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

Replacement Interval Guide

• Vauxhall recommend replacement every 72,000 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(s).

Repair Times – hrs

Remove & install:
CDTi	2,10
DTi	2,00

Special Tools

• Crankshaft timing pin – Kent Moore No.6031.
• Engine support – Kent Moore No.6210-A.
• M6 bolt – for adjusting tensioner.
• Tension gauge – Kent Moore No.6225.
• Tensioning tool – Kent Moore No.6234.

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.

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: Battery fitted under LH seat.

1. Raise and support front of vehicle.
2. Remove:
   • Engine undershield.
   • RH front wheel.
   • RH splash guard.
   • Auxiliary drive belt. DO NOT reuse belt.
   • Auxiliary drive belt tensioner (if necessary).
3. Install engine support to subframe. Tool No.6210-A.
4. Remove:
   • Blanking plug from cylinder block [1] .
   • Engine top cover.
5. Detach wiring harness and fuel pipe from RH engine mounting. Move to one side.
6. Remove:
   • RH engine mounting.
   • RH engine mounting bracket.
7. Turn crankshaft clockwise until camshaft sprocket timing mark aligned [2] .
8. Remove timing belt cover [3] .
9. Mark sprocket and engine with paint or chalk where indicated [4] .
10. Insert crankshaft timing pin [5] . Tool No.6031. Turn crankshaft slowly clockwise until timing pin engages.
11. Ensure timing marks aligned [4] .
12. Remove:
    • Crankshaft pulley bolt [6] .
    • Crankshaft pulley [7] .
13. Slacken tensioner nut [8] . Move tensioner away from belt.
14. Remove timing belt.

Installation

NOTE: DO NOT refit used belt. Timing belt must always be renewed once it has been slackened or removed.

1. Ensure crankshaft timing pin inserted [5] .
2. Ensure timing marks aligned [4] .
3. Fit timing belt in anti-clockwise direction. Ensure marks on belt aligned with marks on sprockets [9] & [10] . Ensure belt is taut on non-tensioned side.NOTE: Observe direction of rotation marks on belt.
4. Fit tensioning tool [11] . Tool No.6234.
5. Remove crankshaft timing pin [5] .
6. Screw an M6 bolt into tensioner bracket until tensioner pulley contacts belt [12] .
7. Apply clockwise torque of 11 Nm [13] .
8. Remove tensioning tool.
9. Attach tension gauge to belt at  [14] . Tool No.6225.
10. Screw in M6 bolt until tension gauge indicates 95±3 Hz.
11. Temporarily tighten tensioner nut [8] . Tightening torque: 10 Nm.
12. Turn crankshaft two turns clockwise.
13. Insert timing pin in crankshaft [5] . Rock crankshaft slightly to ensure timing pin located correctly.
14. Remove crankshaft timing pin [5] .
15. Fit tensioning tool [11] . Tool No.6234.
16. Apply clockwise torque of 11 Nm [13] .
17. Remove tensioning tool.
18. Attach tension gauge to belt at [14] . Tool No.6225.
19. Tension gauge should indicate 90±3 Hz.
20. If not: Repeat tensioning procedure.
21. Tighten tensioner nut [8] . Tightening torque: 50 Nm.
22. Remove M6 bolt [12] .
23. Refit blanking plug [1] . Tightening torque: 20 Nm.
24. Install components in reverse order of removal.
25. Lock flywheel with large screwdriver.
26. Fit new crankshaft pulley bolt [6] . Tightening torque: 20 Nm + 115°±15°.