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Contents Wiring diagrams Section: DOHC Petrol Engine All sections

Replace Guide Roller Toothed Belt Opel Astra H

DOHC Petrol Engine 13 illustrations ~830 words

Remove

  1. 1. Open bonnet
  2. 2. Remove air filter casing (5) with air intake manifold • Unscrew bolt (1) • Disconnect mass air flow meter wiring harness plug (2) • Release clamp (3) • Remove engine vent hose – Release clamp (4)
  1. 3. Detach front toothed belt cover (top) from rear toothed belt cover • Unscrew 3x bolts (1) • Unclip front toothed belt cover (top)
  1. 4. Mark direction of travel of ribbed V-belt.
  2. 5. Release tension in toothed V-belt tensioner (1) using hex. (size 15) in direction of arrow (anticlockwise) and remove ribbed V-belt I Version without AC. II Version with AC.

Note. Note installation position of ribbed V-belt

  1. 6. Raise vehicle by half its height
  2. 7. Remove right front wheel • Unscrew 5x bolts
  3. 8. Raise vehicle
  4. 9. Remove right engine splash guard (2) • Unscrew 4x bolts (1) • Remove 2x body-bound rivets (3)
  1. 10. Detach ribbed V-belt tensioner (1) from alternator support
  1. 11. Pry sealing plug (arrow) out of opening using screwdriver
  2. 12. Insert KM-911 (1) into opening of oil pan and lock flywheel or drive disc
  3. 13. Detach increment disc (2) from crankshaft
  4. 14. Remove lower part of toothed belt cover • Unscrew bolt (3) • Unclip front toothed belt cover (lower) from rear toothed belt cover
  1. 15. Screw toothed belt drive gear bolt into crankshaft
  2. 16. Detach camshaft sensor (1) from cylinder head • Unscrew 2x bolts • Put aside
  1. 17. Turn crankshaft in direction of engine rotation to "Cylinder no.1 TDC" (III) • Marks on camshaft sprockets must be opposite each other (I)
  2. 18. Fix camshaft sprockets in position with KM-852 (II)
  3. 19. Slacken toothed belt tension roller • Slacken bolt of toothed belt tensioning device (IV) • Rotate eccentric adjuster in direction of arrow (clockwise) until pointer (1) is just in front of left stop
  4. 20. Remove toothed belt and place to one side
  1. 21. Detach guide roller toothed belts • Detach intake side guide roller toothed belt (1) from cylinder head – Unscrew bolt • Detach exhaust side guide roller toothed belt (2) from engine damping block support – Unscrew bolt

Install

  1. 22. Attach exhaust side guide roller toothed belt to engine damping block support • Tighten bolt 25 Nm
  2. 23. Attach intake side guide roller toothed belt to cylinder head • Tighten bolt 25 Nm

Important. Note direction of rotation of toothed belt

  1. 24. Position toothed belt • Ensure that tension side (I) is taut • Note timing mark
  1. 25. Tension the toothed belt • Rotate eccentric adjuster in direction of arrow (anticlockwise) until pointer of toothed belt tensioning device is just before right stop • Attach toothed belt tensioning device – Tighten bolt
  1. 26. Remove KM-852
  2. 27. Turn crankshaft over • Rotate crankshaft two turns (720°) in direction of engine rotation using increment disc bolt – Marks on toothed belt drive gear and rear toothed belt cover must align
  3. 28. Toothed Belt Tension, Adjust • Slacken the toothed belt tension roller – Loosen bolt • Rotate eccentric adjuster in direction of arrow (anticlockwise) until pointer (1) of toothed belt tensioning device aligns with "USED" notch mark (2) • Fasten toothed belt tension roller – Tighten bolt 20 Nm
  1. 29. Remove locking tool KM-852
  2. 30. Check toothed belt tension • Rotate crankshaft two more turns (720°) in direction of engine rotation to "Cylinder no.1 TDC" mark • Check toothed belt tensioning device setting

Note. If the toothed belt tensioning device indicator does not align with the relevant notch mark, the adjusting procedure must be repeated

  1. 31. Attach toothed belt tensioning device • Tighten bolt 20 Nm
  2. 32. Remove locking tool KM-852 .
  3. 33. Remove bolt from toothed belt drive gear
  4. 34. Attach camshaft sensor to cylinder head • Tighten 2x bolt 8 Nm – Coat with screw locking compound (red)
  5. 35. Attach front toothed belt cover (lower) • Clip to rear toothed belt cover • Tighten bolt 4 Nm
  6. 36. Attach increment disk to crankshaft • Tighten bolt 95 Nm +45° + 15° – Use new bolt
  7. 37. Remove locking tool KM-911 • Insert new closure plug into opening

Important. Journals on ribbed V-belt tensioner must engage in holes in alternator support

  1. 38. Attach V-belt tensioner to alternator support 35 Nm
  2. 39. Install lower right engine splash guard • Tighten 4x bolts
  3. 40. Fit front wheel 110 Nm
  4. 41. Lower vehicle
  5. 42. Release tension in toothed V-belt tensioner (1) using hex. (size 15) in direction of arrow (anticlockwise), put on ribbed V-belt and tension using ribbed V-belt tensioning device. I Version without AC. II Version with AC.

Note. Ensure running direction and installation position of ribbed V-belt is correct

  1. 43. Attach front toothed belt cover (top) • Clip to rear toothed belt cover • Tighten 3x bolt 4 Nm
  2. 44. Install air cleaner housing and air intake manifold • Tighten bolt • Fasten clamp 3.5 Nm • Attach engine vent hose – Fasten clamp • Connect mass air flow meter wiring harness plug
  3. 45. Close bonnet

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