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Our Insignia project started back in the February 2018 issue. Here’s what we have covered to date.
February 2018 Driven back from the auction near Derby, the oil pressure warning light appeared on the dashboard when Rob had almost made it home.
March 2018 Oil change, new turbo and a new rear wheel bearing. Low oil pressure problem not fixed.
April 2018 In a bid to fix the low oil pressure problem, a seal for the pick-up pipe is renewed, but we discover the main bearings are worn.
May 2018 We decide to remove the engine to strip and rebuild it. Plus, several dents in the bodywork are removed.
June 2018 Full stripdown and inspection of the Insignia’s diesel engine. Our main bearing caps and the crankshaft are scrapped.
July 2018 Replacement main bearing caps are line-bored to the engine block. A secondhand crankshaft is sourced and machined to fit 0.75mm oversize bearings.
August 2018 Reassembly of our repaired and revived engine.
September 2018 The gearbox is stripped and inspected, then it and the engine are refitted.
October 2018 New front brake discs and pads, droplinks, rear coil springs, glow plugs, a 500-amp main fuse, fuel filter and a full set of Avon tyres are fitted.
November 2018 After 1400 miles, disaster strikes with a snapped exhaust camshaft, broken rockers and a damaged crankshaft timing cog.