How to replace timing belt on Vauxhall/Opel Astra J 1.6i Turbo

Replacement Interval Guide

• Vauxhall recommend:
• →2010MY: Replacement every 100,000 miles or 10 years (tensioner pulley and guide pulley must also be replaced).
• 2011MY→: 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

0,80

Special Tools

• Auxiliary drive belt tensioner locking tool – No.EN-6349.
• Camshafts locking tool – No.EN-6340.
• Flywheel locking tool – No.EN-6625.
• Tensioner pulley locking pin – No.EN-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. Raise and support front of vehicle.
2. Remove:
   • Engine top cover (if fitted).
   • RH front wheel.
   • RH splash guard.
   • Air filter housing and hoses.
   • Timing belt upper cover [1] .
3. Turn auxiliary drive belt tensioner away from belt to release tension on belt.
4. Lock auxiliary drive belt tensioner [2] . Use tool No.EN-6349.
5. Remove:
   • Auxiliary drive belt(s).
   • Auxiliary drive belt tensioner.

   NOTE: PAS drive belt requires cutting and cannot be reused.

6. Turn crankshaft clockwise to TDC on No.1 cylinder. Ensure timing marks aligned [3] .
7. Fit flywheel locking tool [4] . Tool No.EN-6625.
8. Remove:
   • Crankshaft pulley bolt [5] .
   • Crankshaft pulley [6] .
   • Timing belt lower cover [7] .
   • Flywheel locking tool [4] .
9. Temporarily fit crankshaft pulley bolt.
10. Ensure timing marks aligned [8] .
11. Install camshafts locking tool [9] . Tool No.EN-6340.
12. Ensure marks on locking tool aligned [10] .
13. Turn tensioner pulley clockwise until locking pin can be inserted [11] . Tool No.EN-6333.
14. 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 and bolt [12] . Tightening torque: 25 Nm.
3. Fit new tensioner pulley and bolt [13] . Tightening torque: 20 Nm.
4. Ensure tensioner pulley tab [14] engaged in cut-out [15] .
5. Fit timing belt in anti-clockwise direction, starting at 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] .
   • Locking tool [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 camshafts locking tool [9] .
10. Ensure marks on locking tool aligned [10] . If not: Repeat installation procedure.
11. Install components in reverse order of removal.
12. Install flywheel locking tool [4] .
13. Fit new crankshaft pulley bolt [5] . Tightening torque: 95 Nm + 45° + 15°.
14. Remove flywheel locking tool [4] .