Replacement Interval Guide
- Vauxhall recommend replacement as follows:
- Replacement every 100,000 miles or 10 years, whichever occurs first (tensioner pulley, guide pulley and crankshaft sprocket must also be checked).
- →2005MY:Replacement every 60,000 miles or 10 years, whichever occurs first (tensioner pulley, guide pulley and crankshaft sprocket must also be checked).
- 2006MY→: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.
- 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:|
- Auxiliary drive belt tensioner tool – Kent Moore No.KM-913-A.
- Engine support and alignment tool – Kent Moore No.KM-6394.
- 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.
- Raise and support vehicle.
- RH wheel.
- RH inner wing panel.
- Engine top cover.
- Air filter housing.
- Slacken water pump bolts.
- Remove auxiliary drive belt.NOTE: Mark direction of rotation on belt with chalk if belt is to be reused.
- Move wiring harness to one side.
- Fit engine support and alignment tool. Tool No.KM-6394.
- Support engine.
- RH engine mounting  .
- RH engine mounting bracket  .
- Timing belt upper cover  .
- Crankshaft pulley bolts  .
- Crankshaft pulley  .
- Water pump pulley bolts.
- Water pump pulley.
- Timing belt lower cover  .
- Turn crankshaft to TDC on No.1 cylinder. Ensure timing marks aligned  .NOTE: This may require up to 6 turns.
- Insert M6 x 1,00 bolt in camshaft sprocket and M8 x 1,25 bolt in injection pump sprocket to lock sprockets in position  &  .
- Slacken tensioner bolt  .
- Move tensioner away from belt. Lightly tighten bolt.
- Remove timing belt.NOTE: Mark direction of rotation on belt with chalk if belt is to be reused.
- Ensure locking bolts located correctly  &  .
- Ensure crankshaft sprocket mark aligned with notch  .
- 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  .
- Remove locking bolts  &  .
- Turn crankshaft 60° anti-clockwise (against normal direction of rotation)  .
- Tighten tensioner bolt. Tightening torque: 38 Nm.
- Turn crankshaft up to 6 turns + 60° clockwise until timing marks aligned  . Ensure locking bolts can be installed  &  .
- Install components in reverse order of removal.
- Fit crankshaft pulley.
- Tighten crankshaft pulley bolts  . Tightening torque: 20 Nm.
- Tighten engine mounting to sidemember bolts. Tightening torque: 40 Nm  .
- Tighten engine mounting to bracket bolts. Tightening torque: 60 Nm + 30° + 15°.
- Tighten engine mounting bracket bolts  . Tightening torque: 40 Nm.