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How to replace timing belt – Vauxhall/Opel Movano A 2.2 DTI

Published September 29, 2015

Replacement Interval Guide

  • Vauxhall recommend replacement every 72,000 miles or 5 years (tensioner and guide pulley must also be replaced).
  • 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 2,20

Special Tools

  • Engine support – Kent Moore No.6210-A.
  • Crankshaft locking pin – Kent Moore No.6203.
  • Camshaft locking tools – Kent Moore No.6204/6205.

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 2.2 DTI
How to replace timing belt – Vauxhall/Opel Movano A 2.2 DTI

Removal

  1. Raise and support vehicle.
  2. Remove:
      • Engine undershield.
      • RH wheel.
      • RH inner wing panel.
  3. Support engine. Use tool No.6210-A.
  4. Unclip:
      • Fuel rail cover.
      • Fuel feed pipe from RH engine mounting. Move to one side.
  5. Remove:
      • RH engine mounting.
      • RH lower support bracket.
      • Timing belt upper cover [1] .
      • Timing belt lower cover [2] .
      • Oil filter housing bolt [3] .
  6. Turn crankshaft clockwise until grooves in camshafts vertically positioned [5] .

    NOTE: Grooves positioned to RH (exhaust) side of engine.

  7. Early models: Ensure crankshaft pulley mark at lower position [4] .
  8. Fit crankshaft locking pin [6] . Tool No.6203.
  9. Rock crankshaft slightly to ensure locking pin located correctly.
  10. Install camshaft locking tools [7] & [8] . Tool Nos.6204/6205.
  11. If tools cannot be fitted correctly: Turn crankshaft one turn clockwise.
  12. Slacken bolts of each camshaft sprocket [9] & [15] .
  13. Slacken tensioner bolt [10] .
  14. Remove:
      • Exhaust camshaft sprocket bolts [9] .
      • Exhaust camshaft sprocket [16] .
      • Guide pulley bolt [17] .
      • Guide pulley.
      • Timing belt.

Installation

  1. Rock crankshaft slightly to ensure locking pin located correctly [6] .
  2. Ensure camshaft locking tools correctly located [7] & [8] .
  3. Fit new guide pulley. Tighten guide pulley bolt to 30 Nm [17] .
  4. Fit new tensioner pulley. Tighten bolt finger tight [10] .

    NOTE: Ensure tensioner pulley located correctly on dowel pin [18] .

  5. Ensure inlet camshaft sprocket bolts [15] not at end of slotted holes [14] .
  6. Fit timing belt in following order:
      • Intermediate shaft sprocket.
      • Guide pulley.
      • Inlet camshaft sprocket.
      • Tensioner pulley.
  7. Fit exhaust camshaft sprocket [16] to belt, then install camshaft sprocket with belt onto end of camshaft. Ensure sprocket bolts not at end of slotted holes [14] .
  8. Turn tensioner anti-clockwise until top of lever arm [11] aligns with upper edge of tool [7] . Use 6 mm Allen key.

    NOTE: Ensure exhaust camshaft sprocket bolts not at end of slotted holes [14] .

  9. Tighten tensioner bolt [10] . Tightening torque: 25 Nm.
  10. Tighten bolts of each camshaft sprocket [9] & [15] . Tightening torque: 10 Nm.
  11. Remove:
      • Locking tools [7] & [8] .
      • Crankshaft locking pin [6] .
  12. Turn crankshaft two turns clockwise.
  13. Fit crankshaft locking pin [6] .
  14. Rock crankshaft slightly to ensure locking pin located correctly.
  15. Install camshaft locking tools [7] & [8] .
  16. Slacken bolts of each camshaft sprocket [9] & [15] .
  17. Slacken tensioner bolt [10] .
  18. Turn tensioner anti-clockwise until raised part of lever arm [12] aligns with upper edge of tool [7] . Use 6 mm Allen key.
  19. Turn tensioner until pointer aligned with notch [13] .
  20. Tighten tensioner bolt [10] . Tightening torque: 25 Nm.
  21. Tighten bolts of each camshaft sprocket [9] & [15] . Tightening torque: 10 Nm.
  22. Remove:
      • Locking tools [7] & [8] .
      • Crankshaft locking pin [6] .
  23. Fit oil filter housing bolt [3] . Tightening torque: 30 Nm.
  24. Install components in reverse order of removal.
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Published in Movano A