How to replace timing chain on Opel/Vauxhall Corsa D 1.0 2006-2009

Special tools

• Camshaft locking tool – No.KM-953.
• Camshaft position (CMP) sensor disc setting tool – No.KM-954.
• Crankshaft timing pin – No.KM-952.
• Crankshaft pulley holding tool 1 – No.KM-6013.
• Crankshaft pulley holding tool 2 – No.KM-956.
• Timing chain tensioner locking pin – No.KM-955-1.

General precautions

• Disconnect battery earth lead.
• Remove spark plugs to ease turning engine.
• Turn engine in normal direction of rotation (unless otherwise stated).
• DO NOT use special tools listed above to lock engine when slackening sprocket or pulley bolts.
• Observe tightening torques.
• If fitted: Mark position of crankshaft position (CKP) sensor before removal.
• Do NOT turn crankshaft via camshaft or other sprockets.
• Do NOT turn crankshaft or camshaft with timing chain removed.

Valve timing procedures

• Turn crankshaft until just before TDC mark on No.1 cylinder [1] .
• Remove blanking plug from cylinder block.
• Slowly turn crankshaft clockwise until timing pin [2] can be inserted in crankshaft.
• Ensure camshaft lobes for No.1 cylinder angled upwards.
• Insert camshaft locking tool in rear of camshafts [3] .
• Install camshaft position (CMP) sensor disc setting tool [4] .
• Remove blanking plug from timing chain front cover [5] .
• Compress timing chain tensioner and lock with timing chain tensioner locking pin [6] .
• If necessary, slacken bolt of each camshaft sprocket to adjust valve timing position [7] .

NOTE: Camshaft sprocket bolts MUST only be used once [7] .

• Tighten bolt of each camshaft sprocket as follows:
  • Stage A – 10 Nm.
  • Stage B – 50 Nm + 60°.
• During installation of crankshaft hub ensure timing mark points upwards [9] .

NOTE: Crankshaft hub bolt MUST only be used once.

• Tighten crankshaft hub bolt [8] . Tightening torque: 150 Nm + 45° + 15°.
• Tighten crankshaft pulley bolts to 8 Nm [10] .

NOTE: Use crankshaft pulley holding tools to prevent crankshaft rotation.

• Refit blanking plug for cylinder block. Tightening torque: 50 Nm.
• Refit blanking plug for timing chain front cover [5] . Tightening torque: 50 Nm.