Replacing the camshaft housing (Opel Insignia A)

Removal

1. Open the hood.

2. Remove the timing belt.

3. Remove the fuel injectors.

4. Remove the fuel rail.

5. Remove the positive crankcase ventilation system pipeline.

6. Remove the turbocharger pressure oil line.

7. Loosen the two bolts (2 and 7) of the engine lifting eyes.



8. Remove the engine lifting eyes (3 and 6).

9. Remove the bracket (5).

10. Loosen the intake manifold bracket bolt (1) and remove the bracket (4).

11. Loosen the mounting bolt (2) and remove the wiring harness bracket (1).



12. Unscrew 17 bolts (3) and remove the camshaft housing (2).



13. Remove the camshaft housing gasket (1).



14. Loosen the bolt (8) and remove the camshaft position sensor (7).



15. Loosen and discard the 4 vacuum pump bolts (4).

16. Remove the vacuum pump (5) with the gasket (6).

17. Unscrew the three bolts (3) of the rear camshaft cover.

18. Remove the rear camshaft cover (2) with the gasket (1).

19. Remove the camshafts:

• Install the EN-46789 retainer.
• Loosen and discard the exhaust camshaft gear bolt (2).

• Remove the exhaust camshaft gear (2).
• Loosen and discard the intake camshaft gear bolt (1).

• Remove the intake camshaft gear (2).
• Remove the EN-46789 retainer.
• Remove the exhaust camshaft oil seal (1) and take out the exhaust camshaft (2).

• Remove the intake camshaft oil seal (1) and take out the intake camshaft (2).

Installation

1. Install the rear camshaft cover (2) with a new seal (1).



2. Install the three camshaft rear cover bolts (3) and tighten to 9 Nm.

3. Install the vacuum pump (5) with a new gasket (6).

4. Install 4 new vacuum pump bolts (4) and tighten in two stages:

• First step: tighten to 5 Nm.
• Second step: tighten to an angle of 50° using the EN-45059 device.

5. Install the camshaft position sensor (7).

6. Install the camshaft position sensor bolt (8) and tighten to 9 Nm.

7. Install the camshafts:

• Install camshafts with NEW seals.
• Install the EN-46789 retainer.
• Install the camshaft gears and tighten the gear mounting bolts in two stages:

• First step: tighten to 30 Nm.
• Second stage: pull to an angle of 52°.

• Remove the EN-46789 retainer.

8. Install a new camshaft housing gasket (1).



9. Install the camshaft housing (2).

10. Install the 17 camshaft housing bolts (3) and tighten to 25 Nm.

11. Install the engine wiring harness bracket (1) and tighten the mounting bolt to 9 Nm.



12. Install the intake manifold bracket (4) and tighten the mounting bolt (1) to 9 Nm.





13. Install the bracket (5) and rigging brackets (3 and 6).

14. Tighten the bolts (2 and 7) of the engine rigging brackets to a torque of 50 Nm.

15. Install the turbocharger pressure oil line.

16. Install the forced crankcase ventilation system pipeline.

17. Install the fuel rail.

18. Install fuel injectors.

19. Install the timing belt.

20. Close the hood.