How to replace timing gears on Vauxhall/Opel Insignia 2.0 CDTI 4×4

Special tools

• Camshaft locking tool x 2 – No.EN-46789.
• Camshaft sprocket holding tool – No.EN-47634.
• Camshaft sprocket holding tool handle – No.EN-956-1.
• Crankshaft alignment tool – No.EN-46788.
• Flywheel locking tool – No.1.860.898.000.

General precautions

• Disconnect battery earth lead.
• Remove glow 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 gears.
• Do NOT turn crankshaft or camshaft with timing gear(s) removed.

Valve timing procedures

• Removal/installation of timing gears requires:
  • Camshaft housing removal.
  • Timing belt removal.
• Remove timing belt.
• Remove camshaft housing.
• Remove timing belt camshaft sprocket.
• Ensure crankshaft alignment tool correctly fitted [1] .
• Remove camshaft gears as follows:
  • Remove blanking plugs from camshaft housing [2] .
  • Install camshaft locking tools [3] .
  • Slacken bolt of each camshaft gear [4] .
  • Remove camshaft locking tools [3] .
  • Remove camshaft gears.
• Install camshaft gears as follows:
  • Install camshaft gears. Finger tighten bolts [4] . Fit new bolts.
  • Install camshaft locking tools [3] .
  • Tighten bolt of each camshaft gear [4] . Tightening torque: 30 Nm + 52°.
• Install timing belt camshaft sprocket.
• Install camshaft housing.
• Install timing belt.