How to Replace timing belt on Opel Astra 1.7D-DTi 2001

Opel Astra 1.7D-DTi 2001 cambelt change instructions and replacement inteval. Full guide!

Special tools

• Engine support and alignment tool – Kent Moore No.KM-6169.

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.
• Check diesel injection pump timing after belt replacement.

Repair times – hrs

Camshaft drive belt/chain – C & A	1,80
Camshaft drive belt/chain – R & I	2,00

Valve timing procedures

Removal

1. Raise and support vehicle.
2. Remove:
   • RH wheel.
   • RH inner wing panel.
   • Air filter housing.
3. Corsa/Combo: Fit engine support and alignment tool. Tool No.KM-6169.
4. Support engine.
5. Remove RH engine mounting and bracket.
6. Corsa/Combo/Astra/Zafira: Refit engine mounting bolt and tighten finger tight [1] .
7. Remove:
   • Auxiliary drive belt(s).
   • AC drive belt tensioner (if fitted).
8. Corsa/Combo: Move wiring harness to one side.
9. Remove timing belt upper cover [2] .
10. Turn crankshaft to TDC on No.1 cylinder. Ensure timing marks aligned [3] .
11. Insert M6 x 1,00 bolt in camshaft sprocket and M8 x 1,25 bolt in injection pump sprocket to lock sprockets in position [4] .
12. If locating holes not aligned: Turn crankshaft one turn clockwise.
    NOTE: DO NOT use timing mark ‘A’ [16] .
13. Remove:
    • Crankshaft pulley bolts [5] .
    • Crankshaft pulley [6] .
    • Timing belt lower cover [7] .
14. Some models:
    • Ensure crankshaft sprocket mark aligned with notch [8] .

    NOTE: There are three types of tensioner.

15. Tensioner type A:
    • Slacken tensioner bolt [9] . Remove tensioner spring [10] .
    • Move tensioner away from belt. Lightly tighten bolts.
16. Tensioner type B:
    • Slacken tensioner bolt [11] .
    • Turn tensioner pulley anti-clockwise to release tension on belt. Use suitable tool. Lightly tighten bolt [11] .
17. Tensioner type C – Vectra-B:
    • Slacken tensioner bolts [12] . Remove tensioner spring [13] .
    • Move tensioner away from belt. Lightly tighten bolts.
18. Remove timing belt.

Installation

1. Ensure timing marks aligned [3] . Ensure locking bolts located correctly [4] .
2. Some models:
   • Ensure crankshaft sprocket mark aligned with notch [8] .
3. Check tensioner pulley for smooth operation.
4. Fit timing belt in anti-clockwise direction, starting at crankshaft sprocket. Ensure belt is taut between sprockets.
   NOTE: If tensioner type B is used to replace tensioner type A fit new bolt [15] . Tighten bolt to 19 Nm.
5. Tensioner type A:
   • Fit tensioner spring [10] . Slacken tensioner bolt [9] .
6. Tensioner type B:
   • Slacken tensioner bolt [11] .
7. Tensioner type C – Vectra-B:
   • Fit tensioner spring [13] .
   • Slacken tensioner bolts [12] .
8. Temporarily fit crankshaft pulley [6] .
9. Remove locking bolts [4] .
10. Turn crankshaft 60° anti-clockwise (against normal direction of rotation) [14] .
11. Tighten tensioner bolt(s). Tightening torque:
    • A: 38 Nm [9] .
    • B: 49 Nm [11] .
    • C: 19 Nm [12] .
12. Remove crankshaft pulley. Fit timing belt lower cover [7] .
13. Fit crankshaft pulley. Tighten bolts to 20 Nm [5] .
14. Turn crankshaft two turns +60° clockwise until timing marks aligned [3] . Ensure locking bolts can be installed [4] .
15. Install components in reverse order of removal.