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[alexandjen]

Once the crankshaft nut is removed the sprocket should just slide off. You will also need to recover the spacer ring behind the sprocket and knock out the woodruff key before tackling the seal.  I punched two holes in the outer surface of the oil seal and screwed self-tappers into this.  It then levered out using a pair of long-nosed pliers.

Take care with the new oil seal. I had a bugger ir a job trying to get this back on and ruined the first seal.  These are £17 quid from Vauxhall, but I got another one from my local autofactors for a fiver.

I used wet and dry to round over the lip of the journal the seal presses over.  You need to clean this again thoroughly and liberally coat the journal and the seal lip with clean oil.  The second one went in just fine.

Ahh many thanks, I've got the sprocket off now after soaking it in WD40 and a couple of light taps she fell off

I was about to ask about the washer as the seal will not go passed it

How do you knock out the woodruff key?

[Andy B]

.....
How do you knock out the woodruff key?

Hammer & screwdriver .....  

[alexandjen]

.....
How do you knock out the woodruff key?

Hammer & screwdriver .....  

Cheers Andy, I've been struggling with various size screw drivers, still no luck.
I'm scared of buggering the thread :-/

[alexandjen]

I take it that it does knock out from the inside of the bolt aperture, so trying to get screwdriver inside where thread is for bolt and tapping upwards?
All I can feel is thread :-/

[Andy B]

I take it that it does knock out from the inside of the bolt aperture, so trying to get screwdriver inside where thread is for bolt and tapping upwards?
All I can feel is thread :-/

NO!!!! It's machined in from the outside. A woodruff key is like a half disc .........
clicky
You need to prise it up at one end.

[alexandjen]

I take it that it does knock out from the inside of the bolt aperture, so trying to get screwdriver inside where thread is for bolt and tapping upwards?
All I can feel is thread :-/

NO!!!! It's machined in from the outside. A woodruff key is like a half disc .........
clicky
You need to prise it up at one end.

Thanks Andy, yes sussed the Woodruff key eventually, came out easy when you no how.

I've changed the oil seal, put it back together and torqued the bolt.

I've replaced the water pump, positioning the new one in exactly the same place as the old one, I can't see any cut out on the rear timing cover to line the lug up with :-/

I think the old pump may be the original
It's covered in a layer of crud, looks like a build up of limescale and there is no groove with o ring seal, looks like someone used some sort of black sealant. Also the paddles are not made of plastic, they are metal ,brass colour.

Next problem is that I can't get the new cambelt on all the sprockets it's as though it is to short, which it isn't as I've measured it against the old one.

Does the water pump position make a difference to the belt length?

[markey mark]

yep turn pump to suit it needs to be in nearly the same place as your old one  

[alexandjen]

yep turn pump to suit it needs to be in nearly the same place as your old one  

That's just it Mark, I have positioned it as the old one, with the lug at 12 o'clock. As said before, I can't see anything to line up the water pump lug with :-?

[markey mark]

yep turn pump to suit it needs to be in nearly the same place as your old one  

That's just it Mark, I have positioned it as the old one, with the lug at 12 o'clock. As said before, I can't see anything to line up the water pump lug with :-?

sure theres a mark somewere bud just carnt remember were  

[RobG]

yep turn pump to suit it needs to be in nearly the same place as your old one  

That's just it Mark, I have positioned it as the old one, with the lug at 12 o'clock. As said before, I can't see anything to line up the water pump lug with :-?

sure theres a mark somewere bud just carnt remember were  [/quote]
The lug on the side of the pump is aligned with a recess in the cylinder block.

[JamesV6CDX]

I usually take off an idler, route the belt, and then fit the idler last.

[RobG]

When you are trying to fit belt are you keeping all the slack on the tensioner side :question

[alexandjen]

yep turn pump to suit it needs to be in nearly the same place as your old one  

That's just it Mark, I have positioned it as the old one, with the lug at 12 o'clock. As said before, I can't see anything to line up the water pump lug with :-?

sure theres a mark somewere bud just carnt remember were  [/quote]
The lug on the side of the pump is aligned with a recess in the cylinder block.

Don't suppose the recess is at 12 oclock

[alexandjen]

I usually take off an idler, route the belt, and then fit the idler last.

Tried that James, after seeing you do it on the DVD, no chance

[JamesV6CDX]

I usually take off an idler, route the belt, and then fit the idler last.

Tried that James, after seeing you do it on the DVD, no chance

Odd - are you doing it differently to how I was?