1988 OPEL VECTRA belt

1•4Maintenance schedule
Every 250 miles (400 km) or weekly
MRefer to “Weekly checks”
Basic service, every 9000 miles
(15 000 km) or 12 months -
whichever comes sooner
Along with the items in “Weekly checks”, carry out the
following:
MRenew the engine oil and oil filter (Section 3).
MCheck all hoses and other components for fluid
leaks (Section 4).
MCheck the steering and suspension components
(Section 5).
MCheck the condition of the driveshaft rubber
gaiters (Section 6).
MCheck the automatic transmission fluid level (if
applicable), (Section 7).
MCheck the radiator for blockage (e.g. dead insects)
and clean as necessary (Section 8).
MCheck and adjust the idle speed and mixture (if
applicable), (Section 9).
MCheck the throttle linkage and lubricate if
necessary (Section 10).
MCheck the exhaust system for corrosion, leaks and
security (Section 11).
MCheck all wiring for condition and security
(Section 12).
MCheck and adjust the ignition timing (if applicable),
(Section 13).
MRenew the brake fluid (Section 14).
MCheck the brake pad friction material for wear
(Section 15).
MCheck the handbrake linkage (Section 16).
MCheck the power steering fluid level (if applicable),
(Section 17).
MCheck the power steering pump drivebelt (if
applicable), (Section 18).
MCheck the rear suspension level control system
height, if fitted (Section 19).
MCheck the bodywork (Section 20).
MLubricate all locks and hinges (Section 21).
MCheck the alternator V-belt (Section 22).
MCheck the headlamp alignment (Section 23).
MReplace battery in the door-lock key (if applicable),
(Section 24).
MCarry out a road test (Section 25).
Note: Vauxhall specify that an Exhaust Emissions Test should be
carried out at least annually. However, this requires special
equipment, and is performed as part of the MOT test (refer to the
end of the manual).
Full service, every 18 000 miles
(30 000 km) or 24 months -
whichever comes sooner
Along with the ‘basic service’, carry out the following:
MRenew the coolant (Section 26).
MRenew the air cleaner element (Section 27).
MCheck the operation of the air cleaner air inlet
temperature control (carburettor models only),
(Section 28).
MRenew the fuel filter (Section 29).
MRenew the spark plugs (SOHC only), (Section 30) *.
MInspect and clean the distributor cap and HT leads
(Section 31).
MCheck the clutch cable adjustment (Section 32).
MCheck the manual transmission oil level (Section 33).
MCheck the automatic transmission (Section 34).
MCheck the brake drum shoe for wear (Section 35).
Major service, every 36 000 miles
(60 000 km) or 48 months -
whichever comes sooner
Along with the ‘full service’, carry out the following:
MRenew timing belt (Section 36).
MRenew the spark plugs (DOHC models only),
(Section 37).
MRenew automatic transmission fluid (Section 38) *.
* Note: If a vehicle is used for heavy-duty work (e.g. taxi work,
caravan/trailer towing, mostly short-distance, stop-start city driving)
the fluid must be changed every 36 months or 27 000 miles (45 000
km), whichever occurs first.

test (refer to Chapter 2A) will provide valuable
information regarding the overall performance
of the main internal components. Such a test
can be used as a basis to decide on the
extent of the work to be carried out. If, for
example, a compression test indicates serious
internal engine wear, conventional
maintenance as described in this Chapter will
not greatly improve the performance of the
engine. It may also prove a waste of time and
money, unless extensive overhaul work is
carried out first.
The following series of operations are those
most often required to improve the
performance of a generally poor-running
engine:Primary operations
a)Clean, inspect and test the battery (See
“Weekly Checks”)
b)Check all the engine related fluids (See
“Weekly Checks”)
c)Check the condition and tension of the
auxiliary drivebelt (Sections 18 and 22, as
appropriate).
d)Renew the spark plugs (Sections 30 and
37, as appropriate).
e)Inspect the distributor cap, rotor arm and
HT leads, as applicable (Section 31).
f)Check the condition of the air filter, and
renew if necessary (Section 27).
g)Check the fuel filter (Section 29).
h)Check the condition of all hoses, and
check for fluid leaks (Section 4).i)Check the idle speed and mixture
settings, as applicable (Section 9).
5If the above operations do not prove fully
effective, carry out the following secondary
operations:
Secondary operations
All items listed under “Primary operations”,
plus the following:
a)Check the charging system (Chapter 5).
b)Check the ignition system (Chapter 5).
c)Check the fuel system (Chapters 4A and
4B).
d)Renew the distributor cap and rotor arm
(Section 31).
e)Renew the ignition HT leads (Section 31).
3Engine oil and filter - renewal
2
1Ideally, the oil should be drained with the
engine hot, just after the vehicle has been
driven.
2On DOHC models, remove the engine
undershield to expose the sump drain plug
and the oil filter.
3Place a container beneath the oil drain plug
at the rear of the sump.
4Remove the oil filler cap from the camshaft
cover, then using a socket or spanner,
unscrew the oil drain plug, and allow the oil to
drain (see illustration). Take care to avoid
scalding if the oil is hot.
5Allow ten to fifteen minutes for the oil to
drain completely, then move the container
and position it under the oil filter.6On 1.8 and 2.0 litre models, improved
access to the oil filter can be gained by
jacking up the front of the vehicle and
removing the right-hand roadwheel (see
illustration). Ensure that the handbrake is
applied, and that the vehicle is securely
supported on axle stands (see “Jacking and
Vehicle Support”). Note that further oil may
drain from the sump as the vehicle is raised.
7Using a strap wrench or a filter removal tool
if necessary, slacken the filter and unscrew it
from the mounting. Alternatively, if the filter is
very tight, a screwdriver can be driven
through the filter casing and used as a lever.
Discard the filter.
8Wipe the mating face on the filter mounting
with a lint-free rag, then smear the sealing ring
of the new filter with clean engine oil of the
specified grade.
9Screw the new filter into position and
tighten it by hand only, do not use any tools.
10Where applicable, refit the roadwheel and
lower the vehicle to the ground. Fully tighten
the roadwheel bolts with the vehicle resting on
its wheels.
11Examine the condition of the oil drain plug
sealing ring and renew if necessary, then refit
the drain plug and tighten it to the specified
torque. 12Refill the engine through the filler on the
camshaft cover, using the specified grade and
quantity of oil. Fill until the level reaches the
“MAX” mark on the dipstick, allowing time for
the oil to drain through the engine to the
sump.
13Refit the oil filler cap, then start the engine
and check for leaks. Note that the oil pressure
warning lamp may stay illuminated for a few
seconds when the engine is started as the oil
filter fills with oil.
14Stop the engine and recheck the oil level,
topping-up if necessary.
15On DOHC models, refit the engine
undershield.
16Dispose of the old engine oil safely; do not
pour it down a drain.
4Hose and fluid leak check
1
1Visually inspect the engine joint faces,
gaskets and seals for any signs of water or oil
leaks. Pay particular attention to the areas
around the camshaft cover, cylinder head, oil
filter and sump joint faces. Remember that,
over a period of time, some very slight
seepage from these areas is to be expected -
what you are really looking for is any
indication of a serious leak. Should a leak be
found, renew the offending gasket or oil seal
by referring to the appropriate Chapters in this
manual.
Every 9000 miles or 12 months 1•9
3.6 Oil filter viewed through right-hand
wheel arch - SOHC model3.4 Sump drain plug location -
2.0 litre DOHC model
(engine undershield removed)
1
Basic service, every 9000 miles (15 000 km) or 12 months
As the drain plug releases
from the threads, move it
away quickly so the stream
of oil, running out of the
sump, goes into the container not up
your sleeve (see illustration).
Note: It is
antisocial and
illegal to dump oil
down the drain.
To find the
location of your
local oil recycling
bank, call this
number free.

14Brake fluid renewal
3
Renew the brake and bleed the system.
Refer to Chapter 9 for full details.
15Brake pad check
2
With the front or rear (as applicable) of the
vehicle raised, remove the wheels and check
brake pads for wear. Renew the pads if the
lining is below that specified. See Chapter 9,
for specifications and full details.
16Handbrake linkage check
2
With the vehicle raised, check the operation
of the handbrake and lubricate the linkages.
Refer to Chapter 9, for further details.
17Power steering fluid check
2
1With the engine off, remove the cap from
the power steering reservoir. It is fitted with a
dipstick.
2The fluid should be visible up to the ‘MAX’
mark (1), (see illustration). If not, top it up
using specified fluid.
3Start the engine and immediately top-up
the fluid to the ‘MIN’ mark (2).
4Do not allow the reservoir to run dry.
5For details on how to bleed the system,
refer to Chapter 10.
18Power steering pump
drivebelt check
2
Note:Vauxhall specify the use of a special
gauge. Checking values for use with this
gauge are given in the Specifications in
Chapter 10, for reference.
Checking
1The correct belt tension can be
approximated by adjusting the length of the
threaded rod. This should give a belt
deflection of approximately 10.0 mm (0.4 in)
under moderate thumb pressure at the
midpoint of the belt run between the pulleys. If
in doubt, err on the slack side, as an
excessively tight belt may cause pump
damage.
2Check the condition of the belt and renew it
if there are any signs of damage or excessive
wear
Adjustment
3Slacken the adjuster and mounting bolts.
4Slacken the adjuster nuts, and adjust the
length of the threaded rod to remove or
tension the belt as desired (see illustration).
5Tighten the adjuster nuts, and tighten the
adjuster and mounting bolts to the specified
torque (see Chapter 10), on completion.
6If a new drivebelt has been fitted, recheck
the tension after a few hundred miles.
19Rear suspension level
control system check
2
Refer to Chapter 10, for details.
20Bodywork check
1
1Clean the outside of the vehicle. If possible,
clean underneath as well. If using a pressure
cleaner take care not to damage any electrical
components, especially in the engine
compartment.
2Check all around for signs of damage or
corrosion and treat accordingly. Repair stone
chips when you can to prevent rusting.
3Read Chapter 11, for more details.
21Lock and hinge check
2
1Lubricate locks and hinges on all doors,
tailgates (or boot lid) and bonnet.
2Check for wear or damage and ensure
correct operation of safety catches.
3Check security of the bonnet stay and it’s
securing clip.
4Read Chapter 11, for further details.
22Alternator V-belt check
2
Note:The new ribbed V-belt, fitted to later
models, can not be adjusted.
1Although special tools are available for
measuring the belt tension, a good
approximation can be achieved. Tension the
belt so that there is approximately 13.0 mm
(0.5 in) of free movement under firm thumb
pressure at the mid-point of the longest run
between pulleys.
2With the mounting bolts just holding the
unit, lever the alternator away from the engine
using a wooden lever at the mounting bracket
end until the correct tension is achieved. Then
1•12Every 9000 miles or 12 months
17.2 Topping-up the power steering fluid
level
18.4 Adjusting the length of the power
steering pump threaded rod
Warning: Brake hydraulic fluid
can harm your eyes and
damage painted surfaces, so
use extreme caution when
handling and pouring it. Do not use fluid
that has been standing open for some
time, as it absorbs moisture from the air.
Excess moisture can cause a dangerous
loss of braking effectiveness.
Old hydraulic fluid is usually
darker in colour than new
fluid.
For a quick check, the thickness of the
friction material on each brake pad can
be measured through the aperture in
the caliper body.

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

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