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

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] .

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