How to Replace timing belt on Vauxhall Insignia 2.0 CDTi 2009

Vauxhall Insignia 2.0 CDTi 2009 cambelt change instructions and replacement inteval. Full guide!

Special tools

• Crankshaft timing tool – No.EN-46788.
• Exhaust camshaft locking tool – No.EN-46789.
• Camshaft sprocket holding tool – No.EN-47634.
• Handle – No.EN-956-1.

Special precautions

• Disconnect battery earth lead.
• DO NOT turn crankshaft or camshaft when timing belt removed.
• Remove glow 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.

Repair times – hrs

Camshaft drive belt/chain – R & I

2,30

Valve timing procedures

Removal

1. Raise and support vehicle.
2. Remove:
   • RH front wheel.
   • RH front inner wing panel.
   • Engine undershield.
   • Auxiliary drive belt.

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

   • Crankshaft pulley bolts [1] .

   NOTE: DO NOT slacken crankshaft centre bolt.

   • Crankshaft pulley [2] .
   • Auxiliary drive belt guide pulley.
   • Engine top cover.
3. Support engine.
4. Remove:
   • Air filter housing.
   • RH engine mounting and bracket.
   • Timing belt covers [3] & [4] .
5. Detach crankcase breather hose from cylinder head.
6. Remove blanking plug in cylinder head for exhaust camshaft locking tool [5] .
7. Fit exhaust camshaft locking tool [6] . Tool No.EN-46789.
8. Turn crankshaft in direction of rotation until locking tool heard to engage [6] .
9. Ensure pin on crankshaft sprocket at 6 o’clock position [7] .
10. Remove oil pump bolt. Insert stud of crankshaft timing tool [8] .
11. Fit timing tool to crankshaft sprocket [9] . Tool No.EN-46788. Ensure pin on crankshaft sprocket located correctly in tool [7] . Secure with bolt [10] .
12. Hold camshaft sprocket. Use tool Nos.EN-47634 & EN-956-1 [11] & [12] .
13. Slacken camshaft sprocket bolt [13] .
14. Slacken tensioner sprocket bolt [14] .
15. Move tensioner sprocket away from belt.
16. Remove:
    • Crankshaft timing tool [9] .
    • Timing belt.
    • Tensioner sprocket bolt [14] .
    • Tensioner sprocket.

Installation

1. Check water pump pulley and guide pulley for smooth operation.
2. Ensure exhaust camshaft locking tool fitted correctly [6].
3. Ensure pin on crankshaft sprocket at 6 o’clock position [7].
4. Fit new tensioner sprocket.
5. Fit tensioner sprocket bolt [14]. Tighten bolt finger tight.
6. Fit timing belt to crankshaft sprocket. Ensure marks on belt aligned [15].
7. Fit timing tool to crankshaft sprocket [9]. Ensure pin on crankshaft sprocket located correctly in tool [7]. Secure with bolt [10].
8. Fit timing belt in clockwise direction, starting at crankshaft sprocket. Ensure belt is taut between sprockets.
9. Ensure timing belt marks aligned [15] , [16] & [17].
10. Lever tensioner sprocket bracket at position [18] until pointer and mark aligned [19] & [20].
11. Ensure tensioner sprocket dot mark at position shown [21].
12. Tighten tensioner sprocket bolt [14]. Tightening torque: 25 Nm.
13. Hold camshaft sprocket. Use tool Nos.EN-47634 & EN-956-1 [11] & [12].
14. Tighten camshaft sprocket bolt [13]. Tightening torque: 120 Nm.
15. Remove:
    • Timing tool [9].
    • Exhaust camshaft locking tool [6].
16. Turn crankshaft two turns clockwise.
17. Fit timing tool to crankshaft sprocket [9]. Ensure pin on crankshaft sprocket located correctly in tool [7]. Secure with bolt [10].
18. Fit exhaust camshaft locking tool [6].
19. Ensure tensioner sprocket pointer and mark aligned [19] & [20]. If not: Repeat tensioning procedure.
20. Remove timing tool [9].
21. Fit oil pump bolt.
22. Remove exhaust camshaft locking tool [6].
23. Fit blanking plug [5].
24. Install components in reverse order of removal.
25. Tighten crankshaft pulley bolts [1]. Tightening torque: 25 Nm.