Replacing the secondary drive chain (drive chain of the water pump and balance shafts) (Opel Insignia A)

Removal

1. Remove the timing chain tensioner:

Loosen the balance shaft drive chain tensioner bolts.
Remove the balance shaft drive chain tensioner (1).

Remove the balance shaft drive chain tensioner (1).

2. Loosen the mounting bolt and remove the balance shaft drive chain tensioner shoe (1).

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3. Loosen the bolts and remove the smaller balance shaft drive chain guide (1).

4. Loosen the mounting bolts and remove the upper balance shaft drive chain guide (1).

Note: Removing all the guides makes it easier to remove the drive chain by allowing it to hang between the sprockets.

5. Remove the chain (1) of the balance shaft and water pump drive.

6. Remove the drive sprocket (2) of the balance shafts and water pump.

Installation

1. Install the drive sprocket of the balance shafts and water pump with the key.

Note: If the balance shafts are not adjusted correctly, the engine will vibrate and make abnormal noise.

2. Install the balance shaft drive chain so that the colored links align with the marks on the balance shaft and crankshaft sprockets. There are three colored links on the chain, two of the same color and one different color. Perform the following procedure to align the links with the marks on the sprockets:

Position the chain so that the colored links are visible.
Position the link of a different colour (1) so that it aligns with the mark on the balance shaft sprocket on the intake side.

Position the link of a different colour (1) so that it aligns with the mark on the balance shaft…

Moving clockwise along the chain, align the first link of the same colour (2) with the mark on the crankshaft sprocket - approximately at the 6 o'clock position of the crankshaft sprocket.
Place the chain (3) on the water pump drive sprocket. The alignment of the links is not important.
Align the last coloured link (4) with the mark on the balance shaft sprocket on the exhaust side.

Note: Do not rotate the chain after installation.

3. Install the lower drive chain guide (1) and tighten the mounting bolts to a torque of 12 Nm.

4. Install the upper drive chain guide (1) and tighten the mounting bolts to a torque of 12 Nm.

5. Install the drive chain tensioner shoe (1) and tighten the bolt to 10 Nm.

6. Reset the balance shaft drive chain tensioner (1) as follows:

Turn the plunger in the tensioner hole by 90° and squeeze.
Turn the plunger back to its original 12 o'clock position and insert the paper retainer (2) into the plunger through the hole in the housing.