vauxhall Workshop Repair Guides

Vauxhall Workshop Service and Repair Manuals

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Replace toothed belt > < Toothed Belt Guide Roller. Replace

Astra H

Replace rear toothed belt cover

  Remove

1.   Open bonnet
2.   Disconnect earth cable from battery
•   Slacken nut
3.  
1. Remove air cleaner housing - Z16XEP LUREF_1.gif
2. Remove air cleaner housing - Z16XE1 LUREF_1.gif

4.   Detach front toothed belt cover (top) (1)
•   Unscrew 2x bolts (2)
•   Release upper catch (3)
•   Pull front toothed belt cover (top) upwards by cast projection (arrow), applying slight tension
Object Number: 2412882 Size: DEFAULT


5.   Detach ribbed V-belt (1)
•   Mark direction of rotation
•   Apply tension to ribbed V-belt tensioner (2) in the direction of the arrow and fix with KM-6130 (3)
– Remove ribbed-V-belt
Object Number: 2412799 Size: DEFAULT


6.   Raise vehicle
7.   Detach lower engine compartment cover / splashguard
8.   Possibility 1: Lock flywheel
•   Remove closure plugs
•   Insert KM-911 (1)
Object Number: 2412823 Size: DEFAULT


9.   Possibility 2: Lock crankshaft
•   Attach KM-6625
– Detach screwed connection (1)
– Insert KM-6625 (2)
– Tighten screwed connection (3)
Object Number: 9007701 Size: DEFAULT


10.   Detach torsional vibration damper (3)
•   Unscrew bolt (4)
11.   Detach ribbed V-belt tensioner (1)
•   Unscrew bolt (2)
– Ribbed V-belt tensioner remains locked with KM-6130
Object Number: 3446322 Size: DEFAULT


12.   Detach front toothed belt cover (bottom) (2)
•   Unscrew 4x bolts (1)
Object Number: 2412824 Size: DEFAULT


13.   Set engine to 60° (measurement l) before TDC
•   Possibility 1: Remove KM-911
•   Possibility 2: Remove KM-6625
– Detach screwed connection
•   Set crankshaft in direction of engine rotation to 60° (measurement l) before TDC
Object Number: 2412867 Size: DEFAULT


14.   Lower vehicle
15.   Remove toothed belt
•   Mark direction of rotation
•   Apply tension to toothed belt tension roller (2) in the direction of the arrow, using an Allen key (1). Fix using KM-6333 (3)
– Remove toothed belt
Object Number: 2412854 Size: DEFAULT


16.   Remove toothed belt tension roller (1)
•   Unscrew bolt (2)
17.   Remove toothed belt guide roller (3)
•   Unscrew bolt (4)
Object Number: 2412825 Size: DEFAULT


18.   Detach exhaust camshaft sprocket
•   Attach KM-6347 (1) in conjunction with KM-956-1 (2) to camshaft sprocket
– Slacken 2x bolt (3) of KM-6347
– Insert KM-6347 in the camshaft sprocket - ensure it is correctly seated
Note:   The grooves of KM-6347 (arrows) must engage with camshaft sprocket
– Turn KM-6347 in the direction of the arrow
– Tighten fixing bolts
•   Slacken camshaft sprocket fixing bolt (4)
– Hold using KM-6347
– 2 people
•   Remove KM-6347
– Undo 2x bolts
•   Unscrew fastening bolt, camshaft sprocket
– Remove camshaft sprocket
Object Number: 2412855 Size: DEFAULT


19.   Detach intake camshaft sprocket
•   Attach KM-6347 in conjunction with KM-956-1 to camshaft sprocket
– Slacken 2x bolt of KM-6347
– Insert KM-6347 in the camshaft sprocket - ensure it is correctly seated
Note:   The grooves of KM-6347 must engage in camshaft sprocket
– Turn KM-6347 in the direction of the arrow
– Tighten fixing bolts
•   Remove camshaft sprocket fastening bolt
– Hold using KM-6347
– 2 people
•   Remove KM-6347
– Slacken fixing bolts
•   Unscrew fastening bolt, camshaft sprocket
– Remove camshaft sprocket
20.   Detach rear toothed belt cover (1)
•   Unclip wiring harness
•   Unscrew 4x bolts (2)
•   Take out camshaft sensor by turning it
Object Number: 2412826 Size: DEFAULT


  Install

21.   Replace rear toothed belt cover
•   Insert camshaft sensor
•   Tighten 4x bolt 6 Nm
•   Clip in wiring harness
22.   Attach KM-6347 to exhaust camshaft sprocket
•   Position camshaft sprocket - note marking
•   Screw in bolt, camshaft sprocket (4)
– Do not tighten
– Attach KM-6347 (1) in conjunction with KM-956-1 (2) to camshaft sprocket
– Release fixing bolts (3) from KM-6347
– Insert KM-6347 in the camshaft sprocket - ensure it is correctly seated
Note:   The grooves of KM-6347 (arrows) must engage with camshaft sprocket
– Turn KM-6347 in the direction of the arrow
– Tighten fixing bolts
Object Number: 2412855 Size: DEFAULT


23.   Tighten outlet camshaft sprocket 50 Nm + 60° + 15°
•   Hold using KM-6347
– 2 people
•   Remove KM-6347
24.   Attach KM-6347 to intake camshaft sprocket
•   Position camshaft sprocket - note marking
•   Screw in bolt, camshaft sprocket
– Do not tighten
– Attach KM-6347 in conjunction with KM-956-1 to camshaft sprocket
– Slacken fixing bolts of KM-6347
– Insert KM-6347 in the camshaft sprocket - ensure it is correctly seated
Note:   The grooves of KM-6347 must engage in camshaft sprocket
– Turn KM-6347 in the direction of the arrow
– Tighten fixing bolts
25.   Tighten intake camshaft sprocket 50 Nm + 60° + 15°
•   Hold using KM-6347
– 2 people
•   Remove KM-6347
Important:   It is absolutely essential to clean the thread
26.   Clean the thread
•   2x thread in cylinder block
27.   Fit toothed belt tightening roll
Note:   Lug must engage in groove
•   Tighten bolt 20 Nm + 120° + 15°
28.   Fit toothed belt guide roller
•   Tighten bolt 20 Nm + 120° + 15°
29.   Insert toothed belt
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
•   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
Object Number: 2412961 Size: DEFAULT


30.   Position toothed belt
Note:   Observe direction of rotation
•   Place toothed belt on exhaust camshaft sprocket
•   Place toothed belt on intake camshaft sprocket
•   Guide toothed belt past the tensioning and guide rollers and place on toothed belt drive gear
•   Apply tension to the toothed belt tension roller and remove KM-6333
– Toothed belt tension roller automatically moves to the correct position
31.   Remove KM-6340
32.   Raise vehicle
33.   Turn crankshaft through 720°
•   2 revolutions in direction of engine rotation
•   Place toothed belt drive gear on the marking, cylinder 1 TDC of combustion stroke (arrows)
Object Number: 2412848 Size: DEFAULT


34.   Lower vehicle
35.   Lock camshaft sprockets in position with KM-6340
Note:   Markings (3) on camshaft sprockets must align - otherwise dismantle toothed belt and place in position again
•   Insert KM-6340-Left (1)
•   Insert KM-6340-Right (2)
Object Number: 2412847 Size: DEFAULT


36.   Remove KM-6340
37.   Raise vehicle
38.   Attach front toothed belt cover (bottom)
•   Tighten 4x bolt 6 Nm
39.   Remove bolt on torsional vibration damper
•   Lock flywheel with KM-911 or KM-6625
•   Unscrew bolt
40.   Fit torsional vibration damper
Important:   Use new bolt
•   Tighten bolt 95 Nm + 45° + 15°
41.   Possibility 1: Remove KM-911
•   Install closure plug
42.   Possibility 2: Detach KM-6625
•   Detach screwed connection
•   Tighten bolted connection
– Use new nuts
43.   Attach ribbed V-belt tensioner
•   Tighten bolt 50 Nm
44.   Insert ribbed V-belt
Note:   Observe direction of rotation
•   Apply tension to ribbed V-belt tensioner anti-clockwise and place ribbed V-belt in position
•   Remove KM-6130
45.   Attach lower engine compartment cover / splashguard
46.   Lower vehicle
Important:   Ensure that it is latched correctly
47.   Attach front toothed belt cover (top)
•   Tighten 2x bolt 6 Nm
48.  
1. Install air cleaner housing - Z16XEP LUREF_1.gif
2. Install air cleaner housing - Z16XE1 LUREF_1.gif

49.   Connect battery
•   Positive and negative terminal
50.   Program volatile memories
51.   Close bonnet

Replace toothed belt > < Toothed Belt Guide Roller. Replace