How to Replace timing belt on Vauxhall/Opel Astra H 1.6 Turbo

Replacement Interval Guide

• Vauxhall recommend:
• →2010: Replacement every 100,000 miles or 10 years (tensioner pulley and guide pulley must also be replaced).
• 2011→: Replacement every 100,000 miles or 6 years (tensioner pulley and guide pulley must also be replaced).
• The previous use and service history of the vehicle must always be taken into account.

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

Remove & install

0,90

Special Tools

• Auxiliary drive belt tensioner locking tool – Kent Moore No.KM-6130.
• Camshaft alignment tool – 2 x Kent Moore No.KM-6340.
• Flywheel locking tool (Astra-H/Corsa-D/Meriva/Zafira-B) – Kent Moore No.KM-6625.
• Flywheel locking tool (Astra-G/H) – Kent Moore No.KM-911.
• Tensioner pulley locking pin – Kent Moore No.KM-6333.

Special Precautions

• Disconnect battery earth lead.
• DO NOT turn crankshaft or camshaft when timing belt removed.
• Remove spark 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

1. Remove air filter housing and hoses.
2. Mark direction of rotation on auxiliary drive belt with chalk.
3. Turn auxiliary drive belt tensioner to release tension on belt. Use ring spanner.
4. Lock auxiliary drive belt tensioner [1] . Use tool No.KM-6130.
5. Remove auxiliary drive belt.
6. Raise and support front of vehicle.
7. Remove:
   • Engine top cover (if fitted).
   • RH front wheel.
   • RH splash guard.
   • Blanking plug from bell housing.
8. Fit flywheel locking tool [2] or [3] . Tool No.KM-911 or No.KM-6625.
9. Remove:
   • Crankshaft pulley bolt [4] .
   • Crankshaft pulley [5] .
   • Auxiliary drive belt tensioner.
   • Timing belt upper cover [6] .
   • Timing belt lower cover [7] .
   • Flywheel locking tool [2] or [3] .
10. Temporarily fit crankshaft pulley bolt.
11. Turn crankshaft clockwise to TDC on No.1 cylinder. Ensure timing marks aligned [8] .
12. Install camshaft alignment tools [9] . Tool No.KM-6340.
13. Ensure marks on alignment tools aligned [10] .
14. Turn tensioner pulley clockwise until locking pin can be inserted. Tool No.KM-6333 [11] .
15. Remove timing belt.

    NOTE: Mark direction of rotation on belt with chalk if belt is to be reused.

Installation

1. Ensure timing marks aligned [8] & [10] .
2. Fit new guide pulley. Tightening torque: 25 Nm.
3. Fit new tensioner pulley and bolt. Tightening torque: 20 Nm.
4. Ensure tensioner tab [12] engaged in cut-out [13] .
5. Fit timing belt in following order:
   • Exhaust camshaft sprocket.
   • Inlet camshaft sprocket.
   • Tensioner pulley.
   • Guide pulley.
   • Crankshaft sprocket.

   NOTE: New belt supplied from manufacturer with fitting/assembly tool. Remove tool after fitment of belt.

6. Remove:
   • Tensioner pulley locking pin [11] .
   • Alignment tools [9] .
7. Turn crankshaft slowly two turns in direction of rotation to TDC on No.1 cylinder.
8. Ensure timing marks aligned [8] .
9. Install camshaft alignment tools [9] .
10. Ensure marks on alignment tools aligned [10] . If not: Repeat installation procedure.
11. Install components in reverse order of removal.

    NOTE: Observe direction of rotation marks on auxiliary drive belt.

12. Install locking tool [2] or [3] .
13. Fit new crankshaft pulley bolt [4] . Tightening torque:
    • A: Z16LET/XE1/XEP – 95 Nm + 30° + 15°.
    • B: A16LER/Z16LER – 95 Nm + 45° + 15°.
14. Remove locking tool [2] or [3] .
15. Astra-G/H: Fit blanking plug to bell housing.
16. Except Astra-G: Fit bolt to cylinder block.