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 Installation

Special Tools

    • KM-6333 Fixing Rod
    • MK-6340 Locking Tool
    • MK-6628 Locking Tool

For equivalent regional tools, refer to Special Tools.


    Object Number: 1937010 Size: SH
  1. Clean the 4 threads, rear timing belt cover.
  2. Install the rear timing belt cover.
  3. Clip in the wiring trough cover.
  4. Apply red locking compound to the 4 NEW rear timing belt cover bolts.

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

  5. Install the 4 NEW rear timing belt cover bolts. Tighten the 4 new bolts to 6 N·m (53 lb in).

    6. Note: Do not tighten the intake camshaft adjuster bolt.

  6. Install the intake camshaft adjuster.
  7. Install the intake camshaft adjuster bolt.

    8. Note: Do not tighten the exhaust camshaft adjuster bolt.

  8. Install the exhaust camshaft adjuster.
  9. Install the exhaust camshaft adjuster bolt.

    10. Note: Note the markings on the camshaft sprockets.

  10. Insert the MK-6340 tool .
  11. Tighten the exhaust camshaft adjuster. Tighten the exhaust camshaft adjuster to 65 N·m (48 lb ft) + 120 degrees + 15 degrees.

    12. Counter-hold at camshaft hexagon.

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

    13. Counter-hold at camshaft hexagon.

  13. Replace the exhaust camshaft adjuster seal ring.
  14. Tighten the exhaust camshaft adjuster closure bolt and tighten to 30 N·m (22 lb ft).
  15. Replace the intake camshaft adjuster seal ring.
  16. Tighten the intake camshaft adjuster closure bolt and tighten to 30 N·m (22 lb ft).
  17. Remove the MK-6628 tool .

    18. Note: The timing belt drive gear and oil pump housing must align.

  18. Position the crankshaft to cylinder number 1 ignition top dead center (TDC).

    19. Object Number: 1941810 Size: LF

    Note: The timing belt tension roller released leg of the spring (1) must engage in the cut-out, arrow, of the pump module.

  19. Insert the intake timing belt tension roller.
  20. Install a NEW timing belt tension roller bolt and tighten to 20 N·m (15 lb ft).
  21. Install the intake timing belt tensioner.

    22. Note: Use an assembly tool.

  22. Insert the timing belt.
  23. Apply preliminary tension clockwise to the timing belt tension roller.
  24. Remove the KM-6333 rod .
  25. Release the tension on the timing belt tensioner.