Removal and installation a multi-ribbed accessory drive belt (Opel Astra H)

General information

1. The operations for removing and installing the multi-ribbed drive belt are in most cases similar for all engines, the differences are determined only by the variants of the tension roller arrangement and the related features. If the belt replacement procedure is not fully described in the descriptions below, you should focus on performing the operations for the Z16XEP gasoline engine.

2. The multi-rib belt is designed to drive auxiliary units such as the generator, water pump and air conditioning pump unit. Depending on the engine model and configuration, the number of drive units may vary, and accordingly the belt length will be different - be careful when buying a new belt for your car. Before removing the belt, it is recommended to draw a diagram of its tension.

3. If the belt is to be reused, mark it with a marker before removing it from the pulleys (in the form of an arrow) to determine the direction of rotation of the multi-rib belt during subsequent installation.

Note: The belt rotates clockwise when viewed from the belt drive side of the engine.

If a previously used belt is installed without observing the direction of rotation, it will be subject to increased wear and tear and will quickly fail.

Z16XEP Engine

Removal

4. Remove the air cleaner (see Section 4).



5. Apply a mark to determine the direction of rotation of the belt during installation.

6. Using a key (see accompanying illustration) by turning it in the direction indicated by the arrow, press the tension roller and fix it with a special rod, then remove the belt.



Installation

7. Place the multi-ribbed belt on the drive pulleys.

8. Using the key, slightly push the tension roller in the direction of the arrow and remove the locking rod. Then slowly turn the key clockwise - the multi-rib belt will be tensioned.

9. Install the air cleaner.

Z18XE Engine

10. Before removing the air cleaner (see Chapter 4) it is necessary to remove the engine cover (see Section 2).

11. To loosen the multi-rib belt, use the center bolt of the tension roller (see accompanying illustration), for which, using a regular wrench (15 mm), press it in the direction of the arrow.

Engines Z20LE(L/R/H)

12. The procedure for loosening the multi-rib belt is shown in the accompanying illustration (the key must be pressed in the direction of the arrow).

Engine Z22YH

13. The multi-rib belt on these models is removed from below, first remove the right engine boot (see Section 5).

14. Turn the tensioner (see accompanying illustration) by the bolt in the direction of the arrow and loosen the multi-rib belt.



15. After installing the multi-rib belt, check the position of the tensioner lever (see accompanying illustration) — when the belt is tensioned, the control mark on the lever should be between the marks limiting the position of the lever.



16. Replace the boot and lower the vehicle onto its wheels.

Z14XEP Engine

17. A special feature of this engine is that to replace the multi-rib belt, it is necessary to remove the right engine support, for which you must first remove the right engine boot and install a special device (see Section 5).

18. After installing the device, lower the car, open the hood and remove the air cleaner (see Chapter 4).

19. Unscrew the bolts securing the right support (see accompanying illustration) and dismantle it.



20. Using the special device KM-6131, press the tension roller in the direction indicated by the long arrow (see accompanying illustration), and fix it in this position. Remove the multi-rib belt.



21. If it is necessary to replace/remove the tension roller, disconnect the right support mounting bracket from the engine block (see accompanying illustration), for which unscrew the 3 mounting bolts. Then press the tension roller again, remove the locking device KM-9S5-2 and release the roller. Unscrew the tensioner mounting bolts (see illustration 7.20) and remove it from the engine.





22. Installation of all removed components is carried out in the reverse order of removal.

Z13DTH Engine

23. The multi-rib belt on these models is removed from below. It is necessary to first remove the right engine boot (see Section 5).

24. Loosen the multi-rib belt by turning the tensioner with a special key (see accompanying illustration 7.24a) in the direction of the arrow and lock the tensioner in this position with the locking rod (see accompanying illustration 7.24b).

Note: At service stations, the KM-6130 device is used for this purpose.

Remove the belt.

Engine Z17DT

25. Loosen the multi-rib belt by turning the tensioner with a key on the central bolt of the tension roller (see accompanying illustration) in the direction of the arrow, and fix the tensioner in this position with the locking rod, then remove the belt.

Z19DT(H) Engines

26. First remove the engine crankcase guard (see Section 5).

27. Loosen the multi-rib belt by turning the tensioner with a special key (see accompanying illustration 7.27a) in the direction of the arrow and lock the tensioner in this position with the locking rod (see accompanying illustration 7.27b), then remove the belt.