Replace Toothed Belt 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 • Turn crankshaft in direction of engine rotation to "1st Cylinder TDC" (III).
14. 14. Lower vehicle
15. 15. Fix camshaft timing gears using KM-6340 • Set camshaft timing gears in such a way that the marks are opposite one another • Fix KM-6340-Left to camshaft timing gear inlet • Insert KM-6340-Right (II)
16. 16. Remove toothed belt • Mark direction of rotation • Apply tension to toothed belt tension roller clockwise with socket wrench and fix with KM-6333 (IV) – Remove toothed belt

17. 17. Insert toothed belt • Insert toothed belt (1) in enclosed assembly tool (2) – If the toothed belt has been used, observe direction of rotation • Guide toothed belt through engine damping block support with assembly tool • Remove assembly tool

Note. Threading the toothed belt through the engine damping block support is only permissible in conjunction with the assembly tool supplied with new toothed belts as otherwise it is possible to damage the toothed belt at this stage by kinking it

18. 18. Position toothed belt • Position toothed belt onto camshaft timing gear outlet • Position toothed belt on camshaft timing gear inlet • Direct toothed belt via the tightening and guiding rollers and position upon toothed belt drive • Apply tension to the toothed belt tension roller and remove KM-6333

Note. Observe direction of rotation

19. 19. Remove KM-6340
20. 20. Raise vehicle
21. 21. Turn crankshaft 720° • 2 revolutions in direction of engine rotation • Set toothed belt drive gear to mark for "1st cylinder TDC" (arrows)

22. 22. Lower vehicle
23. 23. 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

24. 24. Remove KM-6340
25. 25. Raise vehicle
26. 26. Replace lower toothed-belt cover • 4 bolts – Tightening torque 6Nm
27. 27. Remove torsional vibration balancer fixing bolt • Block flywheel using KM-911 • Remove fixing bolt
28. 28. Fit torsional vibration balancer • 1 bolt – Tightening torque 95Nm + 30° + 15°
29. 29. Remove KM-911 • Insert sealing stopper
30. 30. Fit ribbed V-belt tensioner • 1 bolt – Tightening torque 50Nm
31. 31. 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

32. 32. Install engine splash guard • 4 bolts
33. 33. Lower vehicle
34. 34. Fit upper part of ribbed belt over • 2 bolts – Tightening torque 6Nm

Important. Check for correct engagement

35. 35. Fit air intake manifold pipe
36. 36. 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
37. 37. Connect battery
38. 38. Programme transient memory
39. 39. Close bonnet