How to replace timing belt – Vauxhall/Opel Movano A 1.9 D

Replacement Interval Guide

• Vauxhall recommend replacement every 48,000 miles or 5 years.
• The previous use and service history of the vehicle must always be taken into account.

Check For Engine Damage

CAUTION: This engine has been identified as an INTERFERENCE engine in which the possibility of valve-to-piston damage in the event of a timing belt failure is MOST LIKELY to occur. A compression check of all cylinders should be performed before removing the cylinder head.

Repair Times – hrs

Remove & install

3,40

Special Tools

• Crankshaft locking pin – Kent Moore No.6031.
• Injection pump sprocket locking tool – Kent Moore No.6032.
• Engine support – Kent Moore No.6210.

Special Precautions

• Disconnect battery earth lead.
• DO NOT turn crankshaft or camshaft when timing belt removed.
• Remove glow plugs to ease turning engine.
• Turn engine in normal direction of rotation (unless otherwise stated).
• DO NOT turn engine via camshaft or other sprockets.
• Observe all tightening torques.
• Check diesel injection pump timing after belt replacement.

Removal

NOTE: If timing belt has failed, it is possible that the camshaft sprocket key has been damaged which would cause incorrect valve timing.

NOTE: No.1 cylinder is at flywheel end.

1. Raise and support vehicle.
2. Remove:
   • Engine undershield.
   • Air filter housing.
3. Unclip fuel feed pipe from RH engine mounting. Move to one side.
4. Support engine. Tool No.6210.
5. Remove:
   • RH engine mounting and bracket.
   • Auxiliary drive belt.

     NOTE: Auxiliary drive belt(s), tensioner pulley and guide pulley(s) MUST be replaced.

   • Bolt from cylinder block [1] .
6. Turn crankshaft clockwise until camshaft sprocket timing mark aligned with mark on timing belt cover [2] .
7. Fit crankshaft locking pin [3] . Tool No.6031.
8. Rock crankshaft slightly to ensure locking pin located correctly.
9. Ensure marks on belt aligned with marks on sprockets [8] & [9] .
10. Remove crankshaft locking pin.
11. Fit suitable flywheel locking tool.
12. Remove:
    • Crankshaft pulley bolt [4] .
    • Crankshaft pulley [5] .
    • Timing belt covers [6] .
    • Flywheel locking tool.
13. Fit injection pump sprocket locking tool. Tool No.6032.
14. Slacken tensioner nut to release tension on belt [7] .
15. Remove timing belt.

Installation

NOTE: Timing belt, tensioner pulley and guide pulleys MUST be replaced.

1. Rock crankshaft slightly to ensure locking pin located correctly [3] .
2. Observe direction of rotation marks on belt [10] .
3. Fit timing belt. Ensure marks on belt aligned with marks on sprockets [8] & [9] . Ensure belt is taut between sprockets.
4. Remove locking tool from injection pump sprocket.
5. Remove crankshaft locking pin [3] .
6. Turn tensioner pulley anti-clockwise until marks aligned [A] & [B] . Use 6 mm Allen key. Tighten tensioner nut [7] . Tightening torque: 20 Nm.
7. Turn crankshaft two turns clockwise to TDC on No.1 cylinder.
8. Insert crankshaft locking pin [3] .
9. Ensure marks on belt aligned with marks on sprockets [8] & [9] .
10. Ensure tensioner pulley marks aligned [A] & [B] . If not: Repeat tensioning procedure.
11. Remove crankshaft locking pin [3] .
12. Install components in reverse order of removal.
13. Fit new crankshaft pulley bolt [4] . Tightening torque: 20 Nm + 115°.