How to replace timing belt – Vauxhall/Opel Movano A 2.5 D

Replacement Interval Guide

• Vauxhall recommend:
• Arena/Movano 2,5 D:
• →98MY: Replacement every 50,000 miles or 5 years.
• 99MY→: Replacement every 72,000 miles or 5 years.
• Movano 2,8 D/TD:
• Replacement every 60,000 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:
Arena	1,90
Movano	1,00

Special Tools

• Crankshaft pulley timing pin (Arena) – Kent Moore No.KM-966.
• Flywheel timing pin (Movano) – Kent Moore No.KM-966.
• Injection pump sprocket locking pin – Kent Moore No.KM-966.

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

1. Remove:
   • Engine undershield.
   • Air filter assembly.
   • Heater fan intake ducting.
   • Radiator fan(s).
   • Arena: Radiator.
2. Disconnect brake servo hose and throttle cable.
3. Slacken crankshaft pulley bolt [1] .
4. Turn crankshaft to TDC on No.1 cylinder. Ensure timing marks aligned [2] .
5. Remove:
   • Auxiliary drive belt. DO NOT reuse belt.
   • Movano: Water pump pulley.
   • Oil filler cap.
   • Engine top cover [3] .
   • Timing belt upper cover [4] .
6. Ensure camshaft sprocket timing mark aligned with mark on cylinder head cover [5] .
7. Insert locking pin in injection pump sprocket [6] . Tool No.KM-966.
8. Movano: Insert timing pin in flywheel [7] . Tool No.KM-966.
9. Remove:
   • Crankshaft pulley bolt [1] .
   • Crankshaft pulley [8] .
   • Tensioner nut and washer [9] .
   • Timing belt lower cover [10] .
10. Refit nut and washer to stud [9] . DO NOT tighten.
11. Compress tensioner spring to release tension on belt. Retain in position with U-shaped tool [11] .NOTE: Tool can be manufactured from a 14 mm nut cut to shape.
12. Move tensioner pulley away from belt.
13. Remove timing belt.

Installation

1. Ensure camshaft sprocket timing mark aligned [5] .
2. Movano: Ensure flywheel timing pin located correctly [7] .
3. Arena: Temporarily fit crankshaft pulley [8] . Insert crankshaft pulley timing pin [12] . Tool No.KM-966.
4. Ensure injection pump sprocket locking pin located correctly [6] .
5. Arena: Remove crankshaft pulley [8] .
6. Fit timing belt, starting at crankshaft sprocket. Ensure belt is taut on non-tensioned side.
7. Remove nut and washer [9] .
8. Fit timing belt lower cover [10] .
9. Refit nut and washer to stud [9] . DO NOT tighten.
10. Fit crankshaft pulley [8] .
11. Fit crankshaft pulley bolt [1] . Hand tighten.
12. Remove:
    • Tensioner tool [11] .
    • Injection pump sprocket locking pin [6] .
    • Movano: Flywheel timing pin [7] .
13. Tighten crankshaft pulley bolt [1] . Tightening torque: 200 Nm.
14. Turn crankshaft 1/4 turn clockwise.
15. Tighten tensioner nut [9] . Tightening torque: 45 Nm.
16. Turn crankshaft 3/4 turn clockwise.
17. Slacken and tighten tensioner nut [9] . Tightening torque: 45 Nm.
18. Turn crankshaft one turn clockwise to TDC. Ensure timing marks aligned [2] .
19. Ensure camshaft sprocket timing mark aligned [5] .
20. Ensure timing pin and locking pin can be inserted:
    • Arena: [6] & [12] .
    • Movano: [6] & [7] .
21. Install components in reverse order of removal.