How to replace timing belt – Vauxhall/Opel Vectra C 1.9 CDTI

Replacement Interval Guide

• Vauxhall recommend replacement as follows:
• →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	2,40
Astra-H	1,50
Zafira-B	1,30

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 (Astra-H) – Kent Moore No.KM-6397.
• Engine support and alignment tool 2 (Astra-H) – Kent Moore No.KM-6001-A.
• Engine support and alignment tool 1 (Vectra-C/Signum/Zafira-B) – Kent Moore No.KM-6313.
• Engine support and alignment tool 2 (Vectra-C/Signum/Zafira-B) – Kent Moore No.KM-6313-100.
• Exhaust camshaft locking tool – No.EN-46789.

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. 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.
   • Astra-H: Tool No.KM-6397 & KM-6001-A.
   • Vectra-C/Signum/Zafira-B: 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. Fit exhaust camshaft locking tool [7] . Tool No.EN-46789.
14. Turn crankshaft in direction of rotation until camshaft locking tool heard to engage [7] .
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 exhaust camshaft locked in position [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. Disengage camshaft locking tool [7] .
13. Turn crankshaft two turns clockwise.
14. Ensure crankshaft timing tool can be fitted [9] .
15. Ensure camshaft locking tool can be fitted [7] .
16. Remove camshaft locking tool.
17. Remove crankshaft timing tool.
18. Install components in reverse order of removal.
19. Tighten crankshaft pulley bolts [2] . Tightening torque: 25 Nm.
20. Tightening torques:
    • Engine mounting – 55 Nm [4] .
    • Engine mounting bracket – 50 Nm (M10) [6] .
    • Engine mounting bracket – 25 Nm (M6) [6] .