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How to replace timing belt – Vauxhall/Opel Movano A 2.5 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 2,60

Special Tools

  • Crankshaft timing pin – Kent Moore No.KM.6203.
  • Inlet camshaft locking tool – Kent Moore No.KM.6204.
  • Exhaust camshaft locking tool – Kent Moore No.KM.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 2.5 DTI
How to replace timing belt – Vauxhall/Opel Movano A 2.5 DTI

Removal

  1. Raise and support vehicle.
  2. Remove:
      • Engine undershield.
      • Oil filter housing bolt [1] .
  3. Fit crankshaft timing pin [2] . Tool No.KM.6203.
  4. Turn crankshaft clockwise until timing pin engages.
  5. Ensure crankshaft pulley mark at lower position [3] .
  6. Support engine.
  7. Unclip wiring harness from bracket on timing belt upper cover and remove bracket.
  8. Remove timing belt upper cover [4] .
  9. Unclip fuel pipes from RH engine mounting intermediate bracket.
  10. Ensure grooves in camshafts vertically positioned:
      • Narrow groove on the left [5] .
      • Wide groove on the right [6] .
  11. If not: Remove crankshaft timing pin and turn crankshaft one turn clockwise.
  12. Remove PAS reservoir from mounting bracket and move to one side.
  13. Remove:
      • RH engine mounting and intermediate bracket.
      • Timing belt lower cover [7] .
      • RH engine bracket.
  14. Fit inlet camshaft locking tool [8] . Tool No.KM.6204. Tighten bolt finger tight [9] .
  15. Slacken inlet camshaft sprocket bolts one turn [10] .
  16. Adjust position of camshaft until tool can be located correctly.
  17. Tighten inlet camshaft locking tool bolt [9] .
  18. Fit exhaust camshaft locking tool [11] . Tool No.KM.6205. Tighten bolt finger tight [12] .
  19. Slacken exhaust camshaft sprocket bolts one turn [13] .
  20. Adjust position of camshaft until tool can be located correctly.
  21. Tighten exhaust camshaft locking tool bolt [12] .
  22. Slacken tensioner bolt [14] .
  23. Remove:
      • Inlet camshaft sprocket bolts [10] .
      • Inlet camshaft sprocket [15] .
      • Timing belt.
      • Tensioner pulley.
      • Guide pulley.

Installation

  1. Ensure crankshaft pulley mark at lower position [3] .
  2. Ensure timing pin located correctly [2] .
  3. Ensure camshaft locking tools correctly located [8] & [11] .
  4. Fit new guide pulley. Tighten guide pulley bolt to 30 Nm [16] .
  5. Fit new tensioner pulley. Tighten bolt finger tight [14] .
  6. Ensure tensioner pulley located correctly on dowel pin [17] .
  7. Fit inlet camshaft sprocket [15] to belt, then install camshaft sprocket with belt onto end of camshaft.
  8. Align inlet camshaft sprocket with bolts in centre of slotted holes [18] .
  9. Fit timing belt to remaining sprockets and pulleys.
  10. Ensure exhaust camshaft sprocket bolts in centre of slotted holes [18] .
  11. Ensure exhaust camshaft locking tool lever has free movement [19] .
  12. Turn tensioner anti-clockwise until top of lever arm [19] aligns with upper edge of tool [11] . Use 6 mm Allen key.
  13. Tighten tensioner bolt to 25 Nm [14] .
  14. Ensure tensioner pointer at position shown [20] .
  15. Ensure camshaft sprocket bolts not at end of slotted holes [18] .
  16. Tighten bolts of each camshaft sprocket [10] & [13] . Tightening torque: 10 Nm.
  17. Remove:
      • Locking tools [8] & [11] .
      • Crankshaft timing pin [2] .
  18. Turn crankshaft two turns clockwise.
  19. Fit crankshaft timing pin [2] .
  20. Turn crankshaft clockwise until timing pin engages in crankshaft.
  21. Ensure crankshaft pulley mark at lower position [3] .
  22. Fit inlet camshaft locking tool [8] . Tighten bolt finger tight [9] .
  23. Slacken inlet camshaft sprocket bolts one turn [10] .
  24. Adjust position of camshaft until tool can be located correctly.
  25. Tighten inlet camshaft locking tool bolt [9] .
  26. Fit exhaust camshaft locking tool [11] . Tighten bolt finger tight [12] .
  27. Slacken exhaust camshaft sprocket bolts one turn [13] .
  28. Adjust position of camshaft until tool can be located correctly.
  29. Tighten exhaust camshaft locking tool bolt [12] .
  30. Ensure exhaust camshaft locking tool lever has free movement [19] .
  31. Slacken tensioner bolt [14] .
  32. Turn tensioner anti-clockwise until raised part of lever arm [21] aligns with upper edge of tool [11] . Use 6 mm Allen key.
  33. Turn tensioner until pointer aligned with notch [22] .
  34. Tighten tensioner bolt to 25 Nm [14] .
  35. Tighten bolts of each camshaft sprocket [10] & [13] . Tightening torque: 10 Nm.
  36. Remove:
      • Locking tools [8] & [11] .
      • Crankshaft timing pin [2] .
  37. Fit oil filter housing bolt [1] . Tightening torque: 30 Nm.

    NOTE: Coat threads of oil filter housing bolt with suitable thread locking compound.

  38. Install components in reverse order of removal.
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Published in Movano A