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How to Replace timing belt on Vauxhall/Opel Astra H 1.9 CDTi

Replacement Interval Guide

  • Vauxhall recommend replacement as follows:
  • 2004MY:
  • Replacement every 80,000 miles or 6 years, whichever occurs first.
  • 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:
Vectra-C/Signum 2,10
Astra-H 1,20
Zafira-B 1,20

Special Tools

  • Auxiliary drive belt tensioner locking tool – Kent Moore No.KM-6349.
  • Crankshaft timing tool – No.EN-46788.
  • Engine support and alignment tool 1 – Kent Moore No.KM-6313.
  • Engine support and alignment tool 2 – Kent Moore No.KM-6313-100.

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 H 1.9 CDTi
How to Replace timing belt on Vauxhall/Opel Astra H 1.9 CDTi

Removal

  1. Remove:
      • Engine top cover.
      • Air filter housing.
  2. Raise and support vehicle.
  3. Remove:
      • RH wheel.
      • RH inner wing panel.
      • Engine undershield.
  4. Fit engine support and alignment tools. Tool No.KM-6313 & KM-6313-100.
  5. Turn auxiliary drive belt tensioner clockwise to release tension on belt. Use suitable spanner.
  6. Lock auxiliary drive belt tensioner [1] . Use tool No.KM-6349.
  7. Remove:
      • Auxiliary drive belt.
      • Auxiliary drive belt tensioner.
      • Auxiliary drive belt guide pulley.

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

  8. Remove:
      • Crankshaft pulley bolts [2] .
      • Crankshaft pulley [3] .
  9. Lower vehicle.
  10. Remove:
      • RH engine mounting [4] .
      • Timing belt cover [5] .
      • RH engine mounting bracket [6] .
  11. Detach crankcase breather hose from cylinder head.
  12. Turn crankshaft to TDC on No.1 cylinder.
  13. Ensure camshaft sprocket timing marks aligned [7] .
  14. If camshaft sprocket timing marks not aligned: Turn crankshaft one turn clockwise.
  15. Remove oil pump bolt. Insert stud of crankshaft timing tool [8] . Tool No.EN-46788.
  16. Fit crankshaft timing tool [9] . Tool No.EN-46788. Ensure bolt [10] located correctly in crankshaft sprocket.
  17. Slacken tensioner sprocket nut [11] .
  18. Remove crankshaft timing tool [9] .
  19. Remove timing belt.

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

  20. Remove:
      • Tensioner sprocket nut. Clean thread.
      • Tensioner sprocket.

Installation

  1. Check tensioner sprocket for smooth operation.
  2. Fit tensioner sprocket.
  3. Fit tensioner sprocket nut [11] . Apply locking compound to thread.
  4. Ensure camshaft sprocket timing marks aligned [7] .
  5. Fit timing belt in clockwise direction, starting at crankshaft sprocket. Ensure belt is taut between sprockets.
  6. Screw an M6 bolt into timing belt rear cover [12] .
  7. Lever tensioner sprocket bracket at position [13] until pointer [14] and mark [15] aligned.
  8. Tighten tensioner sprocket nut [11] . Tightening torque: 25 Nm.
  9. Fit crankshaft timing tool. Tool No.EN-46788 [9] .
  10. If timing tool cannot be fitted: Repeat tensioning procedure.
  11. Remove crankshaft timing tool [9] .
  12. Turn crankshaft two turns clockwise.
  13. Ensure crankshaft timing tool can be fitted [9] .
  14. Remove crankshaft timing tool.
  15. Install components in reverse order of removal.
  16. Tighten crankshaft pulley bolts [2] . Tightening torque: 25 Nm.
  17. Tightening torques:
      • Engine mounting – 55 Nm [4] .
      • Engine mounting bracket – 50 Nm (M10) [6] .
      • Engine mounting bracket – 25 Nm (M6) [6] .
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