How to replace timing chain on Vauxhall/Opel Insignia 2.8 Turbo 4×4

Special tools

• Camshaft alignment tool 1 – No.EN-48383-1.
• Camshaft alignment tool 2 – No.EN-48383-2.
• Camshaft alignment tool 3 – No.EN-48383-3.
• Crankshaft alignment/turning tool – No.EN-48589.
• Crankshaft pulley holding tool – No.EN-47981.
• Crankshaft pulley holding tool handle – No.EN-956-1.
• Crankshaft pulley installer – No.EN-41998-B.
• Crankshaft pulley removal tool – No.EN-47982.
• Flywheel/drive plate locking tool – No.EN-46106.
• Tensioner locking pin – No.EN-46112.
• Tensioner plunger resetting tool – No.EN-49416.

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

• Stage 1 alignment position (LH bank):
  • Using crankshaft alignment/turning tool, rotate the crankshaft clockwise to the stage 1 alignment position [1] .
  • Install camshaft alignment tool 1 to rear of LH camshafts [2] & [3] .
  • Ensure LH secondary timing chain coloured chain links aligned with timing mark on each sprocket [4] , [5] & [6] .
  • Ensure there are 10 chain links located between the timing marks on both camshaft sprockets [5] & [6] .
  • Ensure there are 22 chain links located between the timing marks on both camshaft sprockets [4] & [5] .
  • Ensure there are 22 chain links located between the timing marks on both camshaft sprockets [4] & [6] .
  • Ensure primary timing chain coloured chain links aligned with timing mark on each sprocket [7] , [8] & [9] .
  • Remove camshaft alignment tool 1.
• Stage 2 alignment position (RH bank):
  • Using crankshaft alignment/turning tool, rotate the crankshaft 115° clockwise to the stage 2 alignment position [10] .
  • Install camshaft alignment tool 2 to rear of LH camshafts [11] & [3] .
  • Install camshaft alignment tool 3 to rear of RH camshafts [12] & [13] .
  • Ensure coloured chain links aligned with timing marks on sprockets [14] , [15] , [16] , [17] , [18] , [19] , [20] , [21] & [22] .
  • Ensure there are 10 chain links located between the timing marks on both camshaft sprockets [19] & [20] .
  • Ensure there are 22 chain links located between the timing marks on both camshaft sprockets [15] & [19] .
  • Ensure there are 22 chain links located between the timing marks on both camshaft sprockets [15] & [20] .
  • Remove camshaft alignment tools.
• Set the timing chain tensioners before installation:
  • Using tensioner plunger resetting tool, turn tensioner plunger clockwise while pushing inward until locked in position [23] .
  • Insert tensioner plunger fully into tensioner body [24] .
  • Insert tensioner locking pin into tensioner body [25] .
• To release tensioner plunger after installation:
  • Remove tensioner locking pin [25] .
  • Press tensioner rail briefly against tensioner to unlock tensioner plunger.