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

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 warning [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°.
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