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3. Prior to Operation
Always ensure tools are used,
inspected and maintained in
compliance with the respective
local, state, national or federal
regulations.
• Before starting to work, disconnect enginge
from power supply. Carefully read operating
instructions for the engine and if necessary
for the other equipment assemblies and
devices (e.g. radio etc.)
ATTENTION
Ensure that the radio code is recorded.
CAUTION
Jacked up vehicles must be secured
adequately.
ATTENTION
Only use appropriate spare parts.
4. Operation
Timing Belt Replacement and Chain Drive
Timing on OPEL / VAUXHALL
Diesel and Petrol Engines
4.1 Diesel Engines
•
Diesel Engines including CDTi
4.2 Petrol Engines
•
Twin Cams n
Cross Reference to OPEL Tool Numbers
•
See page 23
4.1 DIESEL ENGINES
Chain Drive 2.0 and 2.2 DTi Diesel Engines
X20DTL/DTH / X22DTH / Y20DTL/DTH /
Y22DTH/DTR
➪ For model usage / engine codes
refer to Application Chart, pages 6-7.
The correct engine 'timing' position must be re-
established whenever service work requiring
camshaft/valve train adjustment, cylinder head
removal and major engine repairs have been
carried out – refer to "Timing Adjustment".
ATTENTION:
With the 1st cylinder at TDC, the
timing position is correct only when
the Crankshaft Locking Pin 3088-2,
Injection Pump Locking Pin 3088-3 and
Camshaft Setting Tool 3088-1 can all be
installed on the engine.
experienced mechanics. Always wear personal protective equipment.
24
Composition and Function
Maintenance work on engines must be carried out only by
1
Figure
, page 3
Camshaft Setting Tool 3088-1
• Fix the camshaft in its timed position by
locating 3088-1 into the horizontal slot
machined at the back of the camshaft.
NOTE
When 3088-1 is installed the loca-
ting pin on the tool must be upper-
most (top).
2
Figure
, page 3
Crankshaft Locking Pin 3088-2
• Crankshaft Locking Pin 3088-2 positions the
crankshaft at TDC. Insert through the hole
for the crankshaft position sensor in the
cylinder block and engage the slot provided
on the crankshaft.
3
Figure
, page 3
Injection Pump Locking Pin
• When inserted Injection Pump Locking Pin
3088-3 enters a recess in the injection pump
flange and aligns a timing mark on the
simplex injection pump sprocket.
NOTE:
It is most important that when using
Locking Pin 3088-3 it enters the
locating hole smoothly and slides
in and out easily. This indicates correct
timing position has been achieved.
Timing Adjustment
4
Figure
, page 3
Timing Adjustment Assembly
3088-4 and 3088-5
• This "Assembly" comprises Cam Sprocket
Attachment 3088-5 and Timing Adjustment
Fixture 3088-4. It is mounted on the cylinder
head and is used to adjust the position of the
injection pump sprocket to its timed position.
This
adjustment
turning the camshaft sprocket using 3088-5
as this sprocket is directly connected to the
injection pump sprocket by the simplex chain.
• The crankshaft must be locked at TDC with
3088-2. Remove both the simplex and
duplex chain tensioners. Remove bolt of the
camshaft sprocket whilst counter-holding
the camshaft with a spanner. Fit a new bolt,
hand-tight only, and ensure the sprocket
is 'free to turn' on camshaft.
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