GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Opel 🢒 2009 🢒 Insignia HB (Global Epsilon) 🢒 Engine 🢒 Engine Mechanical - 1.6L (LDE or LLU) and 1.8L (2H0) 🢒 Timing Belt Inspection and Adjustment

Timing Belt Inspection and Adjustment Adjustment 2H0

Special Tools

    • EN 6333 Locking Pin
    • EN 6340 Locking Tool
    • EN 6361 Flywheel Holder
    • EN 6628 A Locking Tool

Removal Procedure
  1. Remove the timing belt upper front cover. Refer to Timing Belt Upper Front Cover Removal.
  2. Remove the camshaft cover. Refer to Camshaft Cover Removal.

    3. Object Number: 1944920 Size: SH

    Note: The right half of the EN 6340 locking tool can be recognized by the lettering "Right", arrow, on the tool.

  3. Prepare the right half of the EN 6340 locking tool .
    4. 3.1. Remove the front panel (1) from the EN 6340 locking tool - right.
    3.2. Remove the 2 bolts (2).

    Object Number: 1944922 Size: SH

    Note: 

       • The spot-type marking (4) on the intake camshaft adjuster does not correspond to the groove of the EN 6340 locking tool - left (1) during this process, but must be somewhat above.
       • The spot type marking (3) on the exhaust camshaft adjuster must correspond to the groove on EN 6340 locking tool - right (2).

  4. Insert the EN 6340 locking tool - left (1) and the EN 6340 locking tool - right (2) in the camshaft adjuster.

    5. Object Number: 1944384 Size: SH
  5. Install the EN 6333 locking pin  (1), apply tension to the timing belt tension roller (2) in the direction of the arrow. Install the EN 6333 locking pin  (3).
  6. Mark timing belt in direction of rotation.

    7. Object Number: 2027015 Size: SH
  7. Install the EN 6361 holder  (1), lock the flywheel via the starter ring gear.

    8. Object Number: 2026822 Size: SH
  8. Remove the bolt (2) and the crankshaft balancer (1).

    9. Object Number: 2026840 Size: SH
  9. Remove the 4 timing belt lower front cover bolts (2).
  10. Remove the timing belt lower front cover (1).

    11. Object Number: 2026843 Size: SH
  11. Remove the timing belt idler pulley bolt (1).
  12. Remove the timing belt idler pulley (2).

    13. Object Number: 2026842 Size: SH
  13. Remove the tensioner bolt (2).
  14. Remove the timing belt tensioner (1).
  15. Remove the timing belt.
  16. Remove the EN 6361 holder .
  17. Stop the timing belt tensioner.
  18. Remove the timing belt.

    19. Object Number: 2027016 Size: SH
  19. Turn the crankshaft 60 degrees (A) against the direction of engine rotation.

    20. Object Number: 2026844 Size: SH
  20. Remove the 2 camshaft adjuster closure bolts (1).

    21. Note: 2 mechanics are required.

  21. Loosen the camshaft adjuster bolts (2).

    22. Hold at the appropriate camshaft hexagon.

  22. Remove the camshaft adjuster bolts (2) and the camshaft adjuster (3).

    23. Object Number: 2026512 Size: SH

    Note: If the EN 6628 A locking tool  (1) cannot be inserted, the timing must be set.

  23. Align the camshafts horizontally by the hexagon arrows, until the EN 6628 A locking tool can be inserted in both camshafts.

    24. Object Number: 2026534 Size: SH
  24. Insert the EN 6628 A locking tool  (1) into the camshafts.

Installation Procedure

    Object Number: 2026844 Size: SH

    Note: Do not tighten the camshaft adjuster bolts.

  1. Install the intake camshaft adjuster (3).
  2. Install the intake camshaft adjuster bolts (2).

    3. Caution: Refer to Fastener Caution in the Preface section.

    Note: 2 mechanics are required.

  3. Tighten the camshaft adjuster bolts (2) in three passes:

    4. Hold at the appropriate camshaft hexagon.

    3.1. First pass tighten to 65 N·m(48 lb ft)
    3.2. Second pass to 120 degrees
    3.3. Third pass to 15 degrees
  4. Replace the camshaft adjuster seal rings.
  5. Install the 2 camshaft adjuster closure plugs (1) and tighten to  30 N·m (22 lb ft).
  6. Remove the EN 6628 A locking tool .

    7. Object Number: 2026842 Size: SH
  7. Clean the timing belt tensioner thread.
  8. Install the timing belt tensioner (1) and tighten the NEW timing belt tensioner bolt (2) to  20 N·m (15 lb ft).
  9. Clean the timing belt idler pulley thread.

    10. Object Number: 2026843 Size: SH
  10. Install the timing belt idler pulley (2) and tighten the NEW bolt (1) to  25 N·m (18 lb ft).
  11. Remove the EN 6628 A locking tool .

    12. Object Number: 2027014 Size: SH

    Note: The timing belt drive gear and oil pump housing must align.

  12. Set the engine to top dead center (TDC).

    13. Turn the crankshaft in the direction of engine rotation, by the crankshaft balancer bolt, to cylinder 1 TDC of combustion stroke.


    Object Number: 2027015 Size: SH
  13. Install the EN 6361 flywheel holder  (1), lock the flywheel via the starter ring gear.

    14. Note: Observe direction of rotation.

  14. Insert the timing belt.
  15. Apply preliminary tension clockwise to the timing belt tension roller.
  16. Remove the EN 6333 locking pin .
  17. Release the tension on the timing belt tensioner.

    18. Object Number: 1944954 Size: SH
  18. Install the lower front timing belt cover (3) and tighten the 4 bolts (4) to  6 N·m (53 lb in).

    19. Object Number: 2026822 Size: SH
  19. Install the crankshaft balancer (1) and NEW bolt (2) with screw locking compound and tighten in 3 passes:
    20. 19.1. First pass to  95 N·m (70 lb ft)
    19.2. Second pass to  45 degrees
    19.3. Third pass to  15 degrees
  20. Remove the EN 6361 flywheel holder .
  21. Remove the EN 6340 locking tool .
  22. Check position of the camshaft adjuster.
    23. 22.1. Turn crankshaft 720° in the direction of engine rotation by the crankshaft balancer bolt.

            Note: Note marking, camshaft adjuster.

    22.2. Insert EN 6340 locking tool into camshaft timing gears.

    Object Number: 2026534 Size: SH
  23. Insert the EN 6628 A locking tool  (1) into the camshafts.

    24. Align camshafts by hexagon until EN 6628 A locking tool can be inserted in both camshafts.

  24. Check the crankshaft position.

    25. Marking on crankshaft balancer must align with marking on timing belt lower cover.

  25. Remove the EN 6628 A locking tool .
  26. Install the camshaft cover. Refer to Camshaft Cover Installation.
  27. Install the timing belt upper front cover. Refer to Timing Belt Upper Front Cover Installation.

Timing Belt Inspection and Adjustment Inspection 2H0

Special Tools

    • EN-6340 Locking Tool
    • EN-6628-A Locking Tool

For equivalent regional tools, refer to Special Tools.

Removal Procedure
  1. Remove the timing belt upper front cover. Refer to Timing Belt Upper Front Cover Removal

    2. .


    Object Number: 1936993 Size: SH
  2. Set the engine to TDC.

    3. Set the torsional vibration balancer in the direction of the engine rotation to "1st cylinder TDC" (mark 1).

  3. Remove the camshaft cover. Refer to Camshaft Cover Removal.

    4. Object Number: 1944920 Size: SH

    Note: The right half of the EN-6340 locking tool can be recognized by the lettering Right, arrow, on the tool.

  4. Prepare the right half of the EN-6340 locking tool .
    5. 4.1. Remove the front panel (1) from the EN-6340 locking tool -Right.
    4.2. Remove the 2 bolts (2).

    Object Number: 1944922 Size: SH

    Note: 

       • The spot-type marking (4) on the intake camshaft adjuster does not correspond to the groove of the EN-6340 locking tool -Left (1) during this process, but must be somewhat above.
       • The spot type marking (3) on the exhaust camshaft adjuster must correspond to the groove on EN-6340 locking tool -Right (2).

  5. Insert the EN-6340 locking tool -Left (1) and the EN-6340 locking tool -Right (2) in the camshaft adjuster.

    6. Object Number: 2026512 Size: SH

    Note: If the EN-6628-A locking tool  (1) cannot be inserted, the timing must be set.

  6. Align the camshafts horizontally by the hexagon, arrows, until the EN-6628-A locking tool can be inserted in both camshafts.

    7. Object Number: 2026534 Size: SH
  7. Insert the EN-6628-A locking tool  (1) into the camshafts.

Installation Procedure
  1. Remove the EN-6628-A locking tool .
  2. Remove the EN-6340 locking tool .
  3. Install the camshaft cover. Refer to Camshaft Cover Installation.
  4. Install the timing belt upper front cover. Refer to Timing Belt Upper Front Cover Installation.

Timing Belt Inspection and Adjustment Adjustment 2H0

Special Tools

    • EN 6333 Locking Pin
    • EN 6340 Locking Tool
    • EN 652 Flywheel Holder

For equivalent regional tool, refer to Special Tools.

Removal Procedure
  1. Remove the timing belt upper front cover. Refer to Timing Belt Upper Front Cover Removal.

    2. Object Number: 1936993 Size: SH
  2. Set the engine to TDC.

    3. Set the crankshaft balancer in the direction of the engine rotation to "1st cylinder TDC" (mark 1).


    Object Number: 2188650 Size: SH

    Note: 

       • The spot type marking (3) on the intake camshaft sprocket does not correspond to the groove of the EN 6340 locking tool  -left (1) during this process, but must be somewhat above.
       • The spot type marking (3) on the exhaust camshaft sprocket must correspond to the groove on EN 6340 locking tool  -right (2).

  3. Insert the EN 6340 locking tool  -left (1) and the EN 6340 locking tool  -right (2) in the camshaft sprocket.

    4. Object Number: 1944384 Size: SH
  4. Install the EN 6333 locking pin  (1), apply tension to the timing belt tension roller (2) in the direction of the arrow. Install the EN 6333 locking pin  (3).
  5. Mark timing belt in direction of rotation.

    6. Object Number: 2028375 Size: SH
  6. Install the EN-652 flywheel holder  (1), lock the flywheel (2) via the starter ring gear.

    7. Object Number: 2026822 Size: SH
  7. Remove the bolt (1) and the crankshaft balancer (2).

    8. Object Number: 2188662 Size: SH
  8. Remove the 4 timing belt lower front cover bolts (2).
  9. Remove the timing belt lower front cover (1).
  10. Remove the timing belt.

Installation Procedure

    Object Number: 2027014 Size: SH

    Note: The timing belt drive gear and oil pump housing must align.

  1. Set the engine to top dead center (TDC).

    2. Turn the crankshaft in the direction of engine rotation, by the crankshaft balancer bolt, to cylinder 1 TDC of combustion stroke.

    Note: Observe direction of rotation.

  2. Insert the timing belt.
  3. Apply preliminary tension clockwise to the timing belt tension roller.
  4. Remove the EN 6333 locking pin .
  5. Release the tension on the timing belt tensioner.

    6. Caution: Refer to Fastener Caution in the Preface section.


    Object Number: 2026840 Size: SH
  6. Install the lower front timing belt cover (1) and tighten the 4 bolts (2) to  6 N·m (53 lb in).

    7. Object Number: 2026822 Size: SH
  7. Install the crankshaft balancer (2) and NEW bolt (1) with screw locking compound and tighten in 3 passes:
    8. 7.1. First pass to  95 N·m (70 lb ft)
    7.2. Second pass to  45°
    7.3. Third pass to  15°
  8. Remove the EN-652 flywheel holder .
  9. Remove the EN 6340 locking tool .
  10. Check position of the camshaft sprocket.
    11. 10.1. Turn crankshaft 720° in the direction of engine rotation by the crankshaft balancer bolt.

            Note: Note marking, camshaft sprocket.

    10.2. Insert EN 6340 locking tool into camshaft timing gears.
  11. Check the crankshaft position.

    12. Marking on crankshaft balancer must align with marking on timing belt lower cover.

  12. Install the timing belt upper front cover. Refer to Timing Belt Upper Front Cover Installation.

Timing Belt Inspection and Adjustment Inspection LLU

Special Tools

EN-6340 Locking Tool

For equivalent regional tools, refer to Special Tools.

Removal Procedure
  1. Remove the timing belt upper front cover. Refer to Timing Belt Upper Front Cover Removal.

    2. Object Number: 1936993 Size: SH
  2. Set the engine to TDC.

    3. Set the crankshaft balancer in the direction of the engine rotation to "1st cylinder TDC" (mark 1).

  3. Remove the camshaft cover. Refer to Camshaft Cover Removal.

    4. Object Number: 1944922 Size: SH

    Note: 

       • The spot type marking (4) on the intake camshaft sprocket does not correspond to the groove of the EN-6340 locking tool  - left (1) during this process, but must be somewhat above.
       • The spot type marking (3) on the exhaust camshaft sprocket must correspond to the groove on EN-6340 locking tool  - right (2).

  4. Insert the EN-6340 locking tool  - left (1) and the EN-6340 locking tool  - right (2) in the camshaft sprocket.

Installation Procedure
  1. Remove the EN-6340 locking tool .
  2. Install the camshaft cover. Refer to Camshaft Cover Installation.
  3. Install the timing belt upper front cover. Refer to Timing Belt Upper Front Cover Installation.