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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.
How to replace timing chain on Vauxhall/Opel Insignia 2.8 Turbo 4x4
How to replace timing chain on Vauxhall/Opel Insignia 2.8 Turbo 4×4

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.

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