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How to replace timing chain on Vauxhall/Opel Insignia 2.0 Turbo 4×4

Special tools

  • Camshaft adjuster holding tool – No.EN-48953.
  • Crankshaft pulley alignment tool – No.EN-48585.
  • Crankshaft pulley holding tool – No.EN-38122-A.
  • Flywheel/drive plate holding tool – No.EN-43653.
  • Tensioner plunger resetting tool – No.EN-45027-1/2.
How to replace timing chain on Vauxhall/Opel Insignia 2.0 Turbo 4x4
How to replace timing chain on Vauxhall/Opel Insignia 2.0 Turbo 4×4

General precautions

  • Disconnect battery earth lead.
  • Remove spark plugs to ease turning engine.
  • Turn engine in normal direction of rotation (unless otherwise stated).
  • Observe tightening torques.
  • If fitted: Mark position of crankshaft position (CKP) sensor before removal.
  • Do NOT turn crankshaft via camshaft or other sprockets.
  • Do NOT turn crankshaft or camshaft with timing chain removed.

Valve timing procedures

Removal

  • Engine at TDC on No.1 cylinder.
  • Ensure crankshaft keyway at 12 o’clock position [1] .
  • Ensure timing mark on each camshaft adjuster positioned as shown [2] & [3] .
  • Remove upper chain guide [4] .
  • Remove timing chain tensioner [5] .
  • Hold camshaft adjusters with holding tool [6] .
  • Slacken bolt of each camshaft adjuster [7] .
  • Remove camshaft adjuster holding tool [6] .
  • Remove exhaust camshaft adjuster.
  • Remove tensioner rail and chain guide [8] & [9] .
  • Remove inlet camshaft adjuster and chain.

NOTE: Crankshaft sprocket friction washers (if fitted) MUST be replaced.

  • Remove balancer shaft chain tensioner [10] .
  • Remove balancer shaft chain guides and tensioner rail.
  • Remove balancer shaft chain.

Installation

  • Engine at TDC on No.1 cylinder.
  • Ensure crankshaft keyway at 12 o’clock position [1] .
  • Ensure camshaft dowels aligned as shown [11] .
  • Fit balancer shaft chain ensuring coloured links aligned with timing marks [12] , [13] , [14] & [15] .
  • Install balancer shaft chain guides and tensioner rail.
  • Reset balancer shaft chain tensioner [10] :
      • Turn tensioner plunger clockwise 90° [16] .
      • Push plunger into tensioner housing.
      • Turn tensioner plunger anti-clockwise 90° [16] .
      • Insert suitable pin to lock tensioner plunger [17] .
  • Install balancer shaft chain tensioner [10] .
  • Remove pin from tensioner [17] .
  • Install inlet camshaft adjuster and timing chain as an assembly. Tighten inlet camshaft adjuster bolt finger tight.
  • Install tensioner rail [8] .
  • Install exhaust camshaft adjuster. Finger tighten bolt.
  • Ensure coloured chain links aligned with timing marks on sprockets [2] , [3] & [13] .
  • Install chain guide [9] .
  • Reset timing chain tensioner [5] :
      • Remove tensioner plunger [18] .
      • Turn inner plunger clockwise until it locks [19] .
      • Refit tensioner plunger.
  • Install timing chain tensioner [5] .
  • Hold camshaft adjusters with holding tool [6] .
  • Tighten bolt of each camshaft adjuster to 30 Nm + 100° [7] .
  • Turn crankshaft anti-clockwise slightly to release tensioner plunger.
  • Remove camshaft adjuster holding tool [6] .
  • Ensure coloured chain links aligned with timing marks on sprockets [2] , [3] , [12] , [13] , [14] & [15] .

NOTE: Crankshaft pulley bolt MUST be renewed.

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