Timing Belt for Camshaft Drive — Removal and Installation (Opel Astra G)

Attention! Work is performed on a cold engine.

Removal

1. Remove the top belt cover.

2. Set the piston of the 1st cylinder to TDC of the compression stroke.

3. Remove the crankshaft pulley.

4. Raise the engine on a jack dolly, placing a board on the jack's lifting foot.

5. Unscrew the 3 bolts securing the right engine support bracket to the cylinder block, unscrew the bolts securing the support to the body and remove the bracket with the support.

6. Remove the lower belt cover.

7. Insert a suitable tool into the hole in the tensioner lever and move the lever clockwise until it stops. Lock the lever in this position by inserting the tool into the corresponding hole in the rear plate of the tensioner (see photo).





8. Make sure that the timing marks on the camshaft and crankshaft sprockets are aligned with the marks on the rear belt cover and oil pump housing.



9. Loosen the oil pump bolts and carefully turn the pump with a wrench through the adapter, thereby loosening the belt (see photo).





10. Remove the belt, marking the direction of its movement (see photo). Rotation of the crankshaft after removing the belt is not allowed.



11. Check the condition of the belt. If oil is detected, (even a little bit), breaks and cracks, replace the belt. The belt is changed regardless of its condition after 60,000 km of run.

Installation

12. Clean all sprockets thoroughly. Check that all timing marks are aligned (see photo).



13. Put the belt on the crankshaft and camshaft sprockets, following the direction of the arrow. Tighten the belt from the side of the tensioner roller. First, put the belt on the crankshaft sprocket, then, slightly tightening it, on the camshaft sprocket. Lastly, put the belt on the oil pump sprocket and the tensioner roller.

14. Remove the tool from the tensioner hole. Install the removed engine mount, tighten the mount mounting bolts to the specified torque.

15. Make sure that the timing marks on the sprockets are aligned with the marks on the oil pump housing on the rear cover.

16. Tighten the belt by turning the oil pump, watching the movement of the tensioner lever, and adjust the pump so that the lever is directly next to the limiter (in this case, it is not allowed to stretch the belt too much) Tighten the pump bolts.

17. Temporarily tighten the crankshaft pulley bolt and turn the crankshaft 2 turns in the direction of normal rotation.

18. Loosen the oil pump bolts and position the pump so that the pointer on the tensioner lever is aligned with the notch on the rear tensioner plate. Tighten the bolts (see photo). Turn the crankshaft 2 turns until the timing marks are aligned. Make sure that the pointer on the lever is also aligned with the notch on the plate.





19. If it is not possible to precisely align the lever with the plate, then repeat the tensioning procedure again.

20. Install all removed parts in reverse order.