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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

How to Replace timing belt on Opel/Vauxhall Insignia 2.0 CDTi 2009
How to Replace timing belt on Vauxhall Insignia 2.0 CDTi 2009

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.

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