Removal and installation the timing belt (Opel Astra G)

The timing belt must be removed on a cold engine!

Do not turn the engine with the timing belt removed!

Timing Belt Replacement

Removal

See illustration Timing Belt Replacement.

Material copied from this website opelbook

1. Disconnect the negative cable from the battery.

2. Remove the air cleaner.

3. Set the parking brake, jack up the front of the car and place it on supports. Remove the right front wheel.

4. Mark the direction of rotation of the accessory drive belt with chalk or paint. Using a spanner, loosen the belt and remove it from the engine by releasing the tensioner.

5. Remove the upper section of the timing belt cover [1].

6. Support the engine using the KM-6001 device and install the KM-909-B centering tool.

7. Remove the accessory drive belt tensioner.

8. Remove the right powertrain suspension support assembly with its bracket.



9. Insert the special tool KM-911 [2] into the transmission dome and block the flywheel from turning.



10. Loosen the mounting bolt [3] and remove the crankshaft pulley [4].

11. Remove the lower section of the timing belt cover [5].

12. Remove the flywheel locking tool.

13. Temporarily screw the crankshaft pulley bolt back into place and bring the engine to the TDC position of the end of the compression stroke of the piston of the first cylinder (see Bringing the piston of the first cylinder to the position of the top dead center of the compression stroke (TDC). Make sure that the alignment marks [6] are correctly aligned.

14. Check that the timing mark on the gear is correctly aligned with the corresponding mark on the rear timing drive cover [7]; if necessary, turn the crankshaft one more full revolution.

15. Move the movable segment of the tensioner until the holes [8] are aligned and fix it in this position by inserting a suitable rod into the holes.

16. Remove the timing belt.

Installation

See illustration Timing Belt Replacement.

1. Make sure that the alignment marks [6] and [7] are correctly aligned.

2. Starting from the crankshaft gear and moving counterclockwise, install the timing belt. Make sure the belt is taut in the areas between adjacent wheels.

3. Remove the locking rod [8] from the tensioner and loosen the water pump assembly mounting bolts [9].

4. Using the special tool KM-421-A, turn the pump clockwise, taking up the slack in the belt tape [10] — the movable section of the tensioner should be opposite the stop [11]. Lightly tighten the pump mounting bolts.

5. Turn the crankshaft two full turns clockwise and ensure that the timing marks [6] and [7] are correctly aligned.



6. Loosen the mounting bolts [9] again and using the KM-421-A tool, turn the water pump counterclockwise [12] so that the tensioner pointer is opposite the V-shaped mark on the support plate [13].

7. Tighten the pump mounting bolts to the required torque (8 Nm).

8. Turn the crankshaft two full turns clockwise, bringing the engine to the TDC position of the end of the compression stroke of the piston of the first cylinder - make sure that the alignment marks [6] and [7] are correctly aligned. If the required alignment of the marks does not occur, repeat the belt tension adjustment procedure.

9. Insert the special tool KM-911 into the transmission dome and lock the flywheel [2].

10. Remove the crankshaft pulley bolt [3].

11. Reinstall the removed components in the reverse order of removal.

12. Screw in the crankshaft pulley bolt and tighten it to the required torque.