Toothed Belt Guide Roller. Replace — Opel Astra H (2004-2011)

Toothed Belt Guide Roller. Replace Opel Astra H

DOHC Diesel Engine 18 illustrations ~1251 words

1. Open bonnet
2. Disconnect battery • Detach earth connection from earth terminal
3. Remove engine cover (2) • Detach oil filler port closure cap (1) • Pull off engine cover • Attach oil filler port closure cap

Note. Rubber retainers (3) must remain on engine cover

4. Remove air cleaner housing (5) with air intake hose • Detach wiring harness plug (2) from hot film mass air flow meter • Detach air intake hose from air intake pipe – Release clamp (1) • Detach air cleaner housing from wheel housing – Unscrew bolt (4) • Detach water drain hose (3) from air cleaner housing – Release clamp

5. Remove ribbed V-belt • Mark direction of rotation • Apply tension to ribbed V-belt tensioner via bolt (1) in the direction of the arrow • Fix ribbed V-belt tensioner to bore (2) • Remove ribbed-V-belt

6. Detach wiring trough (4) from front toothed belt cover (top) • Unscrew bolt (2) • Detach wiring harness (3) – Disconnect camshaft sensor wiring harness plug – Release 2x clip • Detach vacuum line (1) – Release 2x clip • Unclip wiring trough in direction of arrow – Undo clip

7. Detach front toothed belt cover (top) (4) • Detach vacuum line (3) – Unclip 3x clip • Unscrew 8x bolts • Remove camshaft sensor bracket (1) – Unscrew bolt (2)

Note. Note different bolt lengths

8. Raise vehicle by its full height
9. Detach the lower engine cover and right engine splash guard
10. Insert KM-6173 (3) • Align support bearing (1) • Raise support bearing until journal (2) sits flush in mount (4) • Fasten KM-6173 – Screw in 2x bolts

11. Attach KM-6001-A (1) • Slacken 4x bolts (arrows) in adjusting rails • Insert KM-6001-A – Insert journals (2) and (5) in guide holes in front axle body • Tighten 4x bolts in adjusting rails • Adjust support bearings, front (4) and rear (3) – Raise support bearings up to the stop on the guide journals

Note. Attaching KM-6001-A guarantees perfect alignment of the drive unit with the front axle body

Note. The guide journals must be seated free from play in the support bearings

Note. Counterhold at bolt (2)

13. Lower vehicle by its full height
14. Remove engine damping block support • Detach from engine damping block bracket – Unscrew 3x bolts (2) • Detach from cylinder block – Unscrew 3x bolts (3) • Remove engine damping block adapter (1)

17. Move crankshaft in direction of engine rotation to "Cylinder no.1 combustion stroke TDC" • Fix with TDC fixing bolt (M6) (1) camshaft drive gear • Fix with TDC fixing bolt (M8) (2) high pressure pump gear

Note. Marking on toothed belt drive gear must align with projection on oil pump cover (arrows)

18. Remove toothed belt • Mark direction of rotation • Slacken the toothed belt tension roller – Loosen bolt (1) • Apply preliminary tension to toothed belt tension roller with hexagon (2) in direction of arrow • Fix toothed belt tension roller in pre-tensioned position – Tighten bolt

20. Install toothed belt guide roller • Tighten bolt 80.4 Nm
21. Install toothed belt • Position toothed belt – Toothed belt must be tensioned in the direction of the arrow from the toothed belt drive gear (5) via the oil pump drive gear (4) and high pressure pump drive gear (2) to the camshaft sprocket (1) – Observe direction of rotation • Slacken the toothed belt tension roller (3) • Remove 2x TDC fixing bolt • Turn crankshaft 60° against the direction of engine rotation • Tighten toothed belt tension roller 38.2 Nm

Note. TDC fixing bolts must be installed in the high pressure drive gear and camshaft drive gear and markings (6) and (7) must align

22. Timing, Check • Turn crankshaft 6 revolutions in direction of engine rotation to the adjustment position • The following factors must be present at the adjustment position 1. TDC fixing bolt M6 (1) must be able to be inserted in the camshaft drive gear 2. TDC fixing bolt M8 (2) must be able to be inserted in the high pressure pump drive gear 3. Marking (4) on the toothed belt drive gear must align with the marking (3) on the oil pump housing cover • Remove 2x TDC fixing bolt

Note. If one of these factors is not present, the timing must be adjusted

23. Install front toothed belt cover (lower) • Tighten 3x bolt 9.8 Nm
24. Install coolant pump drive gear • Tighten 3x bolt 12.3 Nm
25. Install engine damping block bracket • Insert engine damping block adapter • Attach engine damping block support to cylinder block – Tighten 3x bolt 50 Nm • Engine damping block support to engine damping block bracket – Tighten 3x bolt 55 Nm
26. Raise vehicle by its full height

Important. Journal (1) of toothed belt drive gear must engage in the bore (2) of the torsional vibration damper

Note. Counterhold against bolt, toothed belt drive gear

28. Remove engine mount KM-6173
29. Remove engine mount KM-6001-A
30. Install lower engine cover and right engine splash guard
31. Lower vehicle by its full height
32. Install front toothed belt cover (top) • Tighten 8x bolt 9.8 Nm • Install camshaft sensor bracket – Tighten bolt 9.8 Nm • Attach vacuum line to toothed belt cover – Clip in 3x clips

Note. Note different bolt lengths

33. Attach wiring trough to front toothed belt cover (top) • Attach wiring trough – Attach clip • Tighten bolt 9.8 Nm • Attach wiring harness – Clip in 2x clips – Connect camshaft sensor wiring harness plug • Attach vacuum line – Clip in 2x clips
34. Attach wiring trough to front toothed belt cover (top) • Attach wiring trough – Attach clip • Tighten bolt 9.8 Nm • Attach wiring harness – Clip in 2x clips – Connect camshaft sensor wiring harness plug • Attach vacuum line – Clip in 2x clips
35. Attach wiring trough to front toothed belt cover (top) • Attach wiring trough – Attach clip • Tighten bolt 9.8 Nm • Attach wiring harness – Clip in 2x clips – Connect camshaft sensor wiring harness plug • Attach vacuum line – Clip in 2x clips
36. Insert ribbed V-belt • Position ribbed V-belt – I. Ribbed V-belt without air conditioning – II. Ribbed V-belt with air conditioning • Apply tension to ribbed V-belt tensioner via bolt (1) in the direction of the arrow • Take out fixing • Release ribbed V-belt tensioner

Note. Note running direction of ribbed V-belt

37. Install air cleaner housing with air intake hose • Attach water drain hose to air cleaner housing – Fasten clamp • Tighten bolt 15 Nm • Attach air intake hose to air intake pipe – Fasten clamp 3.5 Nm • Connect wiring harness plug to air mass flow meter
38. Install engine cover • Detach oil filler port closure cap • Refit engine cover • Attach oil filler port closure cap
39. Connect battery • Attach earth connection to earth terminal
40. Program volatile memories
41. Close bonnet

Toothed Belt Guide Roller. Replace Opel Astra H