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How to replace timing belt – Vauxhall/Opel Movano A 2.8DTI

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

How to replace timing belt - Vauxhall/Opel Movano A 2.8DTI
How to replace timing belt – Vauxhall/Opel Movano A 2.8DTI
  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.

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