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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

How to replace timing gears - Vauxhall/Opel Movano A 2.5 DTI
How to replace timing gears – Vauxhall/Opel Movano A 2.5 DTI
  • 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] .

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