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How to Replace timing chain 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 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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