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Timing Belt Rear Cover Replacement - 1.6L LDE, LXV, 1.8L 2H0, LUW and LFH > < Crankshaft Rear Oil Seal Replacement

Astra J

Timing Belt Replacement (1.6L LDE, LXV, 1.8L 2H0, LUW and LFH)

Special Tools

•  EN-6333   Timing Belt Tensioner Locking Pin
•  EN-6340   Camshaft Locking Tool
•  EN-6625   Crankshaft Locking Device

For equivalent regional tools, refer to Special Tools .

Removal Procedure

1. Open the hood.
2. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement .
3. Remove the timing belt upper front cover. Refer to Timing Belt Upper Front Cover Removal .
4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
5. Remove the front compartment splash shield. Refer to Front Compartment Splash Shield Replacement .
6. Remove the drive belt tensioner. Refer to Drive Belt Tensioner Replacement .

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7. Set crankshaft balancer in direction of engine rotation until the markings (1) line up with the cylinder 1 at TDC.
8. Remove the crankshaft balancer. Refer to Crankshaft Balancer Replacement .

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9. Remove the 4 lower timing belt cover bolts (2).
10. Remove the lower timing belt cover (1).
11. Lower the vehicle.

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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.
12. Prepare the right half of the EN-6340   locking tool .
  12.1 Remove the 2 bolts (2).
  12.2 Remove the front panel (1) from the EN-6340   locking tool - right.

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13. Install EN-6340   locking tool into the camshaft position actuator adjusters.
Note:  The spot type marking (4) on the intake camshaft adjuster does not correspond to the groove of EN-6340-left during this process but must be somewhat above as shown.
   
  •  Install EN-6340-left   locking tool (1) in the camshaft position actuator adjusters as shown.
Note:  The spot type marking (3) on the exhaust camshaft adjuster must correspond to the groove on EN-6340-right.
   
  •  Install EN-6340   locking tool - right (2) in the camshaft position actuator adjusters as shown.
14. Raise the vehicle.

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15. Apply tension to the timing belt tensioner (2) in the direction of the arrow, using an Allen key (1).
16. Install the EN-6333   locking pin (3).
17. Lower the vehicle.

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Note:  Note the direction of the belt, if the timing belt will be reused.
18. Remove the timing belt (1).

Installation Procedure


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Note:  Threading the timing belt through the engine mount bracket is only permissible in conjunction with the assembly tool supplied with NEW timing belts or otherwise it is possible to damage the toothed belt at this stage by kinking it.

Note:  If the toothed belt has been used, observe the direction of rotation.
1. Install the timing belt (1) in the enclosed assembly tool (2).
2. Guide the timing belt through the engine mount bracket with the assembly tool.
3. Remove the assembly tool.

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4. Install the timing belt (1).
5. Guide the timing belt past the tensioner and place it on the crankshaft sprocket wheel.
6. Place the timing belt on the exhaust and intake camshaft position actuator adjusters.
7. Raise the vehicle.

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

Note:  The timing belt tensioner moves automatically to the correct position.
10. Release tension on timing belt tensioner.

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11. Remove the fastener (1).
12. Remove EN-6625   locking device (2).
13. Lower the vehicle.
14. Remove EN-6340   locking tool .

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15. Check the timing.
Note:  Note the marking at the camshaft sprockets.
   
  •  Turn the crankshaft 720° in the direction of engine rotation by the bolt on the crankshaft balancer.
Note:  The spot type marking (4) on the intake camshaft position actuator adjuster does not correspond to the groove of EN-6340-left during this process but must be slightly above as shown.
   
  •  Install EN-6340   locking tool - left (1) into the camshaft position actuator adjusters as shown.
Note:  The spot type marking (3) on the exhaust camshaft position actuator adjuster must correspond to the groove on EN-6340-right.
   
  •  Install EN-6340   locking tool - right (2) into the camshaft position actuator adjusters as shown.
16. Raise the vehicle.

           2027014



Note:  The crankshaft sprocket and oil pump housing must align.
17. Check the crankshaft position.
18. Lower the vehicle.
19. Remove the EN-6340   locking tool .
20. Raise the vehicle.

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21. Install the lower timing belt cover (1).

Caution: Refer to Fastener Caution

22. Install the 4 lower timing belt cover bolts (2) and tighten to 6 N·m (53 lb in) .
23. Install the crankshaft balancer. Refer to Crankshaft Balancer Replacement .
24. Install the drive belt tensioner. Refer to Drive Belt Tensioner Replacement .
25. Install the compartment splash shield. Refer to Front Compartment Splash Shield Replacement .
26. Lower the vehicle.
27. Install the timing belt upper front cover. Refer to Timing Belt Upper Front Cover Replacement .
28. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement .
29. Close the hood.

Timing Belt Rear Cover Replacement - 1.6L LDE, LXV, 1.8L 2H0, LUW and LFH > < Crankshaft Rear Oil Seal Replacement