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

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] .

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