations). The oil level
should be up to the bottom of the level plug
orifice.
3If necessary, top-up the oil level through the
breather/filler orifice in the gear selector
cover. Unscrew the breather/filler plug, and
top-up with the specified grade of oil, until oil
just begins to run from the level plug orifice.
Refit the level plug and the breather/filler plug
on completion (see illustrations).
4Renewal of the transmission oil is not
specified by the manufacturers, and no drain
plug is provided. If it is desired to renew the oil
as a precaution, the oil may be drained by
removing the differential cover plate. Use a
new gasket when refitting the cover plate. Fillthe transmission through the breather/filler
orifice, as described previously in this
Section.
5Periodically inspect the transmission for oil
leaks, and check the gear selector linkage
components for wear and smooth operation.
34Automatic transmission
check
2
1Carry out a thorough road test, ensuring
that all gearchanges occur smoothly, without
snatching and with no increase in engine
speed between changes.
2Check the operation of the kickdown.
Check that all gear positions can be engaged
at the appropriate movement of the selector
lever and with the vehicle at rest, check that
the operation of the parking pawl in position
“P” prevents it from being moved. Ensure that
the starter motor will work only with the
selector lever in positions “P” or “N”, and thatthe reversing lamps light only when position
“R” is selected.
3The manufacturer’s schedule calls for a
regular check of the electrical control system
using the special Vauxhall test equipment;
owners will have to have this check carried
out by a Vauxhall dealer.
4Periodically inspect the transmission
casing, checking all joint surfaces and seals
for signs of fluid leaks. If any are found, the
fault must be rectified immediately.
5Check also that the transmission breather
hose (under the battery mounting bracket) is
clear and not blocked, kinked or twisted.
35Brake shoe check
2
Note:On models fitted with rear brake pads,
the handbrake operates brake shoes that are
located inside the rear brake discs.
Refer to Chapter 9, for details.
Every 18 000 miles or 24 months 1•15
33.3A Transmission breather/filler plug
(arrowed) - F16 type transmission33.3B Topping-up the transmission oil
level - F13 type transmission
33.2B Transmission oil level plug
(arrowed) - F16 type transmission (viewed
from below, with driveshaft removed)33.2A Transmission oil level plug
(arrowed) - F13 type transmission (viewed
from above)
1

36Timing belt renewal
3
1To minimise risk of major damage to the
engine the timing belt (or cambelt, as it is
sometimes called), needs replacing at least,
on every major service.
2It is good practise however, not only to
renew the belt whenever major engine work is
carried out, but also if you buy a used car with
unclear service history.
3Some models are fitted with an inspection
cover to view the condition of the belt. Whilst
others involve a lot more work.
4Full details on checking and replacement
are shown in Chapters 2A or 2B, as
appropriate.
37Spark plug renewal (DOHC)
2
1This procedure is basically the same shown
in Section 30. However on these models, a
spark plug cover needs to be removed from
the camshaft cover before the plugs can be
removed.
2Take great care when removing and
refitting spark plugs on these engines (see
illustration). Hairline cracks in the ceramic of
the plug can cause occasional or complete
ignition failure. Damage to the catalytic
converter may also occur.
3Special tool (Vauxhall No. KM-194-B), with
a 3 part conical sliding element have beenmade available, to reduce the risk of plug
damage (see illustration).
4After refitting the spark plugs, remember to
replace the plug cover.38Automatic transmission fluid
renewal
2
Renew the transmission fluid as detailed in
Chapter 7B.
1•16Every 36 000 miles or 48 months
37.3 Removing spark plugs using special adapter (DOHC models)
A Torque wrench
B ExtensionC Joint
D Special adapter (P/N KM-194-B)
37.2 Removing a spark plug -
DOHC model
Major service, every 36 000 miles (60 000 km) or 48 months

2B
Note:All specifications as for 2.0 litre SOHC engines, unless shown otherwise
General
Type (all models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Four-cylinder, in-line, water-cooled, transversely mounted. Double
belt-driven overhead camshafts, acting on hydraulic valve lifters
Manufacturer’s engine codes:
20 XEJ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0 litre (1998 cc)
C20 XE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0 litre (1998 cc) + catalyst
X20 XEV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0 litre (1998 cc) + catalyst. ‘Ecotec’ type engine
Compression ratio:
20 XEJ and C20 XE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5 : 1
X20 XEV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.8 : 1
Maximum power:
20 XEJ and C20 XE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 kW (150 bhp) at 6000 rpm
X20 XEV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 kW (136 bhp) at 5400 rpm
Maximum torque:
20 XEJ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196 Nm at 4800 rpm
C20 XE
Up to model year 1993 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196 Nm at 4800 rpm
1993-on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196 Nm at 4600 rpm
X20 XEV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185 Nm at 4000 rpm
Cylinder Head
Overall height of cylinder head (sealing surface to sealing surface):
20 XEJ and C20 XE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135.58 to 135.68 mm
X20 XEV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134.00 mm
Installation height of valve guide:
20 XEJ and C20 XE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.70 to 11.00 mm
X20 XEV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.70 to 14.00 mm
Camshaft
Camshaft bearing journal diameter (all models) . . . . . . . . . . . . . . . . . . . 27.939 to 27.960 mm
Camshaft bearing diameter in housing (all models) . . . . . . . . . . . . . . . . 28.000 to 28.021 mm
Cam lift:
20 XEJ and C20 XE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5 mm
X20 XEV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.0 mm
Maximum permissible radial run-out:
20 XEJ and C20 XE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.04 mm
X20 XEV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.06 mm
Endfloat (all models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.040 to 0.144 mm
Chapter 2 Part B:
DOHC engine procedures
Camshaft front oil seal - removal and refitting . . . . . . . . . . . . . . . . . . .6
Camshafts - removal, inspection and refitting . . . . . . . . . . . . . . . . . . .7
Crankshaft front oil seal - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Cylinder head - dismantling and reassembly . . . . . . . . . . . . . . . . . . .10
Cylinder head - removal and refitting (engine in vehicle) . . . . . . . . . . .8
Cylinder head - removal and refitting (engine removed) . . . . . . . . . . . .9
Engine - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Engine/transmission mountings - renewal . . . . . . . . . . . . . . . . . . . . . .3
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1Oil cooler - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Oil pump - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Sump - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Timing belt, sprockets and belt tensioner and idler pulleys - removal,
refitting and adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Timing belt, with automatic adjuster - removal, refitting and
adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Valve lifters - general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
2B•1
Specifications Contents
Easy,suitable for
novice with little
experienceFairly easy,suitable
for beginner with
some experienceFairly difficult,
suitable for competent
DIY mechanic
Difficult,suitable for
experienced DIY
mechanicVery difficult,
suitable for expert DIY
or professional
Degrees of difficulty
54321

Valves and guidesInletExhaust
Overall length - production (mm):
20 XEJ and C20 XE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105.0105.0
X20 XEV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102.092.0
Overall length - service (mm):
20 XEJ and C20 XE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104.6104.6
X20 XEV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101.791.8
Head diameter (mm):
20 XEJ and C20 XE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33.0 ±0.129.0 ±0.1
X20 XEV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32.0 ±0.129.0 ±0.1
Stem diameter (mm):
20 XEJ and C20 XE
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.955 to 6.9706.945 to 6.960
0.075 mm oversize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.030 to 7.0457.020 to 7.035
0.150 mm oversize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.105 to 7.1207.095 to 7.110
0.250 mm oversize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.205 to 7.2207.195 to 7.210
X20 XEV
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.955 to 5.9705.945 to 5.960
0.075 mm oversize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.030 to 6.0456.020 to 6.035
0.150 mm oversize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.105 to 6.1206.095 to 6.110
Valve guide bore (mm):
20 XEJ and C20 XE
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.000 to 7.015
0.075 mm oversize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.075 to 7.090
0.150 mm oversize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.150 to 7.165
0.250 mm oversize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.400 to 7.415
X20 XEV
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.000 to 6.012
0.075 mm oversize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.075 to 6.090
0.150 mm oversize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.150 to 6.165
Valve seat angle (all models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44°40’
Lubrication system
Lubricant capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .See Chapter 1 Specifications
Oil pressure at idle (engine warm):
20 XEJ and C20 XE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.5 bar
X20 XEV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.5 bar
Torque wrench settingsNmlbf ft
Note: Use new bolts (or nuts, if applicable), where asterisked (*).
Alternator to cylinder block bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . .3526
Brake servo line to inlet manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2015
Camshaft bearing cap to cylinder head (M6) . . . . . . . . . . . . . . . . . . . . .107
Camshaft bearing cap to cylinder head (M8) . . . . . . . . . . . . . . . . . . . . .2015
Camshaft bearing cap to head (X20 XEV) . . . . . . . . . . . . . . . . . . . . . . .86
Camshaft pulley to camshaft (1993-on models):
Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5037
Stage 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Angle tighten by 60°
Stage 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Angle tighten by 15°
Coolant pipe to cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2015
Cover to cylinder head (M6 bolts) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97
Cover to cylinder head (M8 nuts) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2216
Cover to exhaust manifold (X20 XEV) . . . . . . . . . . . . . . . . . . . . . . . . . . .54
Crankshaft pulse pick-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
Exhaust manifold to cylinder head * . . . . . . . . . . . . . . . . . . . . . . . . . . . .2216
Exhaust pipe to adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129
Inlet manifold support to cylinder block . . . . . . . . . . . . . . . . . . . . . . . . .2518
Intermediate shaft bracket to cylinder block . . . . . . . . . . . . . . . . . . . . .5541
Knock sensor to cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2014
Oil cooler lines to adapter/oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . .3022
Oil filter to oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1511
Oil dipstick flange to cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . .2518
Oil pump safety valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3022
Oil pump, threaded adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2317
Power steering pump to support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2518
Spark plug lead cover to cylinder head cover:
20 XEJ and C20 XE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
X 20 XEV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
2B•2DOHC engine procedures

Torque wrench settings (continued)Nmlbf ft
Starter to cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4533
Starter support to cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2518
Temperature regulator plug (M20) * . . . . . . . . . . . . . . . . . . . . . . . . . . . .3022
Timing belt cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
Timing belt drive gear to crankshaft: *
Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .250184
Stage 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Angle tighten by between 40°and 50°
Timing belt guide roller bracket to block . . . . . . . . . . . . . . . . . . . . . . . .2518
Timing belt guide roller to bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2518
Timing belt guide roller to cylinder block:
Engines up to 1993
Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2518
Stage 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Angle tighten by 45°
Stage 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Angle tighten by 15°
1993-on engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2518
Transfer box bracket to cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . .6044
Transmission to cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6044
1General
This part of Chapter 2 describes
procedures that are specific to the DOHC
engine. It should be read in conjunction with
Part A.
The lower engine is basically the same as
the 2.0 litre SOHC. However the pistons are
attached to the connecting rods by gudgeon
pins, which are fully floating, and are secured
by circlips.
Both camshafts on these engines are driven
from the crankshaft by one toothed
composite rubber belt. Each cylinder has four
valves (two inlet and two exhaust), operated
directly from the camshafts by hydraulic
self-adjusting valve lifters. One camshaft
operates the inlet valves, and the other
operates the exhaust valves.
DOHC models are fitted with a remotely
mounted oil cooler.
The distributor is driven directly from the
exhaust camshaft.
2Engine - removal and refitting
4
Removal
1Carry out procedure in Chapter 2A, noting
the following differences.
2With the car safely raised, remove the
engine undershield.
3The fuel hoses need to be disconnected
from the fuel rail.
4Disconnect coolant hoses from the cylinder
block and cylinder head. Also disconnect the
oil cooler pipe unions from the oil pump.
5Unbolt the right-hand driveshaft centre
bearing support bracket from the rear of the
cylinder block.
Refitting
6Refitting the engine is similar to theprocedure in Chapter 2A. The exceptions
being, replacement of the right-hand
driveshaft centre bearing support bracket at
the rear of the cylinder block and retightening
the securing bolts.
7Replace the undershield.
3Engine/transmission
mountings- renewal
3
The procedure for replacing the engine/
transmission is similar to SOHC models, see
Chapter 2A. However this engine is fitted with
an undershield that needs to be removed
before replacing the mounts. Do not forget to
replace the undershield before lowering the
car.
4Timing belt, sprockets and belt
tensioner and idler pulleys-
removal, refitting and adjustment
3
Note: The timing belt should be renewed on
refitting. A two-legged puller may be required
to remove the crankshaft sprocket
Removal
1Disconnect the battery negative lead.2Disconnect the air cleaner trunking from the
airflow meter, then remove the cover and the
air cleaner element from the air cleaner. If
desired, for improved access, the complete
air cleaner assembly can be removed, as
described in Chapter 4B.
3Remove the power steering pump drivebelt,
as described in Chapter 10.
4Remove the alternator drivebelt, as
described in Chapter 5.
5Remove the three securing screws, and
withdraw the outer timing belt cover. Recover
the rubber grommets from the screw holes in
the cover if they are loose.
6Turn the crankshaft using a Torx socket on
the crankshaft sprocket bolt, until the timing
marks on the camshaft sprockets are aligned
with the notches in the camshaft cover. The
notch in the crankshaft pulley should also be
aligned with the pointer on the rear timing belt
cover (see illustrations).
7Extract the six securing bolts using a
splined bit, and withdraw the crankshaft
pulley (see illustration). If necessary,
counterhold the crankshaft using a socket on
the crankshaft sprocket bolt. If the engine is in
the vehicle, the crankshaft can be prevented
from turning by having an assistant engage
first gear and depress the brake pedal.
Alternatively, the flywheel ring gear teeth can
be jammed using a large screwdriver or
similar tool. Before removing the pulley, check
that the timing marks are still aligned.
DOHC engine procedures 2B•3
4.6B . . .and notch in crankshaft pulley
aligned with pointer on rear timing belt
cover (circled)4.6A Camshaft sprocket TDC mark
aligned with notch in camshaft cover
2B

8Loosen the securing bolt and release the
timing belt tensioner pulley, then slide the belt
from the sprockets and pulleys (see
illustration).
9If desired, the sprockets, tensioner and idler
pulleys, and the rear timing belt cover can be
removed as follows, otherwise go on to
paragraph 27.
10To remove the camshaft sprockets, first
disconnect the breather hoses from the
camshaft cover (see illustration).
11Extract the two securing bolts and remove
the spark plug cover (see illustration), then
disconnect the HT leads from the spark plugs,
and unclip them from the end of the camshaft
cover. If necessary, mark the HT leads for
position, to avoid confusion when refitting.
12Unscrew the twenty securing bolts and
withdraw the camshaft cover (see
illustration).13Recover the one-piece rubber gasket (see
illustration).
14Prevent the relevant camshaft from
turning by holding it with a spanner on the
flats provided in front of No 1 cam lobe, and
unscrew the camshaft sprocket bolt (see
illustration).
15Withdraw the sprocket from the end of the
camshaft, then repeat the procedure for the
remaining camshaft sprocket.
16Remove the crankshaft sprocket. It will be
necessary to prevent the crankshaft from
turning by bolting a metal bar to the sprocket
using two of the crankshaft pulley bolts, or by
jamming the flywheel ring gear teeth. A Torx
socket will be required to unscrew the
sprocket bolt -take care, as the bolt is very
tight. If necessary, use a two-legged puller to
remove the sprocket. Recover the
thrustwashers from the end of the crankshaft,
and from under the bolt head.17To remove the belt tensioner pulley,
simply unscrew the securing bolt from the
centre of the pulley, then withdraw the pulley
complete with mounting plate (see
illustration). Recover the spacer sleeve from
the pulley bolt.
18To remove the belt idler pulley, unscrew
the securing bolt from the centre of the pulley,
then withdraw the pulley and recover the
spacer sleeve from the pulley bolt.
19The rear timing belt cover can now be
removed after unscrewing the upper and
middle studs for the timing belt outer cover
screws. Note that the upper stud simply
unscrews from the cylinder head, but the
middle stud is secured by a bolt. Unscrew the
two upper and single lower right-hand rear
belt cover securing bolts, and withdraw the
rear belt cover (see illustrations).
Refitting
20Refit the rear timing belt cover using a
reversal of the removal procedure.
21Refit the belt idler and tensioner pulleys,
noting that the spacer sleeves should be fitted
with their smaller diameters against the
pulleys (see illustration). Do not fully tighten
the tensioner pulley bolt at this stage.
22Refit the thrustwasher to the end of the
crankshaft, then refit the crankshaft sprocket.
2B•4DOHC engine procedures
4.7 Crankshaft pulley and securing bolts
viewed through right-hand wheel arch4.10 Disconnecting a breather hose from
the rear of the camshaft cover
4.17 Timing belt pulley components
1 Tensioner pulley securing bolt
2 Tensioner pulley mounting plate
3 Idler pulley securing bolt
4.14 Spanner positioned to counterhold
exhaust camshaft4.13 Camshaft cover removed to show
one-piece rubber gasket
4.12 Unscrewing a camshaft cover
securing bolt4.11 Removing the spark plug cover
4.8 Timing belt tensioner pulley securing
bolt (arrowed)

Apply a little grease to the threads of the
securing bolt, and tighten it to the specified
torque in the two stages given in the Specifi-
cations. Ensure that the thrustwasher is in
place under the bolt head, and prevent the
crankshaft from turning as during removal.
23Refit the camshaft sprockets. Ensure that
the locating pins on the ends of the camshafts
engage with the holes in the sprockets and
with the sprocket timing marks facing
forwards. Then tighten the securing bolts to
the specified torque in the two stages given in
the Specifications. Prevent the camshafts
from turning as during removal.
24Check the condition of the camshaft
cover rubber gasket and renew if necessary,
then refit the camshaft cover and tighten the
securing bolts (see illustration).
25Refit the HT leads to the spark plugs
(ensuring that they are refitted to their correct
cylinders), then clip the leads to the end of the
camshaft cover. Refit the spark plug cover
and tighten the securing bolts.
26Reconnect the breather hose to the
camshaft cover.
27Temporarily refit the crankshaft pulley,
and ensure that the crankshaft pulley and
camshaft sprocket timing marks are still
aligned as described in paragraph 6. Then fit a
new timing belt around the sprockets and
pulleys, starting at the crankshaft sprocket.
28Refit the crankshaft pulley, and tighten the
securing bolts to the specified torque. If
necessary, prevent the crankshaft from
turning as during removal. 29Adjust the timing belt tension, as
described from paragraph 35 onwards.
30Refit the outer timing belt cover, ensuring
that the rubber grommets are in place in the
screw holes, and tighten the securing screws.
31Refit the alternator drivebelt and adjust
the drivebelt tension, as described in Chapter
5.
32Refit the power steering pump drivebelt
and adjust the drivebelt tension, as described
in Chapter 10.
33Refit the air cleaner components as
applicable, referring to Chapter 4B, if
necessary.
34Reconnect the battery negative lead.
Adjustment
Note: The manufacturers specify the use of
special adjustment wrench Vauxhall tool No
KM-666 for adjusting the timing belt tension. If
access to this tool cannot be obtained an
approximate adjustment can be achieved
using the method described in this Section.
However it is emphasised that the vehicle
should be taken to a dealer at the earliest
possible opportunity to have the tension
adjusted using the special tool. Do not drive
the vehicle over any long distance until the
belt tension has been adjusted by a dealer
Approximate adjustment
35No checking of timing belt adjustment is
specified, and the following adjustment
procedure applies to a newly fitted belt. The
adjustment must be carried out with the
engine cold.36With the timing belt cover removed and
the tensioner pulley bolt slackened, ensure
that the TDC marks on the camshaft
sprockets and the crankshaft pulley are
aligned as described in paragraph 6. If
necessary, turn the crankshaft to achieve
alignment.
37Have an assistant press the tensioner
pulley against the belt until the belt can just be
twisted through 45°, using moderate pressure
with the thumb and forefinger, on the longest
belt run between the exhaust camshaft
sprocket and the belt idler pulley.
38Have the assistant hold the tensioner
pulley in position, and tighten the tensioner
pulley bolt to the specified torque in the two
stages given in the Specifications.
39Turn the crankshaft clockwise through
two complete revolutions, and check that,
with the crankshaft pulley TDC mark aligned
with the pointer on the rear timing belt cover,
the TDC marks on the camshaft sprockets are
still aligned with the notches in the camshaft
cover.
40Proceed as described in paragraphs 30 to
34, inclusive.
41Have the belt tension adjusted by a
Vauxhall dealer using the manufacturer’s
special tool at the earliest opportunity.Adjustment using Vauxhall special
tool (KM-666)
42Proceed as described in paragraphs 35
and 36.
43Fit the special tool KM-666 to the belt
tensioner pulley mounting plate, in
accordance with the tool manufacturer’s
instructions.
44Working anti-clockwise from the TDC
mark on the exhaust camshaft sprocket, mark
the seventh tooth on the sprocket (see
illustration).
45Turn the crankshaft clockwise until this
tooth is aligned with the TDC notch in the
camshaft cover. The crankshaft must be
turned evenly and without jerking, to prevent
the timing belt from jumping off the sprockets
and pulleys.
46Tighten the tensioner pulley bolt to the
specified torque in the two stages given in the
Specifications.
47Remove the special tool.
DOHC engine procedures 2B•5
4.21 Belt tensioner pulley and spacer
sleeve. Note that smaller diameter of
spacer sleeve fits against pulley
4.44 Working anti-clockwise from the TDC
mark on the exhaust camshaft sprocket,
mark the seventh tooth on the sprocket4.24 Tightening a camshaft cover securing
bolt
4.19B Rear timing belt cover lower right-
hand securing bolt4.19A Timing belt outer cover screw upper
stud (1) and rear belt cover upper
securing bolts (2)
2B