How to replace timing belt on Vauxhall/Opel Insignia 1.6

Replacement Interval Guide

• Vauxhall recommend replacement every 100,000 miles or 10 years (tensioner pulley and guide 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:
Astra-H/Zafira-B	1,30
Vectra-C/Signum	1,00
Insignia	1,40

Special Tools

• Auxiliary drive belt tensioner locking tool – Kent Moore No.KM-6349.
• Camshaft sprockets locking tool – Kent Moore No.KM-6340.
• 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:
   • Engine top cover.
   • Air filter housing and hoses.
   • Timing belt upper cover [1] .
   • RH front wheel.
   • RH wheel arch liner.
3. Support engine.
4. Remove RH engine mounting and bracket.
5. Mark direction of rotation on auxiliary drive belt with chalk.
6. Turn auxiliary drive belt tensioner to release tension on belt. Use ring spanner.
7. Lock auxiliary drive belt tensioner [2] . Use tool No.KM-6349.
8. Remove:
   • Auxiliary drive belt.
   • Auxiliary drive belt tensioner.
9. Remove bolt from cylinder block. Install flywheel locking tool [3] . Tool No.KM-6625.
10. Remove:
    • Crankshaft pulley bolt [4] .
    • Crankshaft pulley [5] .
    • Timing belt lower cover [6] .
    • Flywheel locking tool [3] .
11. Temporarily fit crankshaft pulley bolt [4] .
12. Turn crankshaft clockwise to TDC on No.1 cylinder. Ensure timing marks aligned [7] .
13. Remove RH plate from camshaft sprockets locking tool [8] .
14. Fit camshaft sprockets locking tool [9] . Tool No.KM-6340.
15. Ensure timing mark aligned with groove on camshaft sprockets locking tool [10] & [11] .
16. Ensure timing mark on inlet camshaft adjuster is positioned above groove on camshaft sprockets locking tool [12] & [11] .
17. Turn tensioner pulley clockwise until locking pin can be inserted [13] . Tool No.KM-6333.
18. Remove:
    • Guide pulley bolt [14] . Bolt MUST be replaced.
    • Guide pulley [15] .
    • Timing belt.
    • Tensioner pulley locking pin [13] .
    • Tensioner pulley bolt [16] .
    • Tensioner pulley [17] .

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

Installation

NOTE: DO NOT use timing mark ‘B’ [18] .

1. Ensure timing marks aligned [7] .
2. Fit new tensioner pulley and bolt [17] & [16] . Tightening torque: 20 Nm.

   NOTE: New tensioner pulley supplied with locking pin installed [13] . DO NOT remove locking pin until timing belt fitted.

3. Ensure tensioner tab [19] engaged in cut-out [20] .
4. Fit timing belt in anti-clockwise direction, 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.

5. Fit new guide pulley and bolt [14] & [15] . Tightening torque: 25 Nm.
6. Remove:
   • Tensioner pulley locking pin [13] .
   • Camshaft sprockets locking tool [9] .
7. Turn crankshaft slowly two turns in direction of rotation to TDC on No.1 cylinder.
8. Ensure timing marks aligned [7] .
9. Fit camshaft sprockets locking tool [9] .
10. Ensure marks on locking tool aligned [10] & [11] .
11. Ensure timing mark on inlet camshaft adjuster is positioned above groove on camshaft sprockets locking tool [12] & [11] .
12. Remove:
    • Camshaft sprockets locking tool [9] .
    • Crankshaft pulley bolt [4] .
13. Install components in reverse order of removal.
14. Install flywheel locking tool [3] .
15. Fit new crankshaft pulley bolt [4] . Tightening torque: 95 Nm + 30° + 15°.
16. Remove flywheel locking tool [3] .
17. Fit bolt to cylinder block.

    NOTE: Observe direction of rotation marks on auxiliary drive belt.