Important note. Important Note. Telephone: Fax: VAT Registration No.:

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1 Telephone: Fax: VAT Registration No.: Important note NOTE: Timing belt check and replacement intervals are subject to change at any time. To ensure that you are using the most up-to-date and accurate information available connect to Autodata Online. Contact your distributor about connecting to Autodata Online. Important Note All service items are vital to the smooth running and reliability of a vehicle, none more so than the timing belt and its associated components. For this reason we have highlighted important information from the manufacturers' service schedules covering the intervals for checks and replacements. Be sure that you make the vehicle owner aware of this information. Industry best practice is to ensure that the vehicle owner is made aware of the importance of replacing the timing belt and its associated components according to the manufacturers' specification. The service history and the use of the vehicle must be considered when deciding the correct course of action. If there is any doubt to the serviceability of the belt and its components, they should be replaced. Timing belt replacement intervals Where possible the recommended intervals have been compiled from vehicle manufacturers' information. In a few instances no recommendation has been made by the manufacturer and the decision to replace the belt must be made from the evidence of a thorough examination of the condition of the existing belt. Apart from the visible condition of the belt, which is explained fully in the General Instructions/Toothed Timing Belts section, there are several other factors which must be considered when checking a timing belt: 8. Is the belt an original or a replacement? When was the belt last replaced and was it at the correct mileage? Is the service history of the vehicle known? Has the vehicle been operated under arduous conditions which might warrant a shorter replacement interval? Is the general condition of other components in the camshaft drive, such as the tensioner, pulleys, and other ancillary components driven by the timing belt, typically the water pump, sound enough to ensure that the life of the replacement belt will not be affected? If the condition of the existing belt appears good, can you be satisfied that the belt will not fail before the next check or service is due? If the belt does fail, have you considered the consequences? If the engine is an INTERFERENCE type then considerable expensive damage may well be the result. The cost of replacing a belt as part of a routine service could be as little as 5 to 10% of the repair cost following a belt failure. Make sure your customer is aware of the consequences. If in doubt about the condition of the belt - RENEW it. Refer to the Toothed Timing Belts/Service Replacement section for further information relating to arduous or adverse operating conditions, inspection and service replacement. Replacement Interval Guide Replacement Interval Guide Vauxhall recommend replacement as follows:

2 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 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 Repair Times - hrs Check and adjust 1,90 Remove and install 2,40 Special Tools Special Tools Auxiliary drive belt tensioner locking tool - Kent Moore No.KM-634 Crankshaft timing tool - No.EN Engine support and alignment tool 1 (Astra-H) - Kent Moore No.KM-639 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-631 Engine support and alignment tool 2 (Vectra-C/Signum/Zafira-B) - Kent Moore No.KM Exhaust camshaft locking tool - No.EN-4678 Special Precautions 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 Removal

3 Engine top cover. Air filter housing. Raise and support vehicle. RH wheel. RH inner wing panel. Engine undershield. 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 Turn auxiliary drive belt tensioner clockwise to release tension on belt. Use suitable spanner. Lock auxiliary drive belt tensioner [1]. Use tool No.KM-634 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. Crankshaft pulley bolts [2]. Crankshaft pulley [3]. Lower vehicle. RH engine mounting [4]. Timing belt cover [5]. RH engine mounting bracket [6] Detach crankcase breather hose from cylinder head. Turn crankshaft to TDC on No.1 cylinder. Fit exhaust camshaft locking tool [7]. Tool No.EN-4678 Turn crankshaft in direction of rotation until camshaft locking tool heard to engage [7]. Remove oil pump bolt. Insert stud of crankshaft timing tool [8]. Tool No.EN Fit crankshaft timing tool [9]. Tool No.EN Ensure bolt [10] located correctly in crankshaft sprocket. Slacken tensioner sprocket nut [11]. Remove crankshaft timing tool [9]. Remove timing belt. NOTE: Mark direction of rotation on belt with chalk if belt is to be reused. Tensioner sprocket nut. Clean thread. Tensioner sprocket. Installation Installation Check tensioner sprocket for smooth operation. Fit tensioner sprocket. Fit tensioner sprocket nut [11]. Apply locking compound to thread. Ensure exhaust camshaft locked in position [7]. Fit timing belt in clockwise direction, starting at crankshaft sprocket. Ensure belt is taut between sprockets. Screw an M6 bolt into timing belt rear cover [12]. Lever tensioner sprocket bracket at position [13] until pointer [14] and mark [15] aligned.

4 Tighten tensioner sprocket nut [11]. Tightening torque: 25 Nm. Fit crankshaft timing tool. Tool No.EN [9]. If timing tool cannot be fitted: Repeat tensioning procedure. Remove crankshaft timing tool [9]. Disengage camshaft locking tool [7]. Turn crankshaft two turns clockwise. Ensure crankshaft timing tool can be fitted [9]. Ensure camshaft locking tool can be fitted [7]. Remove camshaft locking tool. Remove crankshaft timing tool. Install components in reverse order of removal. Tighten crankshaft pulley bolts [2]. Tightening torque: 25 Nm. Tightening torques: Engine mounting 55 Nm [4]. Engine mounting bracket 50 Nm (M10) [6]. Engine mounting bracket 25 Nm (M6) [6].

Important note. Important Note. Telephone: Fax: VAT Registration No.:

Important note. Important Note. Telephone: Fax: VAT Registration No.: Telephone: Fax: VAT Registration No.: Important note NOTE: Timing belt check and replacement intervals are subject to change at any time. To ensure that you are using the most up-to-date and accurate information