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

Replacement Interval Guide

• Vauxhall recommend replacement every 100,000 miles or 10 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
Hydraulic PAS	+0,10

Special Tools

• Auxiliary drive belt tensioner locking tool – Kent Moore No.KM-6349.
• Camshaft sprockets locking tool – Kent Moore No.KM-6340.
• Flywheel locking tool – Kent Moore No.KM-6625.
• Tensioner pulley locking pin – Kent Moore No.KM-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

WARNING: Engines with variable valve timing: Mark camshaft sprockets and camshaft adjusters with chalk or paint prior to timing belt removal to assist alignment on installation.

1. Raise and support front of vehicle.
2. Remove:
   • Air filter housing and hoses.
   • Timing belt upper cover [1] .
   • Engine undershield.
   • RH lower splash guard.
3. Turn auxiliary drive belt tensioner to release tension on belt. Use ring spanner.
4. Lock auxiliary drive belt tensioner [2] . Use tool No.KM-6349.
5. Remove:
   • Auxiliary drive belt.

     NOTE: DO NOT refit used belt.

   • Auxiliary drive belt tensioner.
6. Remove RH plate from camshaft sprockets locking tool [3] .
7. Turn crankshaft clockwise to TDC on No.1 cylinder. Ensure timing marks aligned [4] .
8. Fit camshaft sprockets locking tool [5] . Tool No.KM-6340.
9. Ensure timing mark aligned with groove on camshaft sprockets locking tool [6] & [7] .
10. Ensure timing mark on inlet camshaft adjuster is positioned above groove on camshaft sprockets locking tool [7] & [8] .
11. Slacken tensioner pulley bolt [9] .
12. Turn tensioner pulley clockwise until locking pin can be inserted. Tool No.KM-6333 [10] . Use Allen key [11] .
13. Remove bolt from cylinder block. Install flywheel locking tool [12] . Tool No.KM-6625.
14. Remove:
    • Crankshaft pulley bolt [13] .
    • Crankshaft pulley [14] .
    • Timing belt lower cover [15] .
    • Guide pulley.
    • Timing belt.
    • Tensioner pulley bolt [9] .
    • Tensioner pulley.

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

Installation

NOTE: If reusing old belt, observe direction of rotation marks on belt.

1. Ensure timing marks aligned [16] .
2. Ensure timing mark aligned with groove on camshaft sprockets locking tool [6] & [7] .
3. Ensure timing mark on inlet camshaft adjuster is positioned above groove on camshaft sprockets locking tool [7] & [8] .
4. Fit new guide pulley and bolt [17] . Tightening torque: 25 Nm.
5. Fit new tensioner pulley and bolt [9] . Tightening torque: 20 Nm.
6. Ensure tensioner pulley locking pin inserted [10] .

   NOTE: New belt supplied from manufacturer with fitting/assembly tool. Remove tool after fitment of belt.

7. Fit timing belt in following order:
   • Tensioner pulley.
   • Crankshaft sprocket.
   • Camshaft sprocket (CA2).
   • Camshaft sprocket (CA1).
8. Ensure belt is taut between sprockets.
9. Turn tensioner pulley clockwise until locking pin can be removed [10] .
10. Release tensioner to tension belt automatically.
11. Tighten tensioner pulley bolt [9] . Tightening torque: 20 Nm.
12. Fit timing belt lower cover [15] .
13. Fit crankshaft pulley [14] .
14. Fit new crankshaft pulley bolt [13] . Coat threads of bolt with suitable thread locking compound. Tightening torque: 95 Nm + 30° + 15°.
15. Remove:
    • Flywheel locking tool [12] .
    • Camshaft sprockets locking tool [5] .
16. Turn crankshaft slowly two turns in direction of rotation to TDC on No.1 cylinder.
17. Fit camshaft sprockets locking tool [5] .
18. Ensure timing mark aligned with groove on camshaft sprockets locking tool [6] & [7] .
19. Ensure timing mark on inlet camshaft adjuster is positioned above groove on camshaft sprockets locking tool [7] & [8] .
20. Ensure timing marks aligned [4] .
21. Remove camshaft sprockets locking tool [5] .
22. Install components in reverse order of removal.

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

    NOTE: If battery has been disconnected, re-initialization of window and sunroof motors may be required.