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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

How to replace timing gears on Vauxhall/Opel Insignia 2.0 CDTI 4x4
How to replace timing gears on Vauxhall/Opel Insignia 2.0 CDTI 4×4
  • 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.

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