How to replace timing chain on Vauxhall/Opel Astra G 2.0 DTI

Special tools

• Camshaft locking tool – No.KM-932.
• Camshaft sprocket holding tool – No.KM-933.
• Crankshaft locking pin – No.KM-929.
• Crankshaft pulley holding tool – No.KM-930 or KM-977-1/956-1.
• Injection pump locking pin – No.KM-927.

General precautions

• Disconnect battery earth lead.
• Remove glow plugs to ease turning engine.
• Turn engine in normal direction of rotation (unless otherwise stated).
• DO NOT use special tools listed above to lock engine when slackening sprocket bolts.
• Observe tightening torques.
• Mark position of crankshaft position (CKP) sensor before removal.
• Do NOT turn crankshaft via camshaft or other sprockets.
• Do NOT turn crankshaft or camshaft with timing chain removed.
• Check diesel injection pump timing after resetting valve timing.

Valve timing procedures

• Turn crankshaft until just before crankshaft pulley timing marks aligned.
• Ensure No.1 cylinder camshaft lobes are facing upwards [1] .
• Remove crankshaft position (CKP) sensor [2] .
• Slowly turn crankshaft clockwise until locking pin can be inserted in crankshaft [3] . Tool No.KM-929.
• Engine at TDC on No.1 cylinder.
• Ensure crankshaft pulley timing marks aligned [4] .
• Insert locking pin in hole in injection pump [5] . Tool No.KM-927.
• Fit locking tool to rear of camshaft [6] . Tool No.KM-932.
• Ensure peg locates in camshaft [7] .
• Injection pump timing adjustment:
  • Ensure crankshaft locking pin inserted [3] . Tool No.KM-929.
  • Remove timing chain tensioners [8] & [9] . Note installation positions.
  • Remove camshaft sprocket bolt [10] . Fit new bolt.
  • Tighten bolt until camshaft sprocket turns freely but does not tilt.
  • Remove injection pump sprocket bolts [11] . Fit new bolts (bolt classification – 10.9).

  NOTE: Injection pump sprocket may have 5 bolts.

  • Turn injection pump sprocket until arrow and hole aligned [12] .
  • Insert locking pin in hole in injection pump [5] . Tool No.KM-927.
  • Install lower timing chain tensioner [9] . Tightening torque: 60 Nm.
  • Remove injection pump locking pin [5] .
  • Tighten injection pump sprocket bolts [11] . Tightening torque: 28 Nm.
  • Adjust valve timing.
• Valve timing procedures:
  • Ensure crankshaft locking pin inserted [3] . Tool No.KM-929.
  • Ensure injection pump locking pin inserted [5] . Tool No.KM-927.
  • Ensure upper timing chain tensioner removed [8] .
  • Ensure new camshaft sprocket bolt tightened until camshaft sprocket turns freely but does not tilt.
  • Ensure arrow on injection pump sprocket and hole aligned [12] .
  • Fit locking tool to rear of camshaft [6] . Tool No.KM-932.
  • Ensure peg locates in camshaft [7] .
  • Install camshaft sprocket holding tool [13] . Tool No.KM-933.
  • Apply slight anti-clockwise pressure on camshaft sprocket using lever [14] . Retain lever in position using locking bolt [15] .
  • Ensure injection pump locking pin can be removed and inserted easily [5] .
  • Tighten camshaft sprocket bolt [10] . Tightening torque: 90 Nm + 60° + 30°.
  • Install upper timing chain tensioner [8] . Tightening torque: 60 Nm.
  • Turn crankshaft 2 turns clockwise to TDC on No.1 cylinder.
  • Install special tools and check valve timing and injection pump timing.
• Timing chain tensioner with release pin [16] :
  • After installation, release timing chain tensioner by pressing pin until click is heard.
  • Ensure pin can be pushed in fully with thumb pressure and returns to original position.

  NOTE: Engine oil pressure will prevent release pin from being pushed in.

• Camshaft rotation can be prevented using spanner at position shown [17] .
• Auxiliary drive belt tensioner:
  • Store in upright position.
  • Bleed incorrectly stored tensioner by repeated compression in upright position.

NOTE: Crankshaft pulley central bolt MUST only be used once.