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

Special tools

  • Camshaft locking tool – No.KM-953-A.
  • Camshaft position (CMP) sensor disc setting tool – No.EN-49977-100.
  • Crankshaft locking pin – No.KM-952.
  • Crankshaft pulley holding tool – No.EN-49979.
  • Crankshaft pulley holding tool handle – No.KM-956-1.
  • Inlet camshaft adjuster locking tool – No.EN-49977-200.
  • 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

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

  • Removal/installation of timing chain requires:
      • Sump removal.
  • Turn crankshaft until just before TDC mark on No.1 cylinder [1] .
  • Remove blanking plug from cylinder block.
  • Slowly turn crankshaft clockwise until crankshaft locking pin can be inserted in crankshaft [2] .
  • Insert camshaft locking tool in rear of camshafts [3] .
  • Lock timing chain tensioner in retracted position [4] :
      • Push tensioner rail against chain tensioner [5] .
      • Insert timing chain tensioner locking pin [6] .
  • Remove timing chain tensioner [4] .
  • Remove tensioner rail, chain guides and timing chain.
  • Fit timing chain.

NOTE: Ensure timing chain is taut between sprockets on non-tensioned side.

  • Install tensioner rail and chain guides.
  • Install timing chain tensioner [4] .
  • Remove timing chain tensioner locking pin [6] .
  • Remove special tools [2] & [3] .
  • Turn crankshaft two turns clockwise until just before TDC on No.1 cylinder [1] .
  • Slowly turn crankshaft clockwise until crankshaft locking pin can be inserted in crankshaft [2] .
  • Insert camshaft locking tool in rear of camshafts [3] .

NOTE: If camshaft locking tool cannot be fitted valve timing is incorrect.

  • Adjust camshafts as follows:
      • Turn crankshaft until just before TDC mark on No.1 cylinder [1] .
      • Remove blanking plug from cylinder block.
      • Slowly turn crankshaft clockwise until crankshaft locking pin can be inserted in crankshaft [2] .
      • Remove blanking plug from timing chain front cover [7] .
      • Turn inlet camshaft slowly clockwise to compress the timing chain tensioner.
      • Insert timing chain tensioner locking pin [6] .
      • Slacken inlet camshaft adjuster bolt [8] .
      • Slacken exhaust camshaft adjuster bolt [9] .

    NOTE: Camshaft rotation can be prevented using spanner on hexagon.

      • Turn camshafts until camshaft locking tool can be inserted correctly [3] .
      • Remove upper timing chain guide [10] .
      • Remove timing chain tensioner locking pin [6] .
      • Install inlet camshaft adjuster locking tool [11] .
      • Install camshaft position (CMP) sensor disc setting tool [12] .
      • Ensure camshaft position (CMP) sensor disc setting tool abuts cylinder head.
      • Secure camshaft position (CMP) sensor disc setting tool to cylinder head.
      • Tighten inlet camshaft adjuster bolt [8] . Tightening torque: 50 Nm + 60°.
      • Tighten exhaust camshaft adjuster bolt [9] . Tightening torque: 50 Nm + 60°.

    NOTE: Camshaft rotation can be prevented using spanner on hexagon.

      • Remove special tools [2] , [3] , [11] & [12] .
      • Turn crankshaft to TDC on No.1 cylinder [1] .
      • Check valve timing.

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