Vauxhall/Opel Zafira 2,0d DTi cambelt change instructionts and replacement inteval. Full guide!
Special tools
- Camshaft locking tool – No.KM-932.
- Camshaft sprocket holding tool – No.KM-933.
- Crankshaft locking pin – No.KM-929.
- Crankshaft pulley holding tool – No.KM-930 or KM-977-1/956-1.
- Injection pump locking pin – No.KM-927.
General precautions
- Disconnect battery earth lead.
- Remove glow 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 bolts.
- Observe tightening torques.
- 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.
- Check diesel injection pump timing after resetting valve timing.
Valve timing procedures
- Turn crankshaft until just before crankshaft pulley timing marks aligned.
- Ensure No.1 cylinder camshaft lobes are facing upwards [1] .
- Remove crankshaft position (CKP) sensor [2] .
- Slowly turn crankshaft clockwise until locking pin can be inserted in crankshaft [3] . Tool No.KM-92
- Engine at TDC on No.1 cylinder.
- Ensure crankshaft pulley timing marks aligned [4] .
- Insert locking pin in hole in injection pump [5] . Tool No.KM-927.
- Fit locking tool to rear of camshaft [6] . Tool No.KM-932.
- Ensure peg locates in camshaft [7] .
- Injection pump timing adjustment:
- Ensure crankshaft locking pin inserted [3] . Tool No.KM-929.
- Remove timing chain tensioners [8] & [9] . Note installation positions.
- Remove camshaft sprocket bolt [10] . Fit new bolt.
- Tighten bolt until camshaft sprocket turns freely but does not tilt.
- Remove injection pump sprocket bolts [11] . Fit new bolts (bolt classification – 10.9).
NOTE: Injection pump sprocket may have 5 bolts.
- Turn injection pump sprocket until arrow and hole aligned [12] .
- Insert locking pin in hole in injection pump [5] . Tool No.KM-927.
- Install lower timing chain tensioner [9] . Tightening torque: 60 Nm.
- Remove injection pump locking pin [5] .
- Tighten injection pump sprocket bolts [11] . Tightening torque: 28 Nm.
- Adjust valve timing.
Valve timing procedures:
- Ensure crankshaft locking pin inserted [3] . Tool No.KM-929.
- Ensure injection pump locking pin inserted [5] . Tool No.KM-927.
- Ensure upper timing chain tensioner removed [8] .
- Ensure new camshaft sprocket bolt tightened until camshaft sprocket turns freely but does not tilt.
- Ensure arrow on injection pump sprocket and hole aligned [12] .
- Fit locking tool to rear of camshaft [6] . Tool No.KM-932.
- Ensure peg locates in camshaft [7] .
- Install camshaft sprocket holding tool [13] . Tool No.KM-933.
- Apply slight anti-clockwise pressure on camshaft sprocket using lever [14] . Retain lever in position using locking bolt
- [15] .
- Ensure injection pump locking pin can be removed and inserted easily [5] .
- Tighten camshaft sprocket bolt [10] . Tightening torque: 90 Nm + 60° + 30°.
- Install upper timing chain tensioner [8] . Tightening torque: 60 Nm.
- Turn crankshaft 2 turns clockwise to TDC on No.1 cylinder.
- Install special tools and check valve timing and injection pump timing.
- Timing chain tensioner with release pin [16] :
- After installation, release timing chain tensioner by pressing pin until click is heard.
- Ensure pin can be pushed in fully with thumb pressure and returns to original position.
NOTE: Engine oil pressure will prevent release pin from being pushed in.
- Camshaft rotation can be prevented using spanner at position shown [17] .
- Auxiliary drive belt tensioner:
- Store in upright position.
- Bleed incorrectly stored tensioner by repeated compression in upright position.
NOTE: Crankshaft pulley central bolt MUST only be used once.