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

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.
How to replace timing belt on Vauxhall/Opel Astra G 1.7 DT Turbo
How to replace timing belt on Vauxhall/Opel Astra G 1.7 DT Turbo

Removal

  1. Remove:
      • Air filter and air intake pipe.
      • Mass air flow (MAF) sensor.
      • Timing belt upper cover [1] .
      • Auxiliary drive belt(s).
  2. Raise and support front of vehicle.
  3. Remove:
      • RH front wheel.
      • Engine undershield.
      • Crankshaft pulley bolts [2] .
      • Crankshaft pulley [3] .
      • Timing belt lower cover [4] .
  4. Support engine. Use tool Nos.KM-6001/KM-909-B.
  5. Remove:
      • RH engine mounting and bracket.
      • Auxiliary drive belt tensioner.
      • Cylinder head cover.
  6. Turn crankshaft to 90° BTDC on No.1 cylinder [5] .
  7. Ensure No.1 cylinder exhaust valve cam lobe points vertically upwards [6] .
  8. Slacken injection pump sprocket bolts [7] . Tighten bolts finger tight.
  9. Slacken tensioner bolt [8] .
  10. Turn tensioner clockwise until pointer to left of LH stop [9] . Use Allen key [10] .
  11. Lightly tighten tensioner bolt [8] .
  12. Remove timing belt.
  13. Remove camshaft sprocket bolt [11] . DO NOT reuse bolt.
  14. 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

  1. Ensure No.1 cylinder exhaust valve cam lobe points vertically upwards [6] .
  2. Ensure crankshaft at 90° BTDC on No.1 cylinder [5] .
  3. Install measuring bar KM-661-1 [12] . Ensure left-hand locating pins are positioned in bores of camshaft housing.
  4. 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.

  5. Set dial gauge to zero with measuring foot on cam lobe base circle.
  6. 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] .
  7. Install holding tool KM-661-2 over No.4 cylinder [14] .
  8. Adjust position of camshaft until dial gauge indicates approximately 0,80 mm. Use spanner [15] .
  9. Carry out fine adjustment of camshaft using screw [16] until dial gauge indicates 0,60-0,64 mm.
  10. Turn injection pump sprocket slowly clockwise. Use spanner [17] . Insert locking pin in injection pump [18] . Tool No.KM-6011.
  11. Turn crankshaft clockwise to TDC on No.1 cylinder. Ensure timing marks aligned [19] .
  12. Insert timing pin in flywheel housing [20] . Tool No.KM-951.

    NOTE: Hold in position by attaching timing pin spring to bolt [21] .

  13. Fit timing belt in clockwise direction, starting at crankshaft sprocket. Ensure belt is taut between sprockets on non-tensioned side.
  14. Slacken tensioner bolt [8] .
  15. Turn tensioner anti-clockwise until pointer near to RH stop [22] . Use Allen key [10] .
  16. Tighten tensioner bolt to 25 Nm [8] .
  17. Hold camshaft sprocket. Tighten bolt [11] . Tightening torque: 75 Nm + 60° + 5°.
  18. Hold injection pump sprocket. Tighten bolts [7] . Tightening torque: 25 Nm.
  19. Remove holding tool [14] .
  20. Carefully remove measuring bar KM-661-1 [12] without altering dial gauge position.
  21. Remove:
      • Flywheel timing pin [20] .
      • Locking pin [18] .
  22. Turn crankshaft slowly two turns clockwise to TDC on No.1 cylinder. Ensure timing marks aligned [19] .
  23. 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] .
  24. Tighten tensioner bolt to 25 Nm [8] .
  25. Turn crankshaft slowly two turns clockwise to TDC on No.1 cylinder. Ensure timing marks aligned [19] .
  26. Check tensioner marks as follows:
      • New belt – ‘V’ notch in bracket [23] .
      • Used belt – 4 mm left of ‘V’ notch [24] .
  27. If not: Repeat tensioning procedure.
  28. Turn crankshaft two turns clockwise. Ensure timing marks aligned [19] . Insert timing pin in flywheel housing [20] . Tool No.KM-951.
  29. Insert locking pin in injection pump [18] . Tool No.KM-6011.
  30. Install measuring bar KM-661-1 [12] . Ensure right-hand locating pins are positioned in bores of camshaft housing [13b] .
  31. Dial gauge should indicate 0,55±0,03 mm.
  32. If not: Repeat installation procedure.
  33. Install components in reverse order of removal.
  34. Tighten crankshaft pulley bolts to 20 Nm [2] .

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