A short version of the guide, how to replace the timing belt kit and crankshaft simering sealant
What will we need?
Timing belt set, 2 guide rollers, idler pulley, timing belt, water pump, crankshaft screw, manual, Continental ContiTech company
Torque wrench - range 20-110Nm YATO or other
5 liters cooler fluid
Simering crankshaft sealer Elring
Spray, degreasing liquid, eg for cleaning brake discs
Universal YATO timing lock to block gears when replacing the belt
Set of socket wrenches, hex keys, torx wrenches and extensions
Safety gloves
We're getting to work;), see THE WHOLE VIDEO. The channel is also full version without acceleration.
I recommend buying all parts in the online store APARTS.PL with the discount code AUTOFAN or FORUMWIEDZY at the end of the order
Disconnect battery cables, starting from minus, ending with positive (effectively insulate the battery terminals from the battery poles so that they do not connect)
We dismantle the air intake pipe from the air filter housing to the damper (disconnect the EVAP solenoid valve cable to the throttle from the air intake pipe and the plug from the IAT air temperature sensor)
We dismantle the air filter housing
We mark the direction of work of the multi-groove accessories with a marker pen or chalk (if we do not replace the strap with a new one, we mark the direction of its work before disassembly, to keep the direction when re-assembly)
We disassemble the multi-groove accessories belt, releasing the tension of the tensioner using a ring wrench on the screw fastening the tensioner and pushing towards the interior of the car
We dismount the upper part of the toothed belt guard (3 screws and plastic hooks)
We disassemble the camshaft sensor (unscrew the 2 screws from the cylinder head and unhook the sensor, make sure that the bolt does not fall into the timing case)
Loosen the right wheel bolts
We raise the car and put it on a stable ground
We dismantle the right front wheel
mark the dash on the rim and hub with a chalk or marker, to keep the wheel balanced by mounting exactly the way it was
We dismantle the plastic cover of the wheel
We set the 5th gear and the second person presses the brake to the stop
Unscrew the crankshaft bolt (CA - Crankshaft Angle)
Pull out the belt pulley of the multi-groove belt from the crankshaft
Unscrew the multi-ribbed belt tensioner
We dismantle the lower part of the toothed belt guard (1 central bolt and several plastic fasteners)
Screw the bolt back into the crankshaft and turn the shaft clockwise so that the mark on the gear and housing covers exactly
We check the arrangement of the 2 camshaft sprockets in relation to the characters on the wheels (there are notches on the wheels that are to be directed towards each other in a straight line, signs can be marked with a marker pen to make them more visible).
We assume a universal camshaft sprocket lock or a sliding lock fitted to a given car model between the camshaft gears
Loosen the tensioning screw of the timing belt tensioning pulley and remove the tensioner
If the screw head is damaged, use a hammer and a hammer, because often you can not unscrew the screw, it was in my case
We leave the car gently on a trestle or wooden block so that it does not stick to the motor cushion
We dismantle the engine cushion (6 screws) to replace the old belt with a new one
We dismantle the old timing belt
We dismantle the 2 timing belt guide pulleys (remember where it was! - they are different)
We install 2 new timing belt guide rollers with a torque wrench, torque 25Nm
The new timing belt is pre-set by the engine bracket
We install the engine cushion (6 screws) back in place and lift the engine to remove the treadmill from under the engine
We drain the cooling system by unscrewing the equalizing tank cap and unscrewing the red valve under the radiator. When the liquid stops, we close the red valve as far as it will go.
We dismantle the water pump
We clean the water pump socket very precisely
We install a new water pump with a moistened seal using a new coolant fluid
If we replace the seal of the crankshaft simering, we extend the gear wheel from the shaft to each other, then using a precision flat screwdriver we pry the sealant and pull it out.
Installation of the sealer should be done using a roller cut from a thin plastic and a smooth cup for beverages or from a PET bottle moistened with motor oil.
We put the roller into the new seal, put it on the crankshaft and move the sealant onto the shaft on the cut out plastic shaft
Slide the crankshaft gear back into place onto the shaft key.
We install the timing belt tensioner - the tensioner protruder must be in a special hole and the voltage indicator must be under the water pump wheel, please observe the tensioner when tightening the screw (gently tighten it to tension the tensioner with the Allen key in the special tensioner hole on tensioner arm). The tightening of the fastening screw will make it impossible to tension the tensioner!
We install a new timing belt in a counter-clockwise direction (with the hands we tighten the belt between the camshaft gears), starting from overlaying the crankshaft pinion, then the right wheel, the right timing gear, the left timing gear, the left handwheel, the water pump, tensioner.
A detailed description of the steps can be found at: https://www.forumwiedzy.pl/opel-astra-g-1-6-16v-x16xel-wymiana-rozrzadu-i-uszczelniacza-walu-korbowego/
Use the Allen key to pre-tension the tension roller
by turning counterclockwise (to the left), the pointer moves to the right until it is just behind the right edge of the scale and we tighten the screw fixing the tension roller
it's perfect!
with two hands set the tensioner, one holding the Allen key with the voltage setting according to the indicator and scale, and the other hand tighten the tensioner bolt, otherwise the voltage will go down
We verify visually that the crankshaft gear and camshaft sprockets are perfectly positioned for signs, everything must be perfect!
We remove the universal lock of the camshafts from the camshafts (loose timing belt between the camshaft sprockets - normal phenomenon)
2x rotate the crankshaft gear in a clockwise direction until it is in the GMP position of the first cylinder.
It's perfect, you can even turn the wheel of the crankshaft one millimeter and the marks will level up.
After 2 turns of the crankshaft, the indicator on the tensioner will go back to the left, which means that the belt will loosen up on its length in the system - NORMAL PHENOMENON, it's supposed to be!
With the Allen key, finally tension the tensioning pulley of the timing belt - slightly loosen the screw securing the belt tensioning roller with the left hand and with the right hand we tension counterclockwise the tension roller until the tensioner indicator is on the line indicating NEW - FRONT TENSION of the new belt.
Tighten the bolt fixing the timing belt tensioning pulley to 20Nm using a torque wrench
2x rotate the crankshaft gear in a clockwise direction until it is in the GMP position
The marks on the timing and crankshaft must match. NOW WE ARE SAFE THAT EVERYTHING IS OK.
Installation of the lower timing cover (1 bolt and plastic hooks)
Install the multi-ribbed belt tensioner
We set the 5th gear and the second person presses the brake to the stop
Fit the pulley to the crankshaft (it will climb onto the wedge) and tighten the new crankshaft bolt to 95Nm with a torque wrench + 30 degrees + 15 degrees by a protractor
Installation of the wheel cover (several screws and dowel black)
Assembly of the wheel (according to previously made markings with a marker pen, to make the wheel balanced on the hub), tighten with the required torque of 110Nm using a torque wrench
Assembling the camshaft sensor (prevent the bolt from falling into the lower timing case when screwing in, for example put a rag or crepe paper while screwing in)
Fitting the upper timing belt cover (3 bolts and plastic hooks)
Installation of a new or used multi-ribbed belt
Installation of the air filter housing
Installation of the air intake pipe from the air filter housing to the throttle
Connection of the air intake temperature sensor plug to the IAT engine
Refill the radiator fluid, pour 5 liters of new liquid - pink and tighten the cap
Mounting the battery clamp to the battery starting from plus, ending at the minus.
We clean the plastic engine cover and stick it to the date, mileage, replacement range, sticker, which is in the timing belt box.
We start the engine and wait until the radiator fan is started for the first time and set the heating in the car to the maximum without running the fan.
Turn the engine off and verify the fluid level in the equalizing tank. When the engine has cooled down, we check the level and top up if necessary.
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