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

Replacement Interval Guide

• Vauxhall recommend:
• →2009MY:
• Replacement every 60,000 miles or 10 years, whichever occurs first (tensioner pulley and guide pulley must also be replaced). Check condition of crankshaft sprocket.
• 09MY-10MY:
• 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.
• 2011MY→:
• Replacement every 100,000 miles or 6 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:
Corsa-D	1,70
Astra-H/Meriva-A/Zafira-B	1,40
Astra-J	1,30
Meriva-B	1,50

Special Tools

• Except Astra-J: Auxiliary drive belt tensioner locking tool – Kent Moore No.KM-6130.
• Astra-J: Auxiliary drive belt tensioner adjusting tool – No.EN-913-A.
• Astra-J: Auxiliary drive belt tensioner locking tool – No.EN-48952.

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:
   • Engine top cover.
   • Air filter housing and air intake hose.
   • Engine undershield.
   • RH front wheel.
   • RH inner wing panel.
3. Turn auxiliary drive belt tensioner to release tension on belt. Use ring spanner or tool No.EN-913-A.
4. Lock auxiliary drive belt tensioner. Use tool No.EN-48952 or No.KM-6130.
5. Remove:
   • Auxiliary drive belt.

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

   • Crankshaft pulley bolts [1] .
   • Crankshaft pulley [2] .
6. Support engine.
7. Remove:
   • RH engine mounting.
   • RH engine mounting bracket.
   • Camshaft position (CMP) sensor.
   • Timing belt upper cover [3] .
   • Timing belt lower cover [4] .
8. Turn crankshaft to TDC on No.1 cylinder. Ensure timing marks aligned [5] .
9. Ensure camshaft sprocket aligning hole at 8 o’clock position.
10. If not: Turn crankshaft one turn clockwise.
11. Screw suitable locking bolts into camshaft sprocket and high-pressure fuel pump sprocket [6] & [7] .
12. Slacken tensioner bolt [8] .
13. Turn tensioner pulley 90° anti-clockwise. Lightly tighten bolt [8] .
14. 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 [6] & [7] .
2. Ensure crankshaft sprocket mark aligned with notch [5] .
3. Check tensioner pulley and guide pulley for smooth operation.
4. Fit timing belt in clockwise direction, starting at crankshaft sprocket. Ensure belt is taut between sprockets.

   NOTE: Ensure directional arrows point in direction of rotation.

5. Slacken tensioner bolt [8] .
6. Allow tensioner to tension belt.
7. Tighten tensioner bolt [8] . Tightening torque: 49 Nm.
8. Remove locking bolts from sprockets [6] & [7] .
9. Turn crankshaft 2 turns clockwise to TDC on No.1 cylinder.
10. Ensure crankshaft sprocket mark aligned with notch [5] .
11. Ensure locking bolts can be installed [6] & [7] .
12. If not: Repeat installation procedure.
13. Remove locking bolts [6] & [7] .
14. Install components in reverse order of removal.
15. Tighten crankshaft pulley bolts [1] . Tightening torque: 20 Nm.

    NOTE: Observe direction of rotation marks on auxiliary drive belt.

    NOTE: If battery has been disconnected, re-initialization of window and sunroof motors and steering position sensor may be required.