How to replace timing belt on Vauxhall/Opel Astra J 1.6i

Replacement Interval Guide

  • Vauxhall recommend replacement every 100,000 miles or 10 years (tensioner pulley and guide pulley must also be replaced).
  • The previous use and service history of the vehicle must always be taken into account.

Check For Engine Damage

CAUTION: This engine has been identified as an INTERFERENCE engine in which the possibility of valve-to-piston damage in the event of a timing belt failure is MOST LIKELY to occur. A compression check of all cylinders should be performed before removing the cylinder head.

Repair Times – hrs

Remove & install 0,80
Hydraulic PAS +0,10

Special Tools

  • Auxiliary drive belt tensioner locking tool – Kent Moore No.KM-6349.
  • Camshaft sprockets locking tool – Kent Moore No.KM-6340.
  • Flywheel locking tool – Kent Moore No.KM-6625.
  • Tensioner pulley locking pin – Kent Moore No.KM-6333.

Special Precautions

  • Disconnect battery earth lead.
  • DO NOT turn crankshaft or camshaft when timing belt removed.
  • Remove spark plugs to ease turning engine.
  • Turn engine in normal direction of rotation (unless otherwise stated).
  • DO NOT turn engine via camshaft or other sprockets.
  • Observe all tightening torques.

How to replace timing belt on Vauxhall/Opel Astra J 1.6i

Removal

WARNING: Engines with variable valve timing: Mark camshaft sprockets and camshaft adjusters with chalk or paint prior to timing belt removal to assist alignment on installation.

  1. Raise and support front of vehicle.
  2. Remove:
      • Air filter housing and hoses.
      • Timing belt upper cover [1] .
      • Engine undershield.
      • RH lower splash guard.
  3. Turn auxiliary drive belt tensioner to release tension on belt. Use ring spanner.
  4. Lock auxiliary drive belt tensioner [2] . Use tool No.KM-6349.
  5. Remove:
      • Auxiliary drive belt.

NOTE: DO NOT refit used belt.

  • Auxiliary drive belt tensioner.
  • Remove RH plate from camshaft sprockets locking tool [3] .
  • Turn crankshaft clockwise to TDC on No.1 cylinder. Ensure timing marks aligned [4] .
  • Fit camshaft sprockets locking tool [5] . Tool No.KM-6340.
  • Ensure timing mark aligned with groove on camshaft sprockets locking tool [6] & [7] .
  • Ensure timing mark on inlet camshaft adjuster is positioned above groove on camshaft sprockets locking tool [7] & [8] .
  • Slacken tensioner pulley bolt [9] .
  • Turn tensioner pulley clockwise until locking pin can be inserted. Tool No.KM-6333 [10] . Use Allen key [11] .
  • Remove bolt from cylinder block. Install flywheel locking tool [12] . Tool No.KM-6625.
  • Remove:
      • Crankshaft pulley bolt [13] .
      • Crankshaft pulley [14] .
      • Timing belt lower cover [15] .
      • Guide pulley.
      • Timing belt.
      • Tensioner pulley bolt [9] .
      • Tensioner pulley.

    NOTE: Mark direction of rotation on belt with chalk if belt is to be reused.

    Installation

    NOTE: If reusing old belt, observe direction of rotation marks on belt.

    1. Ensure timing marks aligned [16] .
    2. Ensure timing mark aligned with groove on camshaft sprockets locking tool [6] & [7] .
    3. Ensure timing mark on inlet camshaft adjuster is positioned above groove on camshaft sprockets locking tool [7] & [8] .
    4. Fit new guide pulley and bolt [17] . Tightening torque: 25 Nm.
    5. Fit new tensioner pulley and bolt [9] . Tightening torque: 20 Nm.
    6. Ensure tensioner pulley locking pin inserted [10] .

    NOTE: New belt supplied from manufacturer with fitting/assembly tool. Remove tool after fitment of belt.

  • Fit timing belt in following order:
      • Tensioner pulley.
      • Crankshaft sprocket.
      • Camshaft sprocket (CA2).
      • Camshaft sprocket (CA1).
  • Ensure belt is taut between sprockets.
  • Turn tensioner pulley clockwise until locking pin can be removed [10] .
  • Release tensioner to tension belt automatically.
  • Tighten tensioner pulley bolt [9] . Tightening torque: 20 Nm.
  • Fit timing belt lower cover [15] .
  • Fit crankshaft pulley [14] .
  • Fit new crankshaft pulley bolt [13] . Coat threads of bolt with suitable thread locking compound. Tightening torque: 95 Nm + 30° + 15°.
  • Remove:
      • Flywheel locking tool [12] .
      • Camshaft sprockets locking tool [5] .
  • Turn crankshaft slowly two turns in direction of rotation to TDC on No.1 cylinder.
  • Fit camshaft sprockets locking tool [5] .
  • Ensure timing mark aligned with groove on camshaft sprockets locking tool [6] & [7] .
  • Ensure timing mark on inlet camshaft adjuster is positioned above groove on camshaft sprockets locking tool [7] & [8] .
  • Ensure timing marks aligned [4] .
  • Remove camshaft sprockets locking tool [5] .
  • Install components in reverse order of removal.

    NOTE: Observe direction of rotation marks on auxiliary drive belt.

    NOTE: If battery has been disconnected, re-initialization of window and sunroof motors may be required.

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