Replacement Interval Guide
- Vauxhall recommend replacement every 80,000 miles or 8 years, whichever occurs first.
- 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 | 1,60 |
Special Tools
- Engine support tool – Kent Moore No.KM-6001.
- Engine alignment tool – Kent Moore No.KM-909-B.
- Dial gauge – Kent Moore No.MKM-571-B.
- Measuring bar – Kent Moore No.KM-661-1.
- Holding tool – Kent Moore No.KM-661-2.
- Injection pump locking pin – Kent Moore No.KM-6011.
- Flywheel timing pin – Kent Moore No.KM-951.
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
- Remove:
- Air filter and air intake pipe.
- Mass air flow (MAF) sensor.
- Timing belt upper cover [1] .
- Auxiliary drive belt(s).
- Raise and support front of vehicle.
- Remove:
- RH front wheel.
- Engine undershield.
- Crankshaft pulley bolts [2] .
- Crankshaft pulley [3] .
- Timing belt lower cover [4] .
- Support engine. Use tool Nos.KM-6001/KM-909-B.
- Remove:
- RH engine mounting and bracket.
- Auxiliary drive belt tensioner.
- Cylinder head cover.
- Turn crankshaft to 90° BTDC on No.1 cylinder [5] .
- Ensure No.1 cylinder exhaust valve cam lobe points vertically upwards [6] .
- Slacken injection pump sprocket bolts [7] . Tighten bolts finger tight.
- Slacken tensioner bolt [8] .
- Turn tensioner clockwise until pointer to left of LH stop [9] . Use Allen key [10] .
- Lightly tighten tensioner bolt [8] .
- Remove timing belt.
- Remove camshaft sprocket bolt [11] . DO NOT reuse bolt.
- Fit new camshaft sprocket bolt [11] . Tighten bolt finger tight. Ensure sprocket can still turn.
NOTE: Mark direction of rotation on belt with chalk if belt is to be reused.
Installation
- Ensure No.1 cylinder exhaust valve cam lobe points vertically upwards [6] .
- Ensure crankshaft at 90° BTDC on No.1 cylinder [5] .
- Install measuring bar KM-661-1 [12] . Ensure left-hand locating pins are positioned in bores of camshaft housing.
- Install dial gauge MKM-571-B with foot of dial gauge on base circle of No.1 cylinder inlet valve cam lobe (2nd lobe from front) [13a] .
NOTE: Dial gauge must be fitted with 10 mm diameter flat measuring foot. Pre-load must not exceed 0,50 mm.
- Set dial gauge to zero with measuring foot on cam lobe base circle.
- Move measuring bar KM-661-1 [12] to left, so that right-hand locating pins are positioned in bores of camshaft housing and dial gauge foot is over cam lobe [13b] .
- Install holding tool KM-661-2 over No.4 cylinder [14] .
- Adjust position of camshaft until dial gauge indicates approximately 0,80 mm. Use spanner [15] .
- Carry out fine adjustment of camshaft using screw [16] until dial gauge indicates 0,60-0,64 mm.
- Turn injection pump sprocket slowly clockwise. Use spanner [17] . Insert locking pin in injection pump [18] . Tool No.KM-6011.
- Turn crankshaft clockwise to TDC on No.1 cylinder. Ensure timing marks aligned [19] .
- Insert timing pin in flywheel housing [20] . Tool No.KM-951.
NOTE: Hold in position by attaching timing pin spring to bolt [21] .
- Fit timing belt in clockwise direction, starting at crankshaft sprocket. Ensure belt is taut between sprockets on non-tensioned side.
- Slacken tensioner bolt [8] .
- Turn tensioner anti-clockwise until pointer near to RH stop [22] . Use Allen key [10] .
- Tighten tensioner bolt to 25 Nm [8] .
- Hold camshaft sprocket. Tighten bolt [11] . Tightening torque: 75 Nm + 60° + 5°.
- Hold injection pump sprocket. Tighten bolts [7] . Tightening torque: 25 Nm.
- Remove holding tool [14] .
- Carefully remove measuring bar KM-661-1 [12] without altering dial gauge position.
- Remove:
- Flywheel timing pin [20] .
- Locking pin [18] .
- Turn crankshaft slowly two turns clockwise to TDC on No.1 cylinder. Ensure timing marks aligned [19] .
- Slacken tensioner bolt [8] . Turn tensioner clockwise until pointer aligned as follows:
- New belt – ‘V’ notch in bracket [23] .
- Used belt – 4 mm left of ‘V’ notch [24] .
- Tighten tensioner bolt to 25 Nm [8] .
- Turn crankshaft slowly two turns clockwise to TDC on No.1 cylinder. Ensure timing marks aligned [19] .
- Check tensioner marks as follows:
- New belt – ‘V’ notch in bracket [23] .
- Used belt – 4 mm left of ‘V’ notch [24] .
- If not: Repeat tensioning procedure.
- Turn crankshaft two turns clockwise. Ensure timing marks aligned [19] . Insert timing pin in flywheel housing [20] . Tool No.KM-951.
- Insert locking pin in injection pump [18] . Tool No.KM-6011.
- Install measuring bar KM-661-1 [12] . Ensure right-hand locating pins are positioned in bores of camshaft housing [13b] .
- Dial gauge should indicate 0,55±0,03 mm.
- If not: Repeat installation procedure.
- Install components in reverse order of removal.
- Tighten crankshaft pulley bolts to 20 Nm [2] .