Replace Toothed Belt Guiding Roller Opel Astra G

Remove

1. 1. Open bonnet
2. 2. Disconnect battery
3. 3. Remove air cleaner housing (5) and air intake manifold (3) • 1 mass air flow meter wiring harness plug (4) • Unclip tank ventilation hose (1) • 1 fastening bolt (2) • 1 clip

4. 4. Remove air intake manifold
5. 5. Detach ribbed V-belt (1) • Mark direction of rotation • Apply tension to the ribbed V-belt tensioner (2) in the direction of the arrow and fix using KM-6130 (3) – Remove ribbed-V-belt

6. 6. Raise vehicle
7. 7. Remove engine splash guard (2) • 4 bolts (1)

8. 8. Block the flywheel • Remove sealing stopper • Insert KM-911 (1)

9. 9. Remove torsional vibration balancer (5) • 1 bolt (6)
10. 10. Remove ribbed V-belt tensioner (3) • 1 bolt (4) – Ribbed V-belt tensioner is locked using KM-6130
11. 11. Remove upper part of toothed belt cover (1) • 2 bolts (2) • Release upper catch (7) • Pull upper part of toothed belt cover upwards by pulling gently on the stalk (arrow)

12. 12. Remove lower cover of toothed belt (2) • 4 bolts (1)

Install

13. 13. Set engine to TDC • Remove KM-911 • Tighten bolt on torsional vibration balancer • Set crankshaft in direction of engine rotation to "1st cylinder TDC" position (arrows)

14. 14. Lower vehicle
15. 15. Fix camshaft timing gears using KM-6340 • Set camshaft timing gears in such a way that the marks (3) are opposite one another • Fit KM-6340-Left (1) to camshaft timing intake pulley • Insert KM-6340-Right (2)

16. 16. Slacken toothed belt • Apply tension to toothed belt tension roller (2) in the direction of the arrow, using an Allan key (1). Fix using KM-6333 (3)
17. 17. Remove toothed belt guiding roller (4) • 1 bolt (5)

Important. Cleaning the thread is extremely important

18. 18. Cleaning the thread • 1 thread – In cylinder block
19. 19. Fit toothed belt guiding roller • 1 bolt – Tightening torque 25 Nm
20. 20. Tension the toothed belt • Apply tension to the toothed belt tension roller and remove KM-6333
21. 21. Remove KM-6340
22. 22. Raise vehicle
23. 23. Turn crankshaft 720° • 2 revolutions in direction of engine rotation • Set toothed belt wheel to mark "1st cylinder TDC positon" (arrows)

24. 24. Lower vehicle
25. 25. Fix camshaft timing gears using KM-6340 • Insert KM-6340-Left (1) • Insert KM-6340-Right (2)

Note. The marks (3) on KM-6340 must be aligned - otherwise remove toothed belt and refit

26. 26. Remove KM-6340
27. 27. Raise vehicle
28. 28. Replace lower toothed-belt cover • 4 bolts – Tightening torque 6Nm
29. 29. Remove torsional vibration balancer fixing bolt • Block flywheel using KM-911 • Remove fixing bolt
30. 30. Fit torsional vibration balancer • 1 bolt – Tightening torque 95Nm + 30° + 15°
31. 31. Remove KM-911 • Insert sealing stopper
32. 32. Fit ribbed V-belt tensioner • 1 bolt – Tightening torque 50Nm
33. 33. Insert ribbed V-belt • Apply tension to ribbed V-belt tensioner in an anti-clockwise direction and position ribbed V-belt. • Remove KM-6130

Note. Observe direction of rotation

34. 34. Install engine splash guard • 4 bolts
35. 35. Lower vehicle
36. 36. Fit front toothed belt cover • Upper part • 2 bolts – Tightening torque 6Nm
37. 37. Fit air intake manifold pipe
38. 38. Install air cleaner housing and air intake manifold • Place 1 mass air flow meter wiring harness plug • Clip in tank ventilation hose • 1 fastening bolt • 1 clip – Tightening torque 3.5Nm
39. 39. Connect battery
40. 40. Programme transient memory
41. 41. Close bonnet