REMOVE INSTAL TOOTHED AND ACCESSORY DRIVE BELT OPEL ASTRA G



OPEL ASTRA G Hatchback (F48_, F08_) 1.6 
Remove/install toothed belt  


Safety instructions 

Rotate engine in the direction of rotation only by the crankshaft pulley.
When turning the camshaft, the crankshaft must not be at TDC.
Crankshaft pulley and camshaft pulley must not be rotated completely with the toothed belt removed.
The toothed belt must not come into contact with oil or coolant!
Adjustment work on the toothed belt must only be carried out with a cold engine.
Note radio code. Disconnect battery (negative terminal).
It is advisable not to reuse the accessory drive belt(s) after removal, but always replace them!

Remove:

Remove engine cover(s).
Disconnect air intake hose from air filter housing.
Disconnect connector at inlet air temperature sensor.
Remove active carbon filter solenoid valve plug.
Disconnect plug - air-mass sensor
Remove right air duct.
Remove crankcase breather hose.
Remove air filter housing.
Lift vehicle Remove the right front wheel.
Remove front wheel arch liner front right. Remove underride guard.
Remove accessory drive belt cover(s).
Accessory drive belt removal
Tension tensioning roller anticlockwise.
Remove fixing device. OE (KM-6130)
Release tensioning roller.
Remove accessory drive belt tensioning device.
Remove closing dowel at the bottom gearbox housing.
Insert crankshaft blocking tool. OE (KM-911)
Unscrew vibration damper screw(s). Remove vibration damper.
Screw in vibration damper screw(s).
Remove toothed belt guard at the bottom. - 
Insert engine support into guide bores of the front axle carrier. OE (KM-6394) (1)
Pins must be seated firmly in the bores. (4) (5)
Raise supports to the engine mounting stop.
(2) (3) (see Figure1) 

Fit support(s) to engine support.
Raise support(s) until the pin sits flush in the engine block bore.
(1) (see Figure2)

Lower vehicle.




Unscrew engine mounting bolt(s). (2)
Unscrew engine damping block screw(s). (4) Remove engine silencer block. (5)
Remove engine mounting. (3)
(see Figure3)

Remove toothed belt guard at the top. (1)  














Set engine to TDC mark of first cylinder. (Arrows)
(see Figure4)











Tighten tensioning roller with suitable tool, in the opposite direction of spring strength.
Set tensioning device using adjusting tool. (1)
(see Figure6)


Disconnect coolant pump.
Loosen toothed belt by turning coolant pump anti-clockwise. OE (KM-421-B)

Remove toothed belt.  






Install:

TDC - Check markings, adjust if necessary. Marks must align.
(see Figure4) and (see Figure5)

When turning the camshaft, the crankshaft must not be at TDC.

Toothed belt must not be kinked during fitting.

Fit toothed belt.
Tighten tensioning roller with suitable tool, in the opposite direction of spring strength.
Remove fixing device.
(see Figure6)

Tension toothed belt by turning coolant pump clockwise. OE (KM-421-B)
Indicator slightly in front of the upper stop. (3) (4)
(see Figure6)

Tighten coolant pump.
Tightening torque : 8 Nm

Rotate engine two revolutions in the engine rotating direction.
Set engine to TDC mark of first cylinder. (Arrows)
(see Figure4)

Marks must align. (1) (2)
(see Figure5) 



--------------------------------------------------------------------------------

Disconnect coolant pump.
Loosen toothed belt by turning coolant pump anti-clockwise.
Indicator must align with the recess in the baseplate. (3) (4)
(see Figure6)

Tighten coolant pump.
Tightening torque : 8 Nm

Rotate engine two revolutions in the engine rotating direction.
TDC - Check markings, adjust if necessary.
Check toothed belt tension again.
Indicator must align with the recess in the baseplate. (3) (4)
(see Figure6)

Continue assembly in reverse order of removal.

Fit accessory drive belt.

Code radio and reprogram vehicle settings if required.
Start engine and check function.

Carry out steering angle sensor basic adjustment. (depending on version)

Check coolant level and correct, if necessary.
Interrogate error log. Carry out a test drive.
Document toothed belt change.  





OPEL ASTRA G Hatchback (F48_, F08_) 1.6 
Accessory Drive - with air-conditioning 


Note
It is advisable not to reuse the accessory drive belt(s) after removal, but always replace them! 

CRS  Crankshaft 
A  Alternator 
AC  Air-conditioning compressor 
T  Tensioning roller  


Remove:

Remove engine cover(s).
Disconnect air intake hose from air filter housing.
Disconnect plug - air-mass sensor
Remove air filter housing.
Remove crankcase breather hose.
Note the accessory drive belt running direction!
Release accessory drive belt.
Release tension of tensioning roller anti-clockwise using suitable tool. (3)
(see Figure2)
Remove accessory drive belt.

Installation in reverse order of removal.

Check accessory drive belt for condition and tension.


Accessory drive belt tension is checked by tensioning device position. (4)
Indicator should be between the two stops. (1) (2) (3)
Accessory drive belt is worn out when the indicator reaches the bottom stop. (1)
(see Figure3)  




OPEL ASTRA G Hatchback (F48_, F08_) 1.6  

Accessory Drive - without air-conditioning system  





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