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

Published September 8, 2015

Replacement Interval Guide

  • Vauxhall recommend replacement as follows:
  • →96MY – replacement every 40,000 miles or 4 years, whichever occurs first.
  • 97MY→ – replacement every 40,000 miles or 4 years, whichever occurs first (tensioner 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:
Vectra 1,20
Astra-G 1,70

Special Tools

  • Camshaft sprocket locking tool – Kent Moore No.KM-853.
  • Engine support tool (Astra) – Kent Moore No.KM-6001.
  • Engine alignment tool (Astra) – Kent Moore No.KM-909-B.

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

Removal

WARNING: Certain engines require modification to tensioner pulley/guide pulleys due to possible failure. Refer to dealer.

  1. Remove:
      • Air filter housing.
  2. Raise and support front of vehicle.
  3. Remove RH front wheel.
  4. Mark direction of rotation on auxiliary drive belt with chalk.
  5. Turn auxiliary drive belt tensioner clockwise to release tension on belt. Use ring spanner.
  6. Insert 4 mm pin through hole in tensioner and into mounting bracket [1] .
  7. Remove:
      • Auxiliary drive belt.
      • Vectra: Engine torque bracket [2] .
      • Timing belt cover(s) [3] .
  8. Astra: Fit engine support and alignment tools. Tool Nos.KM-6001/KM-909-B.
  9. Astra – remove:
      • Auxiliary drive belt tensioner.
      • RH engine mounting and bracket.
  10. Turn crankshaft clockwise until timing marks aligned [4] .
  11. Remove:
      • Crankshaft pulley bolts [5] .
      • Crankshaft pulley [6] .
  12. Ensure crankshaft timing marks aligned [7] .
  13. Timing marks on camshaft sprockets must be aligned with notches in timing belt rear cover [8] .
  14. Lock camshaft sprockets. Use tool No.KM-853 [9] .
  15. Slacken tensioner bolt [10] .
  16. Turn tensioner clockwise until pointer on LH stop: Use Allen key [11] .
      • Type 1 – [12] .
      • Type 2 – [16] .
  17. Lightly tighten tensioner bolt [10] .
  18. Remove timing belt.

Installation

NOTE: Ensure lug on water pump aligned with corresponding lug on cylinder block [20] .

  1. Ensure timing marks aligned [7] & [8] .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 [10] .
  4. Turn tensioner anti-clockwise until pointer on RH stop: Use Allen key [11] .
      • Type 1 – [13] .
      • Type 2 – [17] .
  5. Lightly tighten tensioner bolt [10] .
  6. Remove locking tool [9] .
  7. Turn crankshaft two turns clockwise. Ensure timing marks aligned [7] & [8] .
  8. Lock camshaft sprockets. Use tool No.KM-853 [9] .
  9. Slacken tensioner bolt [10] .
  10. Turn tensioner clockwise until pointer aligned as follows:
      • Type 1:
      • New belt – ‘V’ notch in bracket [14] .
      • Used belt – LH edge of ‘V’ notch [15] .
      • Type 2:
      • New belt – ‘NEW’ notch in bracket [18] .
      • Used belt – ‘USED’ notch in bracket [19] .
  11. Tighten tensioner bolt to 20 Nm [10] .
  12. Remove locking tool [9] .
  13. Turn crankshaft two turns clockwise. Ensure timing marks aligned [7] & [8] .
  14. Check pointer aligned as follows:
      • Type 1:
      • New belt – ‘V’ notch in bracket [14] .
      • Used belt – LH edge of ‘V’ notch [15] .
      • Type 2:
      • New belt – ‘NEW’ notch in bracket [18] .
      • Used belt – ‘USED’ notch in bracket [19] .
  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 [5] .
  18. Tighten engine torque bracket bolts to 60 Nm.
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Published in Astra G