How to replace timing belt on Vauxhall/Opel Astra G 1.7 CDTI

Replacement Interval Guide

• Vauxhall recommend replacement as follows:
• →2005MY:
• Replacement every 100,000 miles or 10 years, whichever occurs first.
• 2006MY→:
• Replacement every 100,000 miles or 10 years, whichever occurs first (tensioner pulley and guide pulley must also be replaced). Check condition of crankshaft sprocket.
• The previous use and service history of the vehicle must always be taken into account.

Check For Engine Damage

CAUTION: This engine has been identified as an INTERFERENCE engine in which the possibility of valve-to-piston damage in the event of a timing belt failure is MOST LIKELY to occur. A compression check of all cylinders should be performed before removing the cylinder head.

Repair Times – hrs

Remove & install

1,20

Special Tools

• Engine support and alignment tool 1 – Kent Moore No.KM-6173.
• Engine support and alignment tool 2 – Kent Moore No.KM-6001-A.

Special Precautions

• Disconnect battery earth lead.
• DO NOT turn crankshaft or camshaft when timing belt removed.
• Remove glow plugs to ease turning engine.
• Turn engine in normal direction of rotation (unless otherwise stated).
• DO NOT turn engine via camshaft or other sprockets.
• Observe all tightening torques.

Removal

1. Raise and support vehicle.
2. Remove:
   • RH wheel.
   • RH inner wing panel.
   • Engine top cover.
   • Air filter housing.
   • Auxiliary drive belt.

   NOTE: Mark direction of rotation on belt with chalk if belt is to be reused.

3. Move wiring harness to one side.
4. Remove timing belt upper cover [1] .
5. Fit engine support and alignment tools. Tool No.KM-6173 & KM-6001-A.
6. Support engine.
7. Remove:
   • RH engine mounting [2] .
   • RH engine mounting bracket [3] .
   • Crankshaft pulley bolts [4] .
   • Crankshaft pulley [5] .
   • Water pump pulley bolts.
   • Water pump pulley.
   • Timing belt lower cover [6] .
8. Turn crankshaft to TDC on No.1 cylinder. Ensure timing marks aligned [7] .

   NOTE: This may require up to 6 turns.

9. Insert M6 x 1,00 bolt in camshaft sprocket [8] .
10. Insert M8 x 1,25 bolt in injection pump sprocket [9] .
11. Slacken tensioner bolt [10] .
12. Move tensioner away from belt [11] . Finger tighten bolt.
13. Remove timing belt.

    NOTE: Mark direction of rotation on belt with chalk if belt is to be reused.

Installation

1. Ensure locking bolts located correctly [8] & [9] .
2. Ensure crankshaft sprocket mark aligned with notch [7] .
3. Check tensioner pulley for smooth operation.
4. Fit timing belt in clockwise direction, starting at crankshaft sprocket. Ensure belt is taut between sprockets.
5. Slacken tensioner bolt [10] .
6. Remove locking bolts [8] & [9] .
7. Turn crankshaft 60° anti-clockwise (against normal direction of rotation) [12] .
8. Tighten tensioner bolt [10] . Tightening torque: 38 Nm.
9. Turn crankshaft up to 6 turns + 60° clockwise until timing marks aligned [7] . Ensure locking bolts can be installed [8] & [9] .
10. Install components in reverse order of removal.
11. Fit crankshaft pulley.
12. Tighten crankshaft pulley bolts [4] . Tightening torque: 20 Nm.
13. Tighten engine mounting bolts [2] . Tightening torque: 55 Nm.
14. Tighten engine mounting bracket bolts [3] . Tightening torque: 40 Nm.