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Vauxhall Workshop Service and Repair Manuals

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Toothed Belt Tension, Adjust > < Replace front toothed belt cover (lower)

Astra H

Replace rear toothed belt cover

  Remove

1.   Open bonnet
2.   Disconnect battery
3.   Remove air filter housing with mass air flow meter
•   Detach mass air flow meter wiring harness plug (3)
•   Detach air intake hose from air intake pipe
– Release clamp (2)
•   Unscrew bolt (1)
Object Number: 3446510 Size: DEFAULT


4.   Remove toothed belt cover upper section
•   Unscrew 2x bolts (1)
Object Number: 2397738 Size: DEFAULT


5.   Remove ribbed V-belt
•   Mark direction of travel of ribbed V-belt.
•   Apply tension to ribbed V-belt tensioner in the direction of the arrow with KM-913
•   Immobilise with KM-6130
– Remove ribbed-V-belt
Object Number: 2397746 Size: DEFAULT


6.   Raise vehicle by its full height
7.   Remove right-hand engine splash protection and lower engine compartment cover
8.   Remove ribbed V-belt tensioner
•   Unscrew 2x bolts (1)
Object Number: 2397747 Size: DEFAULT


9.   Remove torsional vibration damper
•   Unscrew 4x bolts
– Counterhold at toothed belt drive gear fastening bolt
10.   Remove lower part of toothed belt cover
•   Unscrew 2x bolts (1)
•   Detach lower section of toothed belt cover from rear toothed belt cover
Object Number: 2397739 Size: DEFAULT


11.   Attach KM-6173 (3) to front axle body
•   Turn support bearing (2) upwards until the journal sits flush in the mounting (1) on the cylinder block, then secure it.
– Tighten 2x bolts
Object Number: 2398553 Size: DEFAULT


Object Number: 2414110 Size: DEFAULT

12.   Attach KM-6001-A (1)
Note:   Attaching KM-6001-A guarantees perfect alignment of the drive unit with the front axle body
13.   Slacken adjusting rail bolts (arrows) on KM-6001-A .
14.   Insert KM-6001-A as shown
Note:   The journals (2) and (5) must sit in the guide holes of the front axle body
15.   Tighten adjusting rail bolts.
16.   Screw up front support bearing (4) and rear support bearing (3) until they rest against front engine damping block guide journals and rear engine damping block bracket
Note:   Guide journals must rest in support bearings without play

17.   Lower vehicle completely
18.   Detach right engine damping block (1)
•   Detach from side member
– Unscrew 3 bolts
•   Detach from engine damping block support
– Unscrew 3 bolts
Object Number: 2397853 Size: DEFAULT


19.   Turn engine to "Cylinder 1 TDC" (marking 3)
•   Move crankshaft in direction of engine rotation to "cylinder 1 TDC" (mark 3)
Important:   Turn crankshaft slowly and smoothly
•   Rotate at toothed belt drive gear bolt
Note:   Notches on camshaft sprockets must align with marks (1) on cylinder head cover
20.   Lock camshafts with KM-853 (2)
21.   Detach toothed belt
•   Mark toothed belt direction of rotation
•   Undo toothed belt tension roller bolt
•   Rotate eccentric adjuster in direction of arrow (clockwise) until pointer (4) is just before left stop
•   Remove toothed belt
Object Number: 2397740 Size: DEFAULT


22.   Remove KM-853
23.   Detach exhaust-side camshaft sprocket
•   Attach KM-6347 (1) and KM-956-1 (2) to camshaft sprocket on exhaust side
– Release fixing bolts (3) from KM-6347 (1)
– Insert KM-6347 in camshaft sprocket
Note:   Grooves in KM-6347 (arrows) must engage in camshaft sprocket.
– Turn KM-6347 in direction of arrow and tighten fixing bolts
•   Slacken bolt (4) of camshaft sprocket
– Hold using KM-6347
Note:   2 mechanics required
•   Remove KM-6347
– Slacken fixing bolts of KM-6347
•   Unscrew camshaft sprocket bolt (4)
– Remove camshaft timing gear
Object Number: 2412317 Size: DEFAULT


24.   Detach camshaft sprocket on intake side
Note:   Repeat the exhaust side camshaft procedure for the intake side.
25.   Detach cover from cylinder head cover
•   Disconnect wiring harness plug from ignition module
26.   Remove camshaft sensor (1)
•   Disconnect camshaft sensor wiring harness plug
•   Unscrew bolt
27.   Remove 2x toothed belt guide roller (2)
•   Unscrew 2x bolts
28.   Remove engine damping block support (3)
•   Unscrew 3 bolts
29.   Remove toothed belt tension roller (4)
•   Unscrew bolt
30.   Release rear toothed belt cover from top of cylinder head
•   Unscrew 2x bolt (8) from cylinder head
31.   Raise vehicle by its full height
32.   Remove toothed belt drive gear (6)
•   Unscrew bolt
– Counterhold with KM-662-C (5)
33.   Remove rear toothed belt cover
•   Detach 2x bolt (7) from oil pump
Object Number: 2397735 Size: DEFAULT


  Install

34.   Attach rear toothed belt cover to oil pump
•   Tighten 2x bolt 8 Nm
35.   Install toothed belt drive gear
Note:   Pay attention to condition of spring washer
•   Tighten new bolt 130 Nm + 45° ± 5°
– Counterhold with KM-662-C
36.   Lower vehicle completely
37.   Fasten rear toothed belt cover to top of cylinder head
•   Tighten 2x bolt on cylinder head 8 Nm
38.   Install toothed belt tension roller
•   Tighten bolt
Note:   Ensure that detent lever (1) engages in oil pump guide web - tightening to torque does not take place until toothed belt tension has been adjusted
Object Number: 2387623 Size: DEFAULT


39.   Attach engine damping block support to cylinder block
•   Tighten 3x bolt 50 Nm
40.   Attach intake side toothed belt guide roller to cylinder block
•   Tighten bolt 25 Nm
41.   Attach exhaust side guide roller toothed belt to engine damping block support
•   Tighten bolt 25 Nm
42.   Attach camshaft sensor to cylinder head
•   Tighten bolt 6 Nm
•   Fix wiring harness plug
43.   Replace cover on cylinder head cover
•   Connect ignition module wiring harness plug
44.   Attach exhaust-side camshaft sprocket
•   Install camshaft sprocket with timing marks on front
•   Screw in new camshaft sprocket bolt (4)
Note:   Do not tighten
– Attach KM-6347 (1) in conjunction with KM-956-1 (2) to camshaft sprocket
– Release fixing bolts (3) from KM-6347
– Insert KM-6347 in the camshaft sprocket - ensure it is correctly seated
Note:   The grooves of KM-6347 (arrows) must engage with camshaft timing gear
– Turn KM-6347 in the direction of the arrow
– Tighten fixing bolts
Object Number: 2412855 Size: DEFAULT


45.   Tighten camshaft on exhaust side 50 Nm + 60° + 15°
•   Hold using KM-6347
Note:   2 mechanics required
46.   Remove KM-6347
47.   Attach intake side camshaft sprocket
Note:   Use same procedure as for exhaust side
48.   Tighten camshaft on intake side 50 Nm + 60° + 15°
•   Hold using KM-6347
Note:   2 mechanics required
49.   Remove KM-6347
50.   Turn camshaft sprockets to "Cylinder 1 TDC"
•   Set camshaft sprockets to marking
Note:   Mark (1) on cylinder head cover aligns with notches on camshaft sprockets
  1. Intake camshaft sprocket
  2. Exhaust camshaft sprocket
51.   Lock camshaft sprockets in position with KM-853 (2)
52.   Detach KM-6347 from camshaft sprockets with KM-956-1
Object Number: 2413261 Size: DEFAULT


53.   Set crankshaft to "Cylinder 1 TDC" (use shorter route)
54.   Install toothed belt
•   Check toothed belt for wear – replace if necessary.
•   Pay attention to toothed belt direction of movement. Fit toothed belt
Note:   Ensure that tension side (I) is taut
Note:   Observe timing marks!
Object Number: 2397741 Size: DEFAULT


55.   Adjust toothed belt tension LUREF_1.gif
56.   Adjust timing
57.   Fit engine damping block to longitudinal beam
•   Tighten 3x bolt 35 Nm
58.   Attach engine damping block bracket to engine damping block support
•   Tighten 3x bolt 55 Nm
59.   Raise vehicle by its full height
60.   Remove mounts KM-6001-A and KM-6173 .
61.   Attach bottom part of toothed belt cover to rear toothed belt cover
•   Tighten 2x bolt 6 Nm
62.   Attach torsional vibration damper to toothed belt drive gear
•   Tighten 4x bolt 20 Nm
– Counterhold at toothed belt drive gear fastening bolt
63.   Install ribbed V-belt tensioner
•   Screw in 2x bolts
– Tighten compressor support bolt 25 Nm
64.   Install right-hand engine splash protection and lower engine compartment cover
65.   Lower vehicle by its full height
66.   Tighten ribbed V-belt tensioner at top
•   Tighten bolt 25 Nm
67.   Position ribbed V-belt
•   Ensure running direction and installation position of ribbed V-belt is correct
68.   Tension ribbed V-belt tensioner (clockwise) and remove detent
69.   Install front toothed belt cover (top)
•   Clip in to rear toothed belt cover
•   Tighten 2x bolt 6 Nm
70.   Install air cleaner housing with mass air flow meter
•   Insert air cleaner housing
•   Attach air intake hose to air intake pipe
– Fasten clamp
•   Screw in bolt
•   Connect mass air flow meter wiring harness plug
71.   Connect battery
72.   Program volatile memories
73.   Close bonnet

Toothed Belt Tension, Adjust > < Replace front toothed belt cover (lower)