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
- Raise and support vehicle.
- Remove:
- RH wheel.
- RH inner wing panel.
- Air filter housing.
- Corsa/Combo: Fit engine support and alignment tool. Tool No.KM-6169.
- Support engine.
- Remove RH engine mounting and bracket.
- Corsa/Combo/Astra/Zafira: Refit engine mounting bolt and tighten finger tight [1] .
- Remove:
- Auxiliary drive belt(s).
- AC drive belt tensioner (if fitted).
- Corsa/Combo: Move wiring harness to one side.
- Remove timing belt upper cover [2] .
- Turn crankshaft to TDC on No.1 cylinder. Ensure timing marks aligned [3] .
- 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] .
- If locating holes not aligned: Turn crankshaft one turn clockwise.
NOTE: DO NOT use timing mark ‘A’ [16] . - Remove:
- Crankshaft pulley bolts [5] .
- Crankshaft pulley [6] .
- Timing belt lower cover [7] .
- Some models:
- Ensure crankshaft sprocket mark aligned with notch [8] .
NOTE: There are three types of tensioner.
- Tensioner type A:
- Slacken tensioner bolt [9] . Remove tensioner spring [10] .
- Move tensioner away from belt. Lightly tighten bolts.
- Tensioner type B:
- Slacken tensioner bolt [11] .
- Turn tensioner pulley anti-clockwise to release tension on belt. Use suitable tool. Lightly tighten bolt [11] .
- Tensioner type C – Vectra-B:
- Slacken tensioner bolts [12] . Remove tensioner spring [13] .
- Move tensioner away from belt. Lightly tighten bolts.
- Remove timing belt.
Installation
- Ensure timing marks aligned [3] . Ensure locking bolts located correctly [4] .
- Some models:
- Ensure crankshaft sprocket mark aligned with notch [8] .
- Check tensioner pulley for smooth operation.
- 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. - Tensioner type A:
- Fit tensioner spring [10] . Slacken tensioner bolt [9] .
- Tensioner type B:
- Slacken tensioner bolt [11] .
- Tensioner type C – Vectra-B:
- Fit tensioner spring [13] .
- Slacken tensioner bolts [12] .
- Temporarily fit crankshaft pulley [6] .
- Remove locking bolts [4] .
- Turn crankshaft 60° anti-clockwise (against normal direction of rotation) [14] .
- Tighten tensioner bolt(s). Tightening torque:
- A: 38 Nm [9] .
- B: 49 Nm [11] .
- C: 19 Nm [12] .
- Remove crankshaft pulley. Fit timing belt lower cover [7] .
- Fit crankshaft pulley. Tighten bolts to 20 Nm [5] .
- Turn crankshaft two turns +60° clockwise until timing marks aligned [3] . Ensure locking bolts can be installed [4] .
- Install components in reverse order of removal.