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Timing Belt Adjustment - 1.6L LLU > < Engine Support Fixture

Astra J

Timing Belt Adjustment (LDE, LED, LFJ, LXV, 2H0, LUW, LFH)

Special Tools

•  EN-652   Flywheel Holder
•  EN-6333   Locking Pin
•  EN-6340   Locking Tool
•  EN-6628-A   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).
3. Remove the camshaft cover. Refer to Camshaft Cover Removal .

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Note:  The right half of the EN-6340   locking tool can be recognised by the lettering "right", arrow, on the tool.
4. Prepare the right half of the EN-6340   locking tool .
  4.1 Remove the 2 bolts (2).
  4.2 Remove the front panel (1) from the EN-6340   locking tool - right.

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Note: 
•  The spot type marking (4) on the intake camshaft position actuator adjuster does not correspond to the groove of the EN-6340   locking tool - left (1) during this process, but must be somewhat above.
•  The spot type marking (3) on the exhaust camshaft position actuator adjuster must correspond to the groove on EN-6340   locking tool - right (2).

5. Insert the EN-6340   locking tool - left (1) and the EN-6340   locking tool - right (2) in the camshaft position actuator adjuster.

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6. Install the EN-6333   locking pin (1), apply tension to the timing belt tension roller (2) in the direction of the arrow. Install the EN-6333   locking pin (3).
7. Mark timing belt in direction of rotation.

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8. 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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9. Remove and DISCARD the crankshaft balancer bolt (1).
10. Remove the crankshaft balancer (2).

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11. Remove the 4 timing belt lower front cover bolts (2).
12. Remove the timing belt lower front cover (1).

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13. Remove the timing belt idler pulley bolt (1).
14. Remove the timing belt idler pulley (2).

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15. Remove the tensioner bolt (1).
16. Remove the timing belt tensioner (2).

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17. Remove the timing belt (1).
18. Stop the timing belt tensioner (2).
19. Remove the EN-652   flywheel holder to unlock the crankshaft.

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20. Turn the crankshaft 60° (A) against the direction of engine rotation.

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21. Remove the 2 camshaft position actuator adjuster closure bolts (1).

Note:  A second technician is required.
22. Loosen the camshaft position actuator adjuster bolts (2).
  Hold at the appropriate camshaft hexagon.
23. Remove and DISCARD the camshaft position actuator adjuster bolts (2) and the camshaft position actuator adjuster (3).

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24. Align the camshafts horizontally by the hexagon arrows, until the EN-6628-A   locking tool can be inserted in both camshafts.

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25. Insert the EN-6628-A   locking tool (1) into the camshafts.

Installation Procedure


           2026844




Note:  Do not tighten the camshaft adjuster bolts.
1. Install the camshaft position actuator adjuster (3).
2. Install NEW camshaft position actuator adjuster bolts (2).

Caution: Refer to Fastener Caution .

Note:  A second technician is required.
3. Tighten the camshaft position actuator adjuster bolts (2) in three passes:
  Hold at the appropriate camshaft hexagon.
  3.1 First pass tighten to 65 N·m (48 lb ft) .
  3.2 Second pass to 120° .
  3.3 Third pass to 15° .
4. Replace the camshaft position actuator adjuster seal rings.
5. Install the 2 camshaft position actuator adjuster closure plugs (1) and tighten to 30 N·m (22 lb ft) .
6. Remove the EN-6628-A   locking tool .

           2027017



7. Clean the timing belt tensioner thread.
8. Install the timing belt tensioner (2) and tighten the NEW timing belt tensioner bolt (1) to 20 N·m (15 lb ft) .
9. Clean the timing belt idler pulley thread.

           2026843



10. Install the timing belt idler pulley (2) and tighten the NEW bolt (1) to 25 N·m (18 lb ft) .

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

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

           2026841




Note:  Observe direction of rotation.
13. Insert the timing belt (1).
14. Apply preliminary tension clockwise to the timing belt tension roller.
15. Remove the EN-6333   locking pin .
16. Release the tension on the timing belt tensioner.

           2026840



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

           2026822



18. Install the crankshaft balancer (2) and NEW bolt (1) and tighten in 3 passes using the EN-45059   sensor kit :
  18.1 First pass to 95 N·m (70 lb ft) .
  18.2 Second pass to 45° .
  18.3 Third pass to 15° .
19. Remove the EN-652   flywheel holder to unlock the crankshaft.
20. Remove the EN-6340   locking tool .
21. Check position of the camshaft position actuator adjuster.
  21.1 Turn crankshaft 720° in the direction of engine rotation by the crankshaft balancer bolt.
Note:  Note marking, camshaft position actuator adjuster.
  21.2 Insert EN-6340   locking tool into camshaft timing gears.

           2026534



22. Insert the EN-6628-A   locking tool (1) into the camshafts.
23. Align camshafts by hexagon until EN-6628-A   locking tool can be inserted in both camshafts.

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24. Check the crankshaft position.
25. Marking on crankshaft balancer must align with marking on timing belt lower cover, see mark (1).
26. Remove the EN-6628-A   locking tool .
27. Install the camshaft cover. Refer to Camshaft Cover Installation .
28. Install the timing belt upper front cover. Refer to Timing Belt Upper Front Cover Installation .

Timing Belt Adjustment - 1.6L LLU > < Engine Support Fixture