1990 Astra GTE16V 20XE (Manual belt tensioner)
SORRY ITS LONG BUT I DIDN'T WANT TO MISS ANYTHING OUT
H E L P !!!!!!!!!!!!!!!!!!!!!!!! IT ALL STARTED LIKE THIS.......
Some weeks ago now I realised that I was rapidly loosing water from my water pump. Being mechanically minded I thought i'll have a go at this and off I went to buy the parts I needed (Water pump, timing belt, P/S belt and Alternator belt). When I returned I opened up the old haynes manual and proceeded to read the sections on DOHC engine and cooling system.
I then proceeded as follows:
Remove all the stuff that gets in the way (Air mass meter, air filter and box, offside wheel and timing belt cover and spark plugs)
I then turned the engine using the e20 bolt on the crank and lined up the marks on the cams with the two marks above the cams on the rear cover (so far so good should have this done i no time !).
When I look down at the crank pulley I see that the marker on the crank pulley doesnt line up with that on the casing (The marker on the pulley is about 12 mm before the marker on the casing - Arghh ! No mention of this in the book). I then turned the engine again to make sure this was a constant difference which it was)
Anyhow I marked the current position and removed the crank pulley which revealed another mark on the nose of the crank which was also out of line by a similar amount.
Now off with the tensioner and also the timing belt.
Next came the attempted removal of the backplate which just didn't want to move so off came the cam sprockets and then the backplate at last.
Out came the water pump next and in went the new. On with the backplate, cam sprockets, new timing belt and tensioner. Then lining up the two cam sprockets and the crank (to the mark which I made) I tightened up the tensioner and refitted the crank pulley, the new P/S belt and the new alternator belt. On with the air mass meter.
I then turned the engine a couple of times by hand to check alignment with the mark I had made and also to make sure that no piston to valve collision occurs. Replace plugs and leads.
Now to sit in the seat and turn this beast over. The engine turned and tried to start but seemed to be coughing and spluttering and eventually the engine was flooded with a heavy smell of petrol behind the car.
Then I took the plugs out and checked the position of the crank pulley using a chopstick in cylinder 1 (Nearest to cambelt). When the stick was at center travel of its highest position it lined up with the manufacturers mark of the crank pulley.
Lining everything up to the manufacturers mark still resulted in the same problem when I tried to start the engine.
The timing belt has been changed previously (25000 ago by a Vaux dealer) and no mods have ever been done to the engine
What have I done wrong. Which mark should I use.
Why didn't these marks line up to start with.
Someone told me this could be 180 degree out - Is this true ?
At least it's not dripping water on the garage floor anymore !!!