Replacing the primary drive chain (camshaft drive chain) (Opel Insignia A)

Removal

1. Remove the timing chain tensioner:

• Remove the decorative engine cover.
• Remove the air filter outlet duct.
• Remove the cylinder head cover.
• Disconnect the turbocharger cooling pressure line.
• Unscrew the drive chain tensioner (1) from the cylinder head.

2. Remove the oil pump drive gear.

3. Remove the timing chain tensioner shoe.

4. Remove the drive chain guide.

5. Remove the upper drive chain guide.

6. Remove the exhaust camshaft phase shifter.

7. Remove the intake camshaft phase shifter.

8. Remove the chain drive oil nozzle.

9. Remove the drive chain.

Installation

1. Install the intake camshaft phase shifter (1), but do not tighten the mounting bolt.



2. Install the drive chain (2):

• Route the drive chain (2) through the intake camshaft sprocket (1).
• Secure the intake camshaft using tool EN-49212-2 (3).

3. Install the drive chain guide.

4. Install the timing chain tensioner shoe.

5. Install the chain drive oil nozzle.

6. Install the oil pump gear.

7. Turn the crankshaft to align the mark (2) with the pointer (1).



8. Install the exhaust camshaft phase shifter:

• Count the number of drive chain links between the marks on the intake and exhaust camshaft sprockets. To ensure correct installation between the sprocket marks, the drive chain must have 29 links.

Note: When installing, it is necessary to tighten the drive chain. Turn the camshaft clockwise to set the drive sprocket to the desired position.

Install the exhaust camshaft drive sprocket and secure it with the holder in the camshaft.

9. Tighten the exhaust camshaft phase shifter bolt to 30 Nm, then tighten it another 100°.

Note: Use a wrench to hold the exhaust camshaft from turning.

10. Tighten the intake camshaft phase shifter bolt to 30 Nm, then tighten another 100°.

Note: Use a wrench to hold the exhaust camshaft from turning.

11. Secure the exhaust camshaft using tool EN-49212-1.

12. Check again that the drive chain is installed correctly using all marks.

13. Remove the EN-49212 camshaft locks.

14. Install the upper drive chain guide.

15. Install the drive chain tensioner:

• Using a special tool, remove the retaining ring from the tensioner housing.
• Remove the ratchet cylinder from the tensioner housing.
• Place the EN-45027-2 fixture in a vice and turn the ratchet cylinder clockwise using the EN-45027-1 fixture until it stops.

• Install the ratchet cylinder and snap ring into the tensioner housing.

• Install the timing chain tensioner with a new gasket and tighten to 75 Nm.
• Move the drive chain tensioner shoe away from the tensioner to ensure the chain tensioner is functioning.

16. Turn the crankshaft two revolutions and again check the tension and correct installation of the drive chain.



17. Install the cylinder head cover.

18. Install the air filter outlet duct.

19. Install the decorative engine cover.