Removal and installation the timing belt cover (Opel Astra G)

Removal

Engines 1.7L SOHC

Upper section

1. Remove the air cleaner assembly with air ducts and air flow meter (see Chapter Power and exhaust systems).

2. Remove the mounting screws and remove the upper section of the timing belt cover.

Bottom section

1. Remove the top section of the lid (see above).

2. Remove the crankshaft pulley (see Removal and installation the crankshaft pulley).

3. Unscrew the mounting bolts and remove the lower section of the cover from the engine together with the sealing gasket. Check the condition of the gasket, replace it if necessary.

3. Unscrew the mounting bolts and remove the lower section of the cover from the engine together…

Back cover

1. Remove the timing belt (see Removal and installation the timing belt).

2. Remove the camshaft and fuel injection pump gears, idler roller and tensioner assembly (see Removal and installation the timing belt tensioner and timing gears (1.7L engines).

3. Mark the installation position of the right powertrain suspension support, then unscrew the three bolts securing it.

4. Remove the six mounting bolts and remove the rear cover from the engine.

Engines 1.7L DOHC

Upper section

1. Disconnect the negative cable from the battery.

2. Remove the air cleaner assembly with the air ducts (see Chapter Power and exhaust systems).

3. Support the engine with a trolley jack; to distribute the load, place a wooden block between the jack head and the oil pan.

4. Mark the installation location of the right powertrain suspension support component. Remove the three support mounting bolts.

5. Remove the mounting bolts and separate the support bracket from the adapter on the engine block.

5. Remove the mounting bolts and separate the support bracket from the adapter on the engine block.

6. If necessary, disconnect the electrical wiring from the generator (see Chapter Engine electrical equipment).

7. Remove the TORX head mounting bolt. Release the wiring harness routing channel fastening clips and remove the latter from the right rear of the cylinder head.

8. Release the hoses from the retainers on the top cover, unscrew the eight different length mounting bolts and remove the top section of the cover.

Bottom section

1. Remove the accessory drive belt (see Chapter Routine maintenance), - first mark the direction of its rotation with paint or a marker. Set the parking brake, jack up the front of the car and place it on supports. Remove the right front wheel and (with appropriate equipment) crankcase protection.

2. Remove the top section of the lid (see above).

3. Remove the crankshaft pulley (see Removal and installation the crankshaft pulley).

4. Remove the three mounting bolts and remove the lower section of the cover from the oil pump housing.

5. Remove the SAG suspension support mounting adapter.

6. Temporarily screw the timing belt tensioner bracket mounting bolt back into its regular place.

Back cover

1. Remove the timing belt (see Removal and installation the timing belt).

2. Remove the guide roller and tensioner roller, camshaft gears and fuel injection pump (see Removal and installation the timing belt tensioner and timing gears (1.7L engines).

3. Disconnect the tensioner spring.

4. Unscrew the four mounting bolts and remove the rear timing belt cover.

4. Unscrew the four mounting bolts and remove the rear timing belt cover.

2.0L Engines

1. Remove the top chain and sprockets (see Removal and installation of timing chains and sprockets, checking the condition of components (2.0L engines).

2. Remove the cylinder head (see Removal and installation the cylinder head).

Theoretically, the cover can be removed without first removing the head, but this method carries the risk of damaging the cylinder head gasket.

3. Remove the water pump (see Chapter Cooling and heating systems), - before releasing the bolt, temporarily remove the locking rod so as not to break it (don't forget to put the rod back in place after the bolt is loosened)

4. Remove the oil pan (see Removal and installation the oil pan).

5. Remove the generator (see Chapter Engine electrical equipment).

6. Unscrew the lower tensioner cap from the rear of the cover and remove the tensioner plunger - try to remember the installation position of the components. Remove the sealing ring from the cap - the sealing ring must be replaced during installation.

7. Unscrew the bolts securing the timing cover to the cylinder block - the bolts are of different lengths and must be screwed in strictly to their original locations when installed.

8. Carefully separate the cover from the block and remove it from the engine, being careful not to lose the guide bushings. If the guide bushings are loose, remove them and store them in a safe place.

9. Unscrew the axle bolt and remove the upper and lower chain tensioner shoes from the cylinder block.

9. Unscrew the axle bolt and remove the upper and lower chain tensioner shoes from the cylinder…

10. Unscrew the mounting bolts and remove the lower chain guide from the blockers - try to remember the installation position of the components.

11. Temporarily remove the lower timing chain sprocket from the fuel injection pump flange and remove the timing cover gasket from the cylinder block. After removing the gasket, install the sprocket in its place on the pump flange.

Installation

Engines 1.7 l SOHC and DOHC

Installation is carried out in the reverse order of dismantling the components.

2.0L Engines

Before installing the cover, the authors of this Manual recommend replacing the crankshaft seals (see Replacing crankshaft seals).

1. Make sure that the mating surfaces of the cover and engine block are absolutely clean and dry. Check that the guide bushings are in place - install the bushings if necessary.

2. Temporarily remove the sprocket from the fuel injection pump flange and install the sealing gasket in place, making sure it is seated correctly on the guide bushings. Install the sprocket back onto the fuel injection pump flange.

3. Install the lower chain guide on the cylinder block, screw in and tighten the bolts to the required torque.

The damper should be installed with the stepped side facing outward.

4. Reinstall the tensioner shoes, screw in the axle bolt and tighten it to the required torque.

5. Replace the timing belt cover, align the oil pump drive gear with the crankshaft sprocket, then push the cover back into place, making sure the guide bushings fit into the mating bushings.

6. Screw in the mounting bolts and tighten them gradually in several stages to the required force.

7. Place a new O-ring on the lower tensioner cap. Refill the plunger (blind end to the chain). Install the cap onto the chain cover and tighten it to the required torque.

When installing a new tensioner, unlock it by completely pressing the central rod of the cap until it clicks - now the tensioner rod should be freely pressed and smoothly return to its original position.