GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2009 🢒 Astra 🢒 Engine 🢒 Engine Mechanical - 1.6L (LDE or LLU) and 1.8L (2H0) 🢒 Timing Belt Replacement

Special Tools

    • KM-6001-A Engine Mount
    • KM-6333 Fixing Rod
    • MK-6340 Locking Tool
    • KM-6625 Flywheel Locking Device
    • MK-6628 Locking Tool

Removal Procedure
  1. Open the hood.
  2. Disconnect the battery.
    3. 2.1. Disconnect the negative connection from the ground terminal.
    2.2. Loosen the nut.
  3. Remove the air cleaner housing. Refer to Air Cleaner Assembly Replacement.
  4. Remove the front toothed belt cover (top). Refer to Timing Belt Upper Front Cover Replacement.
  5. Raise the vehicle by its full height.
  6. Remove the drive belt tensioner. Refer to Drive Belt Tensioner Replacement.
  7. Lower the vehicle by its full height.
  8. Remove the camshaft cover. Refer to Camshaft Cover Replacement.

    9. Object Number: 1936993 Size: SH
  9. Set the engine to TDC (1).

    10. Turn the crankshaft in the direction of engine rotation by the bolt of the torsional vibration damper to cylinder 1 TDC of combustion stroke.


    Object Number: 1944920 Size: SH

    Note: Recognizable from the lettering "Right" (arrow).

  10. Prepare the right half of MK-6340 for use on the U 18 XER engine.
    11. 10.1. Detach the front panel (1) from MK-6340 .
    10.2. Remove the 2 bolts (2).

    Object Number: 1944922 Size: SH
  11. Insert MK-6340 into the camshaft timing gears.
    12. 11.1. Insert MK-6340 (1, 2) in the camshaft adjuster as shown.

            Note: The spot-type marking (4) on the intake camshaft adjuster does not correspond to the groove of MK-6340 during this process but must be somewhat above as shown.

    11.2. The spot type marking (3) on the exhaust camshaft adjuster must correspond to the groove on MK-6340 .

    Object Number: 1945788 Size: MH
  12. Insert MK-6628 (1) into camshafts.

    13. Note: If MK-6628 cannot be inserted, the timing must be set.

  13. Align camshafts horizontally by the hexagon (arrows) until MK-6628 can be inserted in both camshafts.
  14. Raise the vehicle by its full height.

    15. Object Number: 1944953 Size: LH
  15. Block the crankshaft.

    16. Attach KM-6625 .

    14.1. Detach the screwed connection (1).
    14.2. Insert KM-6625 (2).
    14.3. Tighten the screwed connection (3).
  16. Remove the torsional vibration damper.

    17. Remove the bolt.

  17. Remove the front toothed belt cover (bottom).

    18. Remove the 4 bolts.

  18. Remove KM-6625 .

    19. Detach the screwed connection.


    Object Number: 1936608 Size: LH
  19. Insert KM-6173 Adapter (3).
    20. 18.1. Loosen the 4 bolts (arrows) and hand-tighten.
    18.2. Align KM-6173 at the frame.
    18.3. Position the support bearing (1).
    18.4. Journal (2) must sit in the mount at the cylinder block.
    18.5. Tighten the 4 bolts.

    Object Number: 1948649 Size: LF

    Note: Attaching KM-6001-A guarantees perfect alignment of the drive unit with the frame.

  20. Attach KM-6001-A (1).
    21. 19.1. Loosen the 3 bolts (arrows) in the adjusting rails.
    19.2. Insert KM-6001-A .

    The journals (2, 5) must sit in the guide holes of the frame.

    19.3. Tighten the 3 bolts in the adjusting rails.
    19.4. Adjust the support bearings, front (4) and rear (3).

            Note: The guide journals must be seated free from play in the support bearings.

    19.5. Raise the support bearings up to the stop on the guide journals.
  21. Lower the vehicle by its full height.

    22. Object Number: 1945759 Size: SH
  22. Detach the engine damping block (1) from the side member and the engine damping block support.

    23. Remove the 6 bolts.

  23. Remove the engine damping block with the bracket.

    24. Object Number: 1945760 Size: SH
  24. Remove the engine damping block support (1).

    25. Remove the 3 bolts (2).


    Object Number: 1945761 Size: SH
  25. Remove the center toothed belt cover (1).

    26. Release 2x from the rear of the toothed belt cover.


    Object Number: 1944384 Size: SH
  26. Stop the toothed belt tensioner.

    27. Apply tension to the toothed belt tension roller (2) in the direction of the arrow, using an Allen key (1). Install using KM-6333 (3).


    Object Number: 1945757 Size: SH
  27. Remove the toothed belt tensioner (1).

    28. Remove the bolt (2).

  28. Remove the toothed belt.
  29. Raise the vehicle by its full height.
  30. Remove KM-6625 .

    31. Detach the screwed connection.


    Object Number: 1937030 Size: SH
  31. Turn the crankshaft 60 degrees against the direction of engine rotation.
  32. Place the collecting basin underneath.
  33. Remove the closure bolt, exhaust camshaft adjuster.
  34. Remove the intake camshaft closure bolt.
  35. Remove MK-6340 .
  36. Loosen the exhaust camshaft adjuster.

    37. Counterhold at camshaft hexagon.

  37. Remove the exhaust camshaft adjuster.

    38. Remove the bolt.

  38. Loosen the intake camshaft adjuster.

    39. Counterhold at camshaft hexagon.

  39. Remove the intake camshaft adjuster.

    40. Remove the bolt.

  40. Remove the rear toothed belt cover.
    41. 39.1. Release the wiring trough cover.
    39.2. Remove the 4 bolts.

Installation Procedure
  1. Clean the 4 threads, rear toothed belt cover.

    2. Caution: Refer to Fastener Caution in the Preface section.

  2. Install the rear toothed belt cover.
    3. 2.1. Tighten the 4 new bolts.

    Tighten
    Tighten the 4 new bolts to 6 N·m (53 lb in).

    2.2. Coat the 4 bolts with locking compound (red).
    2.3. Clip in the wiring trough cover.

    Note: Do not tighten the bolt.

  3. Install the intake camshaft adjuster.

    4. Install the bolt.

    Note: Do not tighten the bolt.

  4. Install the exhaust camshaft adjuster.

    5. Install the bolt.

    Note: Note markings on the camshaft sprockets.

  5. Insert MK-6340 .
  6. Tighten the exhaust camshaft adjuster.

    7. Tighten
    Tighten the exhaust camshaft adjuster to 65 N·m (48 lb ft) plus 120 degrees plus 15 degrees.

  7. Counterhold at camshaft hexagon.
  8. Tighten the intake camshaft adjuster.

    9. Tighten
    Tighten the intake camshaft adjuster to 65 N·m (48 lb ft) plus 120 degrees plus 15 degrees.

  9. Counterhold at camshaft hexagon
  10. Tighten the exhaust camshaft adjuster closure bolt.

    11. Tighten
    Tighten the exhaust camshaft adjuster closure bolt to 30 N·m (22 lb ft).

  11. Replace the seal ring.
  12. Tighten the closure bolt, intake camshaft adjuster.

    13. Tighten
    Tighten the closure bolt, intake camshaft adjuster to 30 N·m (22 lb ft).

  13. Replace the seal ring.
  14. Remove MK-6628 .
  15. Raise the vehicle by its full height.

    16. Object Number: 1937010 Size: SH
  16. Position the crankshaft to cylinder number 1 ignition TDC.

    17. Marking, toothed belt drive gear and oil pump housing adapter must align.

  17. Lower the vehicle by its full height.

    18. Object Number: 1941810 Size: LF
  18. Intake toothed belt tensioner.
    19. 14.1. Insert the toothed belt tension roller.
             14.1.1. Use a new bolt.
             14.1.2. Released leg of spring (1) of the toothed belt tension roller must engage in the cut-out (arrow) of the pump module.
    14.2. Tighten the bolt.

    Tighten
    Tighten the bolt to 20 N·m (15 lb ft).

    Note: Use assembly tool.

  19. Insert the toothed belt.
  20. Release tension on the toothed belt tensioner.
    21. 16.1. Apply preliminary tension clockwise to the toothed belt tension roller.
    16.2. Remove KM-6333 .
  21. Install the center toothed belt cover.

    22. Clip on 2x to the toothed belt cover (rear).

  22. Install the support for the engine damping block.

    23. Tighten
    Tighten the 3 bolt to 50 N·m (37 lb ft).

  23. Install the engine damping block.
    24. 19.1. Install to the support.

    Tighten
    Tighten the 3 bolt to 55 N·m (40 lb ft).

    19.2. Install to the side member.

    Tighten
    Tighten the 3 bolts to 55 N·m (40 lb ft).

  24. Raise the vehicle by its full height.
  25. Block the crankshaft.
    26. 21.1. Insert KM-6625 .
    21.2. Install the bolted connection.
  26. Install the front toothed belt cover (lower).

    27. Tighten
    Tighten the 4 bolts to 6 N·m (53 lb in).

    Note: New bolt must be coated with screw locking compound (red).

  27. Install the torsional vibration damper.

    28. Tighten
    Tighten the new bolt to 95 N·m (70 lb ft) plus 30 degrees plus 15 degrees.

  28. Remove KM-6625 .
    29. 24.1. Detach the screwed connection.
    24.2. Tighten the bolted connection.

    Use the new nuts.

  29. Lower the vehicle by its full height.
  30. Remove MK-6340 .
  31. Inspect position of the camshaft sprockets.

    32.         Note: Note marking, camshaft sprockets.

    27.1. Turn the crankshaft 720 degrees in the direction of engine rotation by the bolt on the torsional vibration damper.
    27.2. Insert MK-6340 into the camshaft timing gears.
  32. Inspect the camshaft positions.
  33. Raise the vehicle by its full height.
  34. Inspect the crankshaft position.

    35. Insert MK-6628 in camshafts, align camshafts by hexagon until MK-6628 can be inserted in both camshafts, marking on torsional vibration damper must align with marking on lower part of toothed belt cover.

  35. Install the drive belt tensioner. Refer to Drive Belt Tensioner Replacement.
  36. Lower the vehicle by its full height.
  37. Remove MK-6628 .
  38. Install the camshaft cover. Refer to Camshaft Cover Replacement.
  39. Remove MK-6340 .

    40. Attach the bracket.

    Tighten
    Tighten the 2 bolts.

  40. Install the front toothed belt cover (top). Refer to Drive Belt Replacement.
  41. Install the air cleaner housing. Refer to Air Cleaner Assembly Replacement.
  42. Connect the battery.

    43. Connect the negative connection to the ground terminal.

    Tighten
    Tighten the nut to 5 N·m (44 lb in).

  43. For programming procedures, refer to Control Module References.
  44. Close the hood.