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Vauxhall Workshop Service and Repair Manuals

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Timing, Check > < Vacuum Pump, Remove and Install

Astra H

Toothed Belt Tension, Check and Adjust

  Remove

1.   Open bonnet
2.   Remove engine cover
3.   Remove air cleaner housing
4.   Raise vehicle by its full height
5.   Detach the lower engine cover and right engine splash guard
6.   Fit and adjust KM-6397
•   Fit KM-6397
– Insert upper bracket (2) with support plate below lower oil pan
– Attach lower bracket (3)
– Tighten 2x bolts (1)
•   Adjust KM-6397
– Screw in 2x adjusting bolts (4)
Note:   Support plate (5) must lie flat against oil pan
Object Number: 7360962 Size: DEFAULT


Object Number: 7361595 Size: DEFAULT

7.   Fit KM-6001-A
Note:   Attaching KM-6001-A guarantees perfect alignment of the drive unit with the front axle body
•   Detach front right bracket (1)
•   Insert KM-6001-A
•   Attach front right bracket
•   Insert journals (4) and (5) in guide holes in front axle body
•   Tighten 2x guide rails
– Tighten 3x bolted connections
•   Adjust support bearings (2) and (3)
Note:   The guide journals must be seated free from play in the support bearings

8.   Remove ribbed V-belt
9.   Remove torsional vibration damper (1)
•   Unscrew 4x bolts
Note:   Counterhold toothed belt drive gear at bolt (2)
Object Number: 7360963 Size: DEFAULT


10.   Remove upper ribbed V-belt guide roller (1)
•   Unscrew bolt
Object Number: 7360964 Size: DEFAULT


11.   Lower vehicle by its full height
12.   Remove right engine damping block (1)
•   Detach from engine damping block adapter
– Unscrew 3x bolts (2)
•   Detach from side member
– Unscrew 3x bolts (3)
Object Number: 7360965 Size: DEFAULT


13.   Remove toothed belt cover
•   Unscrew 6x bolt (arrows)
Object Number: 2408169 Size: DEFAULT


14.   Remove engine damping block adapter (1)
•   Unscrew 5x bolts
Note:   Note different bolt lengths
Object Number: 7360966 Size: DEFAULT


15.   Set cylinder no. 1 to TDC of combustion stroke
•   The mark on the camshaft sprocket (1) must align with the mark on the cylinder head cover (2).
Object Number: 2408170 Size: DEFAULT


16.   Toothed Belt Tension, Check
•   Pointer of toothed belt tension roller (1) and bore (arrow) must align.
Note:   If pointer and bore do not align, the toothed belt tension must be reset
Object Number: 3446061 Size: DEFAULT


17.   Remove toothed belt (1)
Note:   Mark direction of rotation
•   Slacken toothed belt tension roller
– Loosen bolt (2)
Object Number: 2408566 Size: DEFAULT


18.   Remove toothed belt tension roller
•   Unscrew bolt

  Install

19.   Clean the thread
20.   Install toothed belt tension roller
Note:   Insert tension roller in guide
•   Screw in bolt
Note:   Insert bolt with locking compound (red). The maximum installation time including torque check is 10 minutes.
21.   Set cylinder no. 1 to TDC of combustion stroke
•   The mark on the camshaft sprocket must align with the mark on the cylinder head cover.
22.   Install toothed belt
Note:   Observe direction of rotation
Important:   Tightened end (1) must be taut
•   Position toothed belt
23.   Raise vehicle by its full height
24.   Tension the toothed belt
•   Screw in bolt (6)
•   Tension the toothed belt
Note:   Push adjusting lever in direction of arrow with a screwdriver (5) until pointer (4) of toothed belt tension roller aligns with mark (2)
•   Tighten bolt, toothed belt tension roller (3) 25 Nm
Object Number: 2408567 Size: DEFAULT


25.   Check crankshaft setting with EN-46788
•   Unscrew oil pump bolt (arrow)
•   Tighten stud bolt (1) EN-46788
•   Attach positioning disk (4) EN-46788
– Screw in bolt (3)
– Screw in nut (2)
•   Remove positioning disk EN-46788
Object Number: 3446087 Size: DEFAULT


26.   Lower vehicle by its full height
27.   Timing, Check
•   Turn crankshaft 720° in the direction of rotation of the engine
•   Check camshaft position
– The mark on the camshaft sprocket must align with the mark on the cylinder head cover.
28.   Raise vehicle by its full height
29.   Check crankshaft setting with EN-46788
Note:   If EN-46788 cannot be fitted, repeat the toothed belt positioning procedure.
•   Fit EN-46788
– Screw in bolt
– Screw in nut
•   Remove EN-46788
– Unscrew stud bolt EN-46788
•   Tighten oil pump bolt 9 Nm
30.   Lower vehicle by its full height
31.   Install engine damping block adapter
Note:   Note different bolt lengths
•   Tighten 3x bolt (M10) 50 Nm
•   Tighten 2x bolt (M8) 25 Nm
32.   Install toothed belt cover
•   Tighten 4x bolt (M6) 9 Nm
•   Tighten 2x bolt (M8) 25 Nm
•   4x clip in camshaft sensor wiring harness
33.   Install right engine damping block
•   Attach engine damping block to adapter
– Tighten 3x bolt 55 Nm
•   to side member
– Tighten 3x bolt 35 Nm
34.   Raise vehicle by its full height
35.   Remove KM-6001-A
36.   Remove KM-6397
37.   Install upper ribbed V-belt guide roller
•   Tighten bolt 50 Nm
38.   Install torsional vibration damper
Note:   Observe correct fitting position
•   Tighten 4x bolt 25 Nm
Note:   Counterhold toothed belt drive gear at bolt
39.   Install ribbed V-belt
40.   Install lower engine cover and right engine splash guard
41.   Lower vehicle by its full height
42.   Install air cleaner housing LUREF_1.gif
43.   Install engine cover
44.   Close bonnet

Timing, Check > < Vacuum Pump, Remove and Install