vauxhall Workshop Repair Guides

Vauxhall Workshop Service and Repair Manuals

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Timing, Check > < Vacuum Pump, Replace

Astra H

Toothed Belt Tension, Adjust

  Remove

1.   Open bonnet
2.   Disconnect battery
•   Detach earth connection from earth terminal
3.   Remove engine cover (2)
•   Detach oil filler port closure cap (1)
•   Pull off engine cover
Note:   Rubber retainers (3) must remain on engine cover
•   Attach oil filler port closure cap
Object Number: 2412632 Size: DEFAULT


4.   Remove air cleaner housing (5) with air intake hose
•   Detach wiring harness plug (2) from hot film mass air flow meter
•   Detach air intake hose from air intake pipe
– Release clamp (1)
•   Detach air cleaner housing from wheel housing
– Unscrew bolt (4)
•   Detach water drain hose (3) from air cleaner housing
– Release clamp
Object Number: 3446547 Size: DEFAULT


5.   Remove ribbed V-belt
•   Mark direction of rotation
•   Apply tension to ribbed V-belt tensioner via bolt (1) in the direction of the arrow
•   Fix ribbed V-belt tensioner to bore (2)
•   Remove ribbed-V-belt
Object Number: 3447354 Size: DEFAULT


6.   Detach wiring trough (4) from front toothed belt cover (top)
•   Unscrew bolt (2)
•   Detach wiring harness (3)
– Disconnect camshaft sensor wiring harness plug
– Release 2x clip
•   Detach vacuum line (1)
– Release 2x clip
•   Unclip wiring trough in direction of arrow
– Undo clip
Object Number: 3447352 Size: DEFAULT


7.   Detach front toothed belt cover (top) (4)
•   Detach vacuum line (3)
– Unclip 3x clip
•   Unscrew 8x bolts
Note:   Note different bolt lengths
•   Remove camshaft sensor bracket (1)
– Unscrew bolt (2)
Object Number: 3447353 Size: DEFAULT


8.   Raise vehicle by its full height
9.   Detach the lower engine cover and right engine splash guard
10.   Insert KM-6173 (3)
•   Align support bearing (1)
•   Raise support bearing until journal (2) sits flush in mount (4)
•   Fasten KM-6173
– Screw in 2x bolts
Object Number: 2412781 Size: DEFAULT


11.   Attach KM-6001-A (1)
Note:   Attaching KM-6001-A guarantees perfect alignment of the drive unit with the front axle body
•   Slacken 4x bolts (arrows) in adjusting rails
•   Insert KM-6001-A
– Insert journals (2) and (5) in guide holes in front axle body
•   Tighten 4x bolts in adjusting rails
•   Adjust support bearings, front (4) and rear (3)
– Raise support bearings up to the stop on the guide journals
Note:   The guide journals must be seated free from play in the support bearings
Object Number: 2414110 Size: DEFAULT


12.   Detach torsional vibration damper (1)
•   Unscrew 4x bolts
Note:   Counterhold at bolt (2)
Object Number: 2412637 Size: DEFAULT


13.   Lower vehicle by its full height
14.   Remove engine damping block support
•   Detach from engine damping block bracket
– Unscrew 3x bolts (2)
•   Detach from cylinder block
– Unscrew 3x bolts (3)
•   Remove engine damping block adapter (1)
Object Number: 2412638 Size: DEFAULT


15.   Remove coolant pump drive gear (1)
•   Unscrew 3 bolts
Object Number: 2412639 Size: DEFAULT


16.   Remove front toothed belt cover (lower) (1)
•   Unscrew 3x bolts (2)
Object Number: 2412640 Size: DEFAULT


17.   Slacken the toothed belt tension roller
•   Loosen bolt (1)
Object Number: 2413421 Size: DEFAULT


18.   Turn crankshaft 60° against the direction of engine rotation
Object Number: 2412643 Size: DEFAULT


  Install

19.   Fasten toothed belt tension roller
•   Tighten bolt 38.2 Nm
20.   Install front toothed belt cover (lower)
•   Tighten 3x bolt 9.8 Nm
21.   Install coolant pump drive gear
•   Tighten 3x bolt 12.3 Nm
22.   Install engine damping block bracket
•   Insert engine damping block adapter
•   Attach engine damping block support to cylinder block
– Tighten 3x bolt 50 Nm
•   Engine damping block support to engine damping block bracket
– Tighten 3x bolt 55 Nm
23.   Raise vehicle by its full height
Important:   Journal (1) of toothed belt drive gear must engage in the bore (2) of the torsional vibration damper
24.   Install torsional vibration damper
•   Tighten 4x bolt 19.6 Nm
Note:   Counterhold against bolt, toothed belt drive gear
Object Number: 2412652 Size: DEFAULT


25.   Remove engine mount KM-6173
26.   Remove engine mount KM-6001-A
27.   Install lower engine cover and right engine splash guard
28.   Lower vehicle by its full height
29.   Install front toothed belt cover (top)
•   Tighten 8x bolt 9.8 Nm
Note:   Note different bolt lengths
•   Install camshaft sensor bracket
– Tighten bolt 9.8 Nm
•   Attach vacuum line to toothed belt cover
– Clip in 3x clips
30.   Attach wiring trough to front toothed belt cover (top)
•   Attach wiring trough
– Attach clip
•   Tighten bolt 9.8 Nm
•   Attach wiring harness
– Clip in 2x clips
– Connect camshaft sensor wiring harness plug
•   Attach vacuum line
– Clip in 2x clips
31.   Insert ribbed V-belt
Note:   Note running direction of ribbed V-belt
•   Position ribbed V-belt
– I. Ribbed V-belt without air conditioning
– II. Ribbed V-belt with air conditioning
•   Apply tension to ribbed V-belt tensioner via bolt (1) in the direction of the arrow
•   Take out fixing
•   Release ribbed V-belt tensioner
Object Number: 2415977 Size: DEFAULT


32.   Install air cleaner housing with air intake hose
•   Attach water drain hose to air cleaner housing
– Fasten clamp
•   Tighten bolt 15 Nm
•   Attach air intake hose to air intake pipe
– Fasten clamp 3.5 Nm
•   Connect wiring harness plug to air mass flow meter
33.   Install engine cover
•   Detach oil filler port closure cap
•   Refit engine cover
•   Attach oil filler port closure cap
34.   Connect battery
•   Attach earth connection to earth terminal
35.   Program volatile memories
36.   Close bonnet

Timing, Check > < Vacuum Pump, Replace