How to replace timing belt on Vauxhall/Opel Insignia 1.8

Replacement Interval Guide

• Vauxhall recommend replacement every 100,000 miles or 10 years (tensioner pulley must also be replaced).
• The previous use and service history of the vehicle must always be taken into account.

Check For Engine Damage

CAUTION: This engine has been identified as an INTERFERENCE engine in which the possibility of valve-to-piston damage in the event of a timing belt failure is MOST LIKELY to occur. A compression check of all cylinders should be performed before removing the cylinder head.

Repair Times – hrs

Remove & install

1,20

Special Tools

• Camshaft sprockets locking tool – Kent Moore No.KM-6340.
• Camshafts timing tool – Kent Moore No.KM-6628-A.
• Flywheel locking tool – Kent Moore No.KM-6625.
• Tensioner pulley locking pin – Kent Moore No.KM-6333.

Special Precautions

• Disconnect battery earth lead.
• DO NOT turn crankshaft or camshaft when timing belt removed.
• Remove spark plugs to ease turning engine.
• Turn engine in normal direction of rotation (unless otherwise stated).
• DO NOT turn engine via camshaft or other sprockets.
• Observe all tightening torques.

Removal

WARNING: Engines with variable valve timing: Mark camshaft sprockets and camshaft adjusters with chalk or paint prior to timing belt removal to assist alignment on installation.

1. Raise and support front of vehicle.
2. Remove:
   • Air filter housing and hoses.
   • Timing belt upper cover [1] .
   • Engine top cover.
   • Cylinder head cover.
   • RH front wheel.
   • RH wheel arch liner.
   • Auxiliary drive belt.
   • Auxiliary drive belt tensioner.
3. Support engine.
4. Remove:
   • RH engine mounting and bracket.
   • Bolt from rear of cylinder block.
5. Fit flywheel locking tool [2] . Tool No.KM-6625.
6. Remove:
   • Crankshaft pulley bolt [3] .
   • Crankshaft pulley [4] .
   • Timing belt lower cover [5] .
   • Flywheel locking tool [2] .
7. Temporarily fit crankshaft pulley bolt [3] .
8. Turn crankshaft clockwise to TDC on No.1 cylinder. Ensure timing marks aligned [6] .
9. Remove RH plate from camshaft sprockets locking tool [7] .
10. Fit camshaft sprockets locking tool [8] . Tool No.KM-6340.
11. Ensure timing mark aligned with groove on camshaft sprockets locking tool [9] & [10] .
12. Ensure timing mark on inlet camshaft adjuster is positioned above groove on camshaft sprockets locking tool [9] & [11] .
13. Ensure camshafts timing tool can be fitted [12] . Tool No.KM-6628-A.
14. Turn tensioner pulley clockwise until locking pin can be inserted [13] . Tool No.KM-6333.
15. Remove:
    • Timing belt.
    • Tensioner pulley locking pin [13] .
    • Tensioner pulley bolt [14] .
    • Tensioner pulley [15] .

    NOTE: Mark direction of rotation on belt with chalk if belt is to be reused.

Installation

1. Ensure timing marks aligned [6] .
2. Ensure camshaft sprockets locking tool fitted correctly [8] .
3. Ensure camshafts timing tool can be fitted [12] .
4. Fit new tensioner pulley [15] .
5. Ensure tensioner tab [16] engaged in cut-out [17] .
6. Fit new tensioner pulley bolt [14] . Tightening torque: 20 Nm.
7. Ensure tensioner pulley locking pin inserted [13] .
8. Fit timing belt, starting at crankshaft sprocket. Ensure belt is taut between sprockets.NOTE: New belt supplied from manufacturer with fitting/assembly tool. Remove tool after fitment of belt.
9. Remove:
   • Tensioner pulley locking pin [13] .
   • Camshafts timing tool [12] .
   • Camshaft sprockets locking tool [8] .
10. Turn crankshaft slowly two turns in direction of rotation to TDC on No.1 cylinder.
11. Fit camshaft sprockets locking tool [8] .
12. Ensure marks on locking tool aligned [9] & [10] .
13. Ensure timing mark on inlet camshaft adjuster is positioned above groove on camshaft sprockets locking tool [9] & [11] .
14. Ensure camshafts timing tool can be fitted [12] .
15. Remove:
    • Camshaft sprockets locking tool [8] .
    • Camshafts timing tool [12] .
16. Fit flywheel locking tool [2] .
17. Remove crankshaft pulley bolt [3] . DO NOT reuse bolt.
18. Fit new crankshaft pulley bolt [3] . Tightening torque: 95 Nm + 30° + 15°.
19. Remove flywheel locking tool [2] .
20. Fit bolt to cylinder block.
21. Install components in reverse order of removal.NOTE: Observe direction of rotation marks on auxiliary drive belt.