How to replace timing belt on Vauxhall/Opel Astra G 2.0 Turbo

Replacement Interval Guide

• Vauxhall recommend:
• →2004MY – replacement every 40,000 miles or 4 years (tensioner and guide pulleys must also be replaced).
• 2005MY→ – replacement every 80,000 miles or 8 years (tensioner and guide pulleys 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

1,30

Special Tools

• Camshaft sprocket locking tool – Kent Moore No.KM-853.
• Engine support tool – Kent Moore No.KM-6001-A.
• Engine alignment tool – Kent Moore No.KM-6173.

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.
2. Raise and support front of vehicle.
3. Remove:
   • RH front wheel.
   • RH splash guard.
4. Mark direction of rotation on auxiliary drive belt with chalk.
5. Turn auxiliary drive belt tensioner anti-clockwise to release tension on belt.
6. Remove:
   • Auxiliary drive belt.
   • Timing belt upper cover [1] .
7. Fit engine support and alignment tools. Tool Nos.KM-6001-A/KM-6173.
8. Remove:
   • Auxiliary drive belt tensioner.
   • RH engine mounting and bracket.
9. Turn crankshaft clockwise until timing marks aligned [2] .
10. Remove:
    • Crankshaft pulley bolts [3] .
    • Crankshaft pulley [4] .
    • Timing belt lower cover [5] .
11. Ensure crankshaft timing marks aligned [6] .
12. Timing marks on camshaft sprockets must be aligned with notches in timing belt rear cover [7] .
13. Lock camshaft sprockets. Use tool No.KM-853 [8] .
14. Slacken tensioner bolt [11] .
15. Turn tensioner clockwise until pointer on LH stop. Use Allen key [10] .
    • Type 1: [9] .
    • Type 2: [17] .
16. Lightly tighten tensioner bolt [11] .
17. Remove timing belt.

Installation

NOTE: Ensure lug on water pump aligned with corresponding lug on cylinder block [19] .

1. Ensure timing marks aligned [6] & [7] .

   NOTE: If camshaft sprockets have been removed: Ensure correct dowel location of sprockets.

2. Fit timing belt in anti-clockwise direction, starting at crankshaft sprocket. Ensure belt is taut between sprockets.
3. Slacken tensioner bolt [11] .
4. Turn tensioner anti-clockwise until pointer on RH stop. Use Allen key [10] .
   • Type 1: [12] .
   • Type 2: [18] .
5. Lightly tighten tensioner bolt [11] .
6. Remove locking tool [8] .
7. Turn crankshaft two turns clockwise. Ensure timing marks aligned [6] & [7] .
8. Lock camshaft sprockets. Use tool No.KM-853 [8] .
9. Slacken tensioner bolt [11] .
10. Turn tensioner clockwise until pointer aligned as follows:
    • Type 1:
    • New belt – ‘V’ notch in bracket [13] .
    • Used belt – LH edge of ‘V’ notch [15] .
    • Type 2:
    • New belt – ‘NEW’ notch in bracket [14] .
    • Used belt – ‘USED’ notch in bracket [16] .
11. Tighten tensioner bolt to 20 Nm [11] .
12. Remove locking tool [8] .
13. Turn crankshaft two turns clockwise. Ensure timing marks aligned [6] & [7] .
14. Check pointer aligned as follows:
    • Type 1:
    • New belt – ‘V’ notch in bracket [13] .
    • Used belt – LH edge of ‘V’ notch [15] .
    • Type 2:
    • New belt – ‘NEW’ notch in bracket [14] .
    • Used belt – ‘USED’ notch in bracket [16] .
15. If not: Repeat tensioning procedure.
16. Install components in reverse order of removal.

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

17. Tighten crankshaft pulley bolts to 20 Nm [3] .