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
- Raise and support vehicle.
- 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.
- Move wiring harness to one side.
- Remove timing belt upper cover [1] .
- Fit engine support and alignment tools. Tool No.KM-6173 & KM-6001-A.
- Support engine.
- 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] .
- Turn crankshaft to TDC on No.1 cylinder. Ensure timing marks aligned [7] .
NOTE: This may require up to 6 turns.
- Insert M6 x 1,00 bolt in camshaft sprocket [8] .
- Insert M8 x 1,25 bolt in injection pump sprocket [9] .
- Slacken tensioner bolt [10] .
- Move tensioner away from belt [11] . Finger tighten bolt.
- Remove timing belt.
NOTE: Mark direction of rotation on belt with chalk if belt is to be reused.
Installation
- Ensure locking bolts located correctly [8] & [9] .
- Ensure crankshaft sprocket mark aligned with notch [7] .
- Check tensioner pulley for smooth operation.
- Fit timing belt in clockwise direction, starting at crankshaft sprocket. Ensure belt is taut between sprockets.
- Slacken tensioner bolt [10] .
- Remove locking bolts [8] & [9] .
- Turn crankshaft 60° anti-clockwise (against normal direction of rotation) [12] .
- Tighten tensioner bolt [10] . Tightening torque: 38 Nm.
- Turn crankshaft up to 6 turns + 60° clockwise until timing marks aligned [7] . Ensure locking bolts can be installed [8] & [9] .
- Install components in reverse order of removal.
- Fit crankshaft pulley.
- Tighten crankshaft pulley bolts [4] . Tightening torque: 20 Nm.
- Tighten engine mounting bolts [2] . Tightening torque: 55 Nm.
- Tighten engine mounting bracket bolts [3] . Tightening torque: 40 Nm.