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How to replace timing chain – Vauxhall/Opel Movano A 3.0 CDTI

Special tools

  • Engine support tool – No.KM-6210-A.
  • Flywheel locking tool – No.KM-6433-1.
  • High-pressure fuel pump gear puller 1 x 2 – No.KM-161-3.
  • High-pressure fuel pump gear puller 2 – No.KM-161-B.
  • High-pressure fuel pump sprocket holding tool – No.KM-6245.

General precautions

  • Disconnect battery earth lead.
  • Remove glow plugs to ease turning engine.
  • Turn engine in normal direction of rotation (unless otherwise stated).
  • DO NOT use special tools listed above to lock engine when slackening sprocket bolts.
  • Observe tightening torques.
  • Mark position of crankshaft position (CKP) sensor before removal.
  • Do NOT turn crankshaft via camshaft or other sprockets.
  • Do NOT turn crankshaft or camshaft with timing chain removed.

Valve timing procedures

How to replace timing chain - Vauxhall/Opel Movano A 3.0 CDTI
How to replace timing chain – Vauxhall/Opel Movano A 3.0 CDTI
  • Engine at TDC on No.1 cylinder [1] .
  • Ensure timing marks on camshaft sprocket aligned with blue coloured links [2] .
  • Ensure timing mark on high-pressure fuel pump sprocket aligned with yellow coloured link [3] .
  • Ensure timing marks on camshaft gears aligned with timing marks on auxiliary gear 1 [4] .
  • Align timing marks on crankshaft gear and auxiliary gear 2 [5] .
  • Align timing marks on auxiliary gear 2 and high-pressure fuel pump gear [6] .
  • Align timing marks on auxiliary gear 2 and balancer shaft gear 1 [7] .
  • Align timing marks on auxiliary gear 2 and auxiliary gear 3 [8] .
  • Align timing marks on auxiliary gear 3 and balancer shaft gear 2 [9] .
  • Remove tensioner assembly before carrying out engine repairs [10] .
  • Reset timing chain tensioner:
      • Turn ratchet clockwise to release tensioner [11] .
      • Push plunger into tensioner body in direction of arrow [12] .
      • Insert suitable pin to lock tensioner plunger [13] .
  • Fit camshaft sprocket and timing chain. Ensure camshaft sprocket aligns with exhaust camshaft gear locating pin [14] .
  • Install tensioner after repairs [10] .
  • Remove locking pin [13] .
  • Tighten camshaft sprocket bolt. Tightening torque: 63 Nm.

NOTE: Remove blanking plug from timing cover. Before removing high-pressure fuel pump gear lock auxiliary gear 2 with suitable bolt [15] .

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