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Engine Replacement - 1.6L LDE - 6T40 > < Timing Belt Adjustment - LDE, LED, LFJ, LXV, 2H0, LUW, LFH

Astra J

Timing Belt Adjustment (1.6L LLU)

Special Tools

•  EN-652   Flywheel Holder
•  EN-6333   Locking Pin
•  EN-6340   Locking Tool
•  EN-45059   Torque Angle Sensor Kit

For equivalent regional tool, refer to Special Tools .

Removal Procedure

1. Remove the timing belt upper front cover. Refer to Timing Belt Upper Front Cover Removal .

           1936993


2. Set the crankshaft balancer in the direction of the engine rotation to "1st cylinder TDC" (mark 1).

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Note:  Markings (3) on EN-6340   locking tool (1, 2) must align.
3. Insert the EN-6340   locking tool (1, 2) into the camshaft sprocket wheels.

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4. Install the EN-6333   locking pin (3), apply tension to the timing belt tension roller (2) in the direction of the arrow, using an Allen key (1).

           2028375


5. Install the EN-652   flywheel holder (1), lock the flywheel (2) (or automatic transmission flex respectively) via the starter ring gear.

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6. Remove the bolt (1) and the crankshaft balancer (2).

           2188662


7. Remove the 4 timing belt lower front cover bolts (2).
8. Remove the timing belt lower front cover (1).

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Note:  Observe direction of rotation.
9. Remove the timing belt (1).

Installation Procedure


           2027014



Note:  The timing belt drive gear and oil pump housing must align.
1. Set the engine to top dead center (TDC).
  Turn the crankshaft in the direction of engine rotation, by the crankshaft balancer bolt, to cylinder 1 TDC of combustion stroke.

           2026841



Note:  Observe direction of rotation.
2. Insert the timing belt (1).

           1937014


3. Apply tension to the timing belt tensioner (2) in the direction of the arrow, using an allen key (1).
4. Remove the EN-6333   locking pin (3).

Caution: Refer to Fastener Caution .

           2026840


5. Install the lower front timing belt cover (1) and tighten the 4 bolts (2) to 6 N·m (53 lb in) .

           2026822


6. Install the crankshaft balancer (2) and a NEW bolt (1) and tighten in 3 passes using the EN-45059   sensor kit :
  6.1 First pass to 95 N·m (70 lb ft) .
  6.2 Second pass to 45° .
  6.3 Third pass to 15° .
7. Remove the EN-652   flywheel holder .
8. Remove the EN-6340   locking tool .
9. Check the position of the camshaft sprocket.
  9.1 Turn the crankshaft 720° in the direction of engine rotation by the crankshaft balancer bolt.
Note:  Note marking, camshaft sprocket.
  9.2 Insert the EN-6340   locking tool into the camshaft sprockets.

           1936993


10. Check the crankshaft position.
  Marking on crankshaft balancer must align with marking on timing belt lower cover, see mark (1).
11. Install the timing belt upper front cover. Refer to Timing Belt Upper Front Cover Installation .

Engine Replacement - 1.6L LDE - 6T40 > < Timing Belt Adjustment - LDE, LED, LFJ, LXV, 2H0, LUW, LFH