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Crankshaft Rear Oil Seal Replacement > < Engine Flywheel Replacement

Astra J

Timing Belt Replacement

•  EN-956-1   Extension
•  EN-46788   Crankshaft Fixing Tool
•  EN-46789   Camshaft Locking Tool
•  EN-47634   Camshaft Sprocket Holding Tool

For equivalent regional tools, refer to Special Tools .

Removal Procedure

1. Open the hood.
2. Protect the fender with covers.
3. Remove the battery cover and disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .
4. Remove the engine sight shield. Refer to Engine Sight Shield Replacement .
5. Remove the front wheelhouse liner. Refer to Front Wheelhouse Liner Replacement .
6. Remove the engine mount bracket. Refer to Engine Mount Bracket Replacement .
7. Lower the vehicle. Refer to Lifting and Jacking the Vehicle .

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Note:  Avoid the contact with cooling fluid and oil, it will damage the timing belt and can not be reused.
8. Set the cylinder one to TDC:
  •  Remove the camshaft housing closure bolt.
  •  Install the EN-46789   locking tool (1) in the camshaft housing.
  •  Turn the engine clockwise until the EN-46789   locking tool (1) audibly engages.

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9. Remove the oil pump bolt (1).

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10. Install the fixing tool stud (1) of the EN-46788   fixing tool .

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11. Lock the crankshaft, using the EN-46788   fixing tool (1).

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12. Loosen the camshaft sprocket (1).
13. Loosen the camshaft sprocket bolt, by using the EN-47634   holding tool (2) with the EN-956-1   extension (3).

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14. Loosen the timing belt tensioner bolt (2) to release the tension from the timing belt.
15. Remove the EN-46788   fixing tool .

Note:  DO NOT damage the timing belt. A damaged timing belt can not be reused.

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

Installation Procedure


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1. Lock the crankshaft, using the EN-46788   fixing tool (1).
   
  •  Install the NEW timing belt to the crankshaft sprocket.
Note:  Make sure that the timing belt does not fall out of the sprocket during the installation procedure.
  •  Install the EN-46788   fixing tool (1).

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2. Install the timing belt in the following sequence:

Note:  The marks on the timing belt must fit to the marks on the sprockets, see arrows in picture.

Note:  The timing belt tensioner must be lose.
  •  Start with the crankshaft sprocket (4).
  •  Second the timing belt tensioner (5).
  •  Third the water pump (6).
  •  Fourth the high pressure pump sprocket (1).
  •  Fifth the camshaft sprocket (2).
  •  The last one is the belt idler pulley (3).

Caution: Refer to Fastener Caution .

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3. Bring the tensioner (1) in correct tension.
  •  Loosen the tensioner bolt.
  •  Bring the mobile index to the reference position (bore), see at arrows in picture.
  •  Tighten the tensioner bolt to 25 N·m (18 lb ft) .

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4. Fasten the camshaft sprocket bolt.
  •  Install the EN-47634   holding tool (2) to the camshaft sprocket (1).
  •  Hold up with the EN-956-1   extension (3) and tighten the camshaft sprocket bolt to 120 N·m (89 lb ft) .
5. Remove the EN-47634   holding tool (2) and the EN-956-1   extension (3).
6. Remove the EN-46788   fixing tool and the EN-46789   locking tool .

Note:  It is absolute necessary to turn the engine clockwise, not in another direction.
7. Rotate the engine 720°.
8. Check the engine timing.
  •  Install the EN-46789   locking tool .
  •  Install the EN-46788   fixing tool .
9. Remove the EN-46789   locking tool and the EN-46788   fixing tool .

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10. Install the oil pump bolt and tighten to 9 N·m (80 lb in) .
11. Install the engine mount bracket. Refer to Engine Mount Bracket Replacement .
12. Install the front wheelhouse liner. Refer to Front Wheelhouse Liner Replacement .
13. Lower the vehicle. Refer to Lifting and Jacking the Vehicle .
14. Install the engine sight shield. Refer to Engine Sight Shield Replacement .
15. Connect the negative battery cable and install the battery cover. Refer to Battery Negative Cable Disconnection and Connection .
16. Remove the covers from the fender.
17. Close the hood.

Crankshaft Rear Oil Seal Replacement > < Engine Flywheel Replacement