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How to Replace timing belt on Vauxhall / Opel Zafira -A 2,0 D DTi

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

How to Replace timing chain on Vauxhall / Opel Zafira -A 2,0 D DTi
How to Replace timing chain on Vauxhall / Opel Zafira -A 2,0 D DTi
  • 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.

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