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

Special tools

• Crankshaft locking pin – Kent Moore No.KM-6203.
• Flywheel/drive plate locking tool – Kent Moore No.KM-911.
• Injection pump gear holding tool – Kent Moore No.KM-6293.
• Injection pump gear puller – Kent Moore No.KM-6207.
• Intermediate gear locking tool – Kent Moore No.KM-6294.
• Two-piece gear alignment tool – Kent Moore No.KM-6295.

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

• Removal/installation of timing gears requires:
  • Engine removal.
  • Timing belt removal.
• Engine at TDC on No.1 cylinder [1] .
• Rock crankshaft slightly to ensure crankshaft locking pin located correctly [2] .
• Ensure crankshaft keyway at 12 o’clock position [3] .
• Align timing mark on injection pump gear with mark on timing case [4] .
• Ensure injection pump gear holding tool can be fitted [5] .
• Intermediate gears have no timing marks [6] & [7] .
• Tighten injection pump gear nut to 90 Nm [8] .
• Tighten coolant pump gear nut to 60 Nm [9] .