How to replace timing gears – Vauxhall/Opel Movano A 2.2 DTI

Special tools

• Crankshaft locking pin – No.KM-6203.
• Flywheel/drive plate locking tool – No.KM-652.
• Injection pump gear holding tool – No.KM-6293.
• Injection pump gear puller – No.KM-6207.
• Intermediate gear locking tool – No.KM-6294.

General precautions

• Disconnect battery earth lead.
• Remove glow plugs to ease turning engine.
• Turn engine in normal direction of rotation (unless otherwise stated).
• Observe tightening torques.
• If fitted: Mark position of crankshaft position (CKP) sensor before removal.
• Do NOT turn crankshaft via camshaft or other gears.
• Do NOT turn crankshaft or camshaft with timing gear(s) removed.

Valve timing procedures

• Engine at TDC on No.1 cylinder.
• Rock crankshaft slightly to ensure crankshaft locking pin located correctly [1] .
• Ensure crankshaft keyway at 12 o’clock position [2] .
• Align timing mark on injection pump gear with mark on timing case [3] .
• Ensure injection pump gear holding tool can be fitted [4] .
• Intermediate gears have no timing marks [5] & [6] .
• Tighten injection pump gear nut to 90 Nm [7] .
• Tighten coolant pump gear nut to 40 Nm [8] .