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

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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6 votes

One Comment

  1. Andy Andy

    The bottom pulley has a cap over the bolt – this is leaking oil. What is the cause of this? One can see the half moons on the pulley which allows the oil in. But the oil is leaking through the cap. What is the cause of this? Is this a safety feature letting us know there is a problem with the oil pump.

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