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

Replacement Interval Guide

• Vauxhall recommend:
• 2004MY – replacement every 60,000 miles or 6 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 alignment tool – Kent Moore No.KM-6173.
• Engine support tool – Kent Moore No.KM-6001-A.

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

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

1. Remove:
   • Air filter housing.
   • Timing belt upper cover [1] .
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. Remove:
   • Auxiliary drive belt.
   • Auxiliary drive belt tensioner.
5. Raise and support front of vehicle.
6. Remove:
   • RH front wheel.
   • RH inner wing panel.
7. Support engine. Tool Nos.KM-6001-A/KM-6173.
8. Remove:
   • RH engine mounting [2] .
   • Crankshaft pulley bolts [3] .
   • Crankshaft pulley [4] .
   • Timing belt lower cover [5] .
   • Camshaft position (CMP) sensor (if fitted).
9. Turn crankshaft clockwise to TDC on No.1 cylinder. Ensure crankshaft timing marks aligned [6] .
10. Timing marks on camshaft sprockets must be aligned with marks on cylinder head cover [7] .
11. Lock camshaft sprockets. Use tool No.KM-853 [8] .
12. Slacken tensioner bolt [9] .
13. Turn tensioner clockwise until pointer on LH stop. Use Allen key [10] .
    • Type 1 – [11] .
    • Type 2 – [12] .
14. Lightly tighten tensioner bolt [9] .
15. Remove timing belt.

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

Installation

1. Ensure mark on water pump aligned with mark on cylinder block [13] .
2. Ensure timing marks aligned [6] & [7] .
3. Fit timing belt in anti-clockwise direction, starting at crankshaft sprocket. Ensure belt is taut between sprockets.
4. Slacken tensioner bolt [9] .
5. Turn tensioner anti-clockwise until pointer on RH stop. Use Allen key [10] .
   • Type 1 – [14] .
   • Type 2 – [15] .
6. Lightly tighten tensioner bolt [9] .
7. Remove locking tool from camshaft sprockets [8] .
8. Turn crankshaft two turns clockwise. Ensure timing marks aligned [6] & [7] .
9. Lock camshaft sprockets. Use tool No.KM-853 [8] .
10. Slacken tensioner bolt [9] .
11. Turn tensioner clockwise until pointer aligned as follows:
    • Type 1:
    • New belt – ‘V’ notch in bracket [16] .
    • Used belt – LH edge of ‘V’ notch [17] .
    • Type 2:
    • New belt – ‘NEW’ notch in bracket [18] .
    • Used belt – ‘USED’ notch in bracket [19] .
12. Lightly tighten tensioner bolt [9] .
13. Remove locking tool from camshaft sprockets [8] .
14. Turn crankshaft slowly two turns clockwise. Ensure timing marks aligned [6] & [7] .
15. Check pointer aligned as follows:
    • Type 1:
    • New belt – ‘V’ notch in bracket [16] .
    • Used belt – LH edge of ‘V’ notch [17] .
    • Type 2:
    • New belt – ‘NEW’ notch in bracket [18] .
    • Used belt – ‘USED’ notch in bracket [19] .
16. Tighten tensioner bolt to 20 Nm [9] .
17. Install components in reverse order of removal.
18. Tighten crankshaft pulley bolts [3] . Tightening torque: 20 Nm.
19. Tightening torques:
    • A: Engine mounting to bracket – 55 Nm [2] .
    • B: Engine mounting to sidemember – 35 Nm [2] .

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