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Condition Value
expand_moreAir intake system
expand_moreIntake manifold
Opel diesel straight-4 3.0 L ZD3 200 134 HP at 3600 RPM, 320 N⋅m at 1800 RPM 16.23 lbf⋅ft
Opel diesel straight-4 3.0 L ZD3 202 134 HP at 3600 RPM, 320 N⋅m at 1800 RPM 16.23 lbf⋅ft
Opel diesel straight-4 1.9 L F9Q 772 80 HP at 3500 RPM, 200 N⋅m at 2000 RPM 20.65 lbf⋅ft
Opel diesel straight-4 1.9 L F9Q 774 80 HP at 3500 RPM, 200 N⋅m at 2000 RPM 20.65 lbf⋅ft
All other modifications 8.85 lbf⋅ft
expand_moreAuxiliary assemblies
expand_moreAuxiliary drive belt deflection pulley
Opel diesel straight-4 2.5 L G9U 754 113 HP 32.45 lbf⋅ft
Opel diesel straight-4 2.5 L G9U 720 113 HP 32.45 lbf⋅ft
Opel diesel straight-4 2.5 L G9U 724 113 HP 32.45 lbf⋅ft
Opel diesel straight-4 3.0 L ZD3 200 134 HP at 3600 RPM, 320 N⋅m at 1800 RPM 40.57 lbf⋅ft
Opel diesel straight-4 3.0 L ZD3 202 134 HP at 3600 RPM, 320 N⋅m at 1800 RPM 40.57 lbf⋅ft
Without air-conditioning system 32.45 lbf⋅ft
Opel diesel straight-4 2.5 L G9U 754 98 HP 32.45 lbf⋅ft
All other modifications 22.13 lbf⋅ft
expand_moreAuxiliary drive belt tensioner
All Opel diesel straight-4 3.0 L ZD3 200 engines 19.18 lbf⋅ft
All Opel diesel straight-4 3.0 L ZD3 202 engines 19.18 lbf⋅ft
All other modifications 15.49 lbf⋅ft
Auxiliary drive belt tensioner 15.49 lbf⋅ft
expand_moreAir-conditioning compressor
Air-conditioning compressor bracket 33.19 lbf⋅ft
Air-conditioning compressor pressure line 5.9 lbf⋅ft
expand_moreAlternator
Lower screws 33.19 lbf⋅ft
Upper screws 16.23 lbf⋅ft
Opel diesel straight-4 2.5 L G9U 650 143 HP, 300 N⋅m 22.13 lbf⋅ft
Opel diesel straight-4 2.5 L G9U 632 143 HP, 320 N⋅m 22.13 lbf⋅ft
Opel diesel straight-4 1.9 L F9Q 772 80 HP at 3500 RPM, 200 N⋅m at 2000 RPM 18.44 lbf⋅ft
Opel diesel straight-4 1.9 L F9Q 774 80 HP at 3500 RPM, 200 N⋅m at 2000 RPM 18.44 lbf⋅ft
Opel diesel straight-4 2.5 L G9U 650 99 HP at 3500 RPM, 260 N⋅m at 1600 RPM 22.13 lbf⋅ft
All other modifications 15.49 lbf⋅ft
Generator bracket 22.13 lbf⋅ft
expand_moreHydraulic lines at the servo-steering pump
2.5 DTi with diesel straight-4 2.5 L 98 HP engine (2003.10–) 15.49 lbf⋅ft
expand_moreServo pump pulley
Opel diesel straight-4 3.0 L ZD3 200 134 HP at 3600 RPM, 320 N⋅m at 1800 RPM 8.11 lbf⋅ft
Opel diesel straight-4 3.0 L ZD3 202 134 HP at 3600 RPM, 320 N⋅m at 1800 RPM 8.11 lbf⋅ft
All other modifications 7.38 lbf⋅ft
expand_moreServo steering pump
expand_moreVacuum pump
Opel diesel straight-4 3.0 L ZD3 200 134 HP at 3600 RPM, 320 N⋅m at 1800 RPM 16.23 lbf⋅ft
Opel diesel straight-4 3.0 L ZD3 202 134 HP at 3600 RPM, 320 N⋅m at 1800 RPM 16.23 lbf⋅ft
All other modifications 16.96 lbf⋅ft
expand_moreCarburetion
expand_moreFuel-distributing pipe
Opel diesel straight-4 3.0 L ZD3 200 134 HP at 3600 RPM, 320 N⋅m at 1800 RPM 19.18 lbf⋅ft
Opel diesel straight-4 3.0 L ZD3 202 134 HP at 3600 RPM, 320 N⋅m at 1800 RPM 19.18 lbf⋅ft
Opel diesel straight-4 2.5 L G9U 650 143 HP, 300 N⋅m 18.44 lbf⋅ft
Opel diesel straight-4 2.5 L G9U 632 143 HP, 320 N⋅m 18.44 lbf⋅ft
Opel diesel straight-4 1.9 L F9Q 772 80 HP at 3500 RPM, 200 N⋅m at 2000 RPM 14.7517.7 lbf⋅ft
Opel diesel straight-4 1.9 L F9Q 774 80 HP at 3500 RPM, 200 N⋅m at 2000 RPM 14.7517.7 lbf⋅ft
Opel diesel straight-4 2.2 L G9T 750 89 HP 16.96 lbf⋅ft
Opel diesel straight-4 2.2 L G9T 720 89 HP 16.96 lbf⋅ft
Opel diesel straight-4 2.2 L G9T 722 89 HP at 3650 RPM, 260 N⋅m at 1500 RPM 16.96 lbf⋅ft
Opel diesel straight-4 2.5 L G9U 650 99 HP at 3500 RPM, 260 N⋅m at 1600 RPM 18.44 lbf⋅ft
expand_moreAll other modifications
G9U 750 engine 18.44 lbf⋅ft
Otherwise 16.96 lbf⋅ft
expand_moreHigh-pressure pump pulley
expand_moreAll Opel diesel straight-4 1.9 L F9Q 774 engines
First stage 11.06 lbf⋅ft
Second stage 60°
All other modifications 66.38 lbf⋅ft
expand_moreInjection hoses
On injector 18.44 lbf⋅ft
Otherwise 19.91 lbf⋅ft
expand_moreInjection nozzle (injector)
Opel diesel straight-4 3.0 L ZD3 202 134 HP at 3600 RPM, 320 N⋅m at 1800 RPM 17.7 lbf⋅ft
Opel diesel straight-4 3.0 L ZD3 200 134 HP at 3600 RPM, 320 N⋅m at 1800 RPM 17.7 lbf⋅ft
Opel diesel straight-4 1.9 L F9Q 774 80 HP at 3500 RPM, 200 N⋅m at 2000 RPM 14.7522.13 lbf⋅ft
Opel diesel straight-4 1.9 L F9Q 772 80 HP at 3500 RPM, 200 N⋅m at 2000 RPM 14.7522.13 lbf⋅ft
expand_moreAll other modifications
expand_moreFlywheel side
First stage 4.43 lbf⋅ft
Second stage 360°
Front side 4.43 lbf⋅ft
Injection pump 22.13 lbf⋅ft
expand_moreInjection pump pulley
Nuts 73.76 lbf⋅ft
Screws 28.03 lbf⋅ft
expand_moreCharging
expand_moreTurbo charger
Opel diesel straight-4 3.0 L ZD3 200 134 HP at 3600 RPM, 320 N⋅m at 1800 RPM 22.13 lbf⋅ft
Opel diesel straight-4 3.0 L ZD3 202 134 HP at 3600 RPM, 320 N⋅m at 1800 RPM 22.13 lbf⋅ft
On exhaust manifold 19.18 lbf⋅ft
Replace sealing rings.
All other modifications 20.65 lbf⋅ft
Turbocharger bracket 15.49 lbf⋅ft
Turbocharger oil feed line 16.23 lbf⋅ft
Replace sealing rings.
Turbocharger oil return line 8.85 lbf⋅ft
Replace sealing rings.
expand_moreCooling system
expand_moreCoolant pump
Nuts 35.4 lbf⋅ft
30 mm screws 19.18 lbf⋅ft
80 mm screws 19.18 lbf⋅ft
85 mm screws 35.4 lbf⋅ft
All other modifications 7.38 lbf⋅ft
Coolant pump pulley 8.11 lbf⋅ft
Radiator mounting 14.75 lbf⋅ft
expand_moreCylinder head
expand_moreCamshaft bearing
All Opel diesel straight-4 1.9 L F9Q 772 engines 14.75 lbf⋅ft
All Opel diesel straight-4 1.9 L F9Q 774 engines 14.75 lbf⋅ft
expand_moreAll Opel diesel straight-4 3.0 L ZD3 200 engines
First stage 8.85 lbf⋅ft
Second stage 15.49 lbf⋅ft
expand_moreCylinder head screws
Figure 1. Cylinder head, Cylinder head screws, Opel diesel straight-4 3.0 L ZD3 200 134 HP at 3600 RPM, 320 N⋅m at 1800 RPM.
Figure 1. Cylinder head, Cylinder head screws, Opel diesel straight-4 3.0 L ZD3 200 134 HP at 3600 RPM, 320 N⋅m at 1800 RPM.
First stage 32.45 lbf⋅ft
Replace and lightly oil the screws. See figure 1.
Second stage 100°
Third stage slacken
Fourth stage 30.98 lbf⋅ft
Fifth stage 90°
Sixth stage 90°
First stage 22.13 lbf⋅ft
Second stage 294306°
Figure 2. Cylinder head, Cylinder head screws, Opel diesel straight-4 1.9 L F9Q 774 80 HP at 3500 RPM, 200 N⋅m at 2000 RPM.
Figure 2. Cylinder head, Cylinder head screws, Opel diesel straight-4 1.9 L F9Q 774 80 HP at 3500 RPM, 200 N⋅m at 2000 RPM.
First stage 22.13 lbf⋅ft
Replace screws. See figure 2.
Second stage 22.13 lbf⋅ft
Control tensioner
Third stage 224236°
expand_moreAll other modifications
First stage 22.13 lbf⋅ft
Replace screws. See figure 2.
Second stage 294306°
Rocker bridge 9.59 lbf⋅ft
Valve cover 8.85 lbf⋅ft
expand_moreEngine block
expand_moreConnecting rod bearing
Opel diesel straight-4 3.0 L ZD3 202 134 HP at 3600 RPM, 320 N⋅m at 1800 RPM 59 lbf⋅ft
Opel diesel straight-4 3.0 L ZD3 200 134 HP at 3600 RPM, 320 N⋅m at 1800 RPM 59 lbf⋅ft
First stage 14.75 lbf⋅ft
Second stage 40°
expand_moreAll other modifications
First stage 18.44 lbf⋅ft
Second stage 4961°
expand_moreCrankshaft central screws
All Opel diesel straight-4 3.0 L ZD3 200 engines 280.27 lbf⋅ft
All Opel diesel straight-4 3.0 L ZD3 202 engines 280.27 lbf⋅ft
expand_moreAll other modifications
First stage 36.88 lbf⋅ft
Second stage 8496°
expand_moreCrankshaft pulley
First stage 14.75 lbf⋅ft
Replace screws.
Second stage 115±15°
expand_moreFlywheel
Opel diesel straight-4 3.0 L ZD3 202 134 HP at 3600 RPM, 320 N⋅m at 1800 RPM 125.39 lbf⋅ft
Opel diesel straight-4 3.0 L ZD3 200 134 HP at 3600 RPM, 320 N⋅m at 1800 RPM 125.39 lbf⋅ft
First stage 14.75 lbf⋅ft
Replace screws.
Second stage 70°
expand_moreG9T 720 and G9T 722 engines
First stage 18.44 lbf⋅ft
Replace screws.
Second stage 32.4541.3 lbf⋅ft
expand_moreG9T 750 engine
First stage 14.75 lbf⋅ft
Second stage 32.4541.3 lbf⋅ft
expand_moreAll other modifications
First stage 14.75 lbf⋅ft
Second stage 3951°
expand_moreMain bearing
Opel diesel straight-4 1.9 L F9Q 772 80 HP at 3500 RPM, 200 N⋅m at 2000 RPM 47.94 lbf⋅ft
Opel diesel straight-4 1.9 L F9Q 774 80 HP at 3500 RPM, 200 N⋅m at 2000 RPM 47.94 lbf⋅ft
expand_moreAll other modifications
First stage 14.75 lbf⋅ft
Second stage 140160°
expand_moreEngine control
Camshaft drive belt deflection pulley 22.13 lbf⋅ft
Camshaft timing chain guide rail 12.54 lbf⋅ft
Camshaft timing chain tensioning rail 12.54 lbf⋅ft
Camshaft timing gear 44.25 lbf⋅ft
Chain tensioner 19.18 lbf⋅ft
Control drive chain tensioning rail 12.54 lbf⋅ft
Inlet camshaft wheel 7.38 lbf⋅ft
Outlet camshaft wheel 7.38 lbf⋅ft
Timing case cover 19.18 lbf⋅ft
Use sealant.
Toothed belt guard 7.38 lbf⋅ft
Toothed belt guard at the bottom 7.38 lbf⋅ft
Toothed belt guard at the top 18.44 lbf⋅ft
expand_moreToothed belt tensioning roller
All Opel diesel straight-4 1.9 L F9Q 772 engines 36.88 lbf⋅ft
All Opel diesel straight-4 1.9 L F9Q 774 engines 36.88 lbf⋅ft
All other modifications 18.44 lbf⋅ft
expand_moreToothed belt tightener
Opel diesel straight-4 1.9 L F9Q 772 80 HP at 3500 RPM, 200 N⋅m at 2000 RPM 36.88 lbf⋅ft
Opel diesel straight-4 1.9 L F9Q 774 80 HP at 3500 RPM, 200 N⋅m at 2000 RPM 36.88 lbf⋅ft
All other modifications 18.44 lbf⋅ft
expand_moreEngine lubrication
expand_moreOil drain plug
Opel diesel straight-4 3.0 L ZD3 202 134 HP at 3600 RPM, 320 N⋅m at 1800 RPM 25.08 lbf⋅ft
Opel diesel straight-4 3.0 L ZD3 200 134 HP at 3600 RPM, 320 N⋅m at 1800 RPM 25.08 lbf⋅ft
Opel diesel straight-4 2.5 L G9U 650 143 HP, 300 N⋅m 13.28 lbf⋅ft
Opel diesel straight-4 2.5 L G9U 632 143 HP, 320 N⋅m 13.28 lbf⋅ft
Opel diesel straight-4 1.9 L F9Q 772 80 HP at 3500 RPM, 200 N⋅m at 2000 RPM 14.75 lbf⋅ft
Opel diesel straight-4 1.9 L F9Q 774 80 HP at 3500 RPM, 200 N⋅m at 2000 RPM 14.75 lbf⋅ft
G9T 720 and G9T 722 engines 16.23 lbf⋅ft
G9T 750 engine 18.44 lbf⋅ft
Opel diesel straight-4 2.5 L G9U 650 99 HP at 3500 RPM, 260 N⋅m at 1600 RPM 13.28 lbf⋅ft
expand_moreAll other modifications
G9U 750 engine 18.44 lbf⋅ft
expand_moreOil filter housing
Oil filter cover 18.44 lbf⋅ft
On the engine block 18.44 lbf⋅ft
Oil filter cover 18.44 lbf⋅ft
On the engine block 18.44 lbf⋅ft
expand_moreAll other modifications
Oil filter cover 18.44 lbf⋅ft
expand_moreOil lines
expand_moreOil feed lines
At the turbocharger 16.23 lbf⋅ft
expand_moreOil feed lines at the turbo charger
On the engine block 16.23 lbf⋅ft
expand_moreOil feed lines
At the turbocharger 16.23 lbf⋅ft
expand_moreReturn line
At the turbocharger 8.85 lbf⋅ft
expand_moreOil feed lines
At the turbocharger 11.06 lbf⋅ft
expand_moreOil feed lines
At the turbocharger 16.23 lbf⋅ft
expand_moreReturn line
At the turbocharger 5.9 lbf⋅ft
expand_moreAll other modifications
expand_moreOil feed lines
At the turbocharger 11.06 lbf⋅ft
expand_moreReturn line
At the turbocharger 5.9 lbf⋅ft
Oil pump 18.44 lbf⋅ft
expand_moreOil sump
Opel diesel straight-4 3.0 L ZD3 202 134 HP at 3600 RPM, 320 N⋅m at 1800 RPM 5.16 lbf⋅ft
Opel diesel straight-4 3.0 L ZD3 200 134 HP at 3600 RPM, 320 N⋅m at 1800 RPM 5.16 lbf⋅ft
First stage 5.9 lbf⋅ft
Second stage 11.06 lbf⋅ft
Opel diesel straight-4 2.2 L G9T 720 89 HP 7.38 lbf⋅ft
Opel diesel straight-4 2.2 L G9T 750 89 HP 7.38 lbf⋅ft
Opel diesel straight-4 2.2 L G9T 722 89 HP at 3650 RPM, 260 N⋅m at 1500 RPM 7.38 lbf⋅ft
expand_moreAll other modifications
First stage 3.69 lbf⋅ft
Second stage 6.64 lbf⋅ft
expand_moreEngine management
Camshaft sensor 7.38 lbf⋅ft
Crankshaft sensor 16.23 lbf⋅ft
expand_moreGlow plugs
G9U 750 engine 8.11 lbf⋅ft
Otherwise 11.06 lbf⋅ft
Opel diesel straight-4 3.0 L ZD3 200 134 HP at 3600 RPM, 320 N⋅m at 1800 RPM 12.54 lbf⋅ft
Opel diesel straight-4 3.0 L ZD3 202 134 HP at 3600 RPM, 320 N⋅m at 1800 RPM 12.54 lbf⋅ft
Opel diesel straight-4 1.9 L F9Q 774 80 HP at 3500 RPM, 200 N⋅m at 2000 RPM 11.06 lbf⋅ft
Opel diesel straight-4 1.9 L F9Q 772 80 HP at 3500 RPM, 200 N⋅m at 2000 RPM 11.06 lbf⋅ft
G9T 720 and G9T 722 engines 11.06 lbf⋅ft
G9T 750 engine 8.11 lbf⋅ft
All other modifications 8.11 lbf⋅ft
expand_moreEngine mounting
expand_moreEngine bracket
On the engine block 18.44 lbf⋅ft
expand_moreEngine mounting
expand_moreAll Opel diesel straight-4 1.9 L F9Q 774 engines
Nuts 62.69 lbf⋅ft
Screws 45.73 lbf⋅ft
expand_moreAll Opel diesel straight-4 2.5 L G9U 650 engines
M10 × 55 screws 32.45 lbf⋅ft
M12 × 40 screws 62.69 lbf⋅ft
Nuts 62.69 lbf⋅ft
expand_moreAll Opel diesel straight-4 3.0 L ZD3 200 engines
Right 62.69 lbf⋅ft
expand_moreAll other modifications
Nuts on the chassis 62.69 lbf⋅ft
Replace screws.
Screws on the chassis 62.69 lbf⋅ft
Replace screws.
Screws on the engine bracket 44.25 lbf⋅ft
Replace screws.
expand_moreExhaust system
expand_moreCatalytic converter
At the turbocharger 16.23 lbf⋅ft
On the engine block 33.19 lbf⋅ft
At the turbocharger 19.91 lbf⋅ft
All other modifications 15.49 lbf⋅ft
expand_moreExhaust manifold
Opel diesel straight-4 3.0 L ZD3 200 134 HP at 3600 RPM, 320 N⋅m at 1800 RPM 30.98 lbf⋅ft
Opel diesel straight-4 3.0 L ZD3 202 134 HP at 3600 RPM, 320 N⋅m at 1800 RPM 30.98 lbf⋅ft
G9T 750 engine 22.13 lbf⋅ft
Otherwise 19.91 lbf⋅ft
All other modifications 22.13 lbf⋅ft
expand_moreExhaust pipe
Opel diesel straight-4 2.5 L G9U 650 143 HP, 300 N⋅m 15.49 lbf⋅ft
Opel diesel straight-4 2.5 L G9U 632 143 HP, 320 N⋅m 15.49 lbf⋅ft
Opel diesel straight-4 1.9 L F9Q 774 80 HP at 3500 RPM, 200 N⋅m at 2000 RPM 15.49 lbf⋅ft
Opel diesel straight-4 1.9 L F9Q 772 80 HP at 3500 RPM, 200 N⋅m at 2000 RPM 15.49 lbf⋅ft
Opel diesel straight-4 2.5 L G9U 650 99 HP at 3500 RPM, 260 N⋅m at 1600 RPM 15.49 lbf⋅ft
All other modifications 19.91 lbf⋅ft
Primary catalytic converter 17.7 lbf⋅ft
Replace sealing rings.
expand_moreStart system
expand_moreStarter
Opel diesel straight-4 3.0 L ZD3 200 134 HP at 3600 RPM, 320 N⋅m at 1800 RPM 25.81 lbf⋅ft
Opel diesel straight-4 3.0 L ZD3 202 134 HP at 3600 RPM, 320 N⋅m at 1800 RPM 25.81 lbf⋅ft
Opel diesel straight-4 2.5 L G9U 650 143 HP, 300 N⋅m 33.19 lbf⋅ft
Opel diesel straight-4 2.5 L G9U 632 143 HP, 320 N⋅m 33.19 lbf⋅ft
Opel diesel straight-4 2.5 L G9U 650 99 HP at 3500 RPM, 260 N⋅m at 1600 RPM 33.19 lbf⋅ft
All other modifications 32.45 lbf⋅ft

Please be noted that all capacities listed here are approximate. Check fluid levels when adding or refilling as recommended in your 2009 Opel Movano Box Van user's manual. Keep in mind that all information here is provided “as is” without any warranty of any kind.

Before doing any DIY service please check your insurance policy and Opel warranty policy for your region. In some regions DIY service may invalidate your warranty.

Conquer your fears and never give up!

DIY car service is not as difficult as it looks like and it might save you thousands of dollars per year. It might be even fun and a good thing to do with your kids on a weekend to teach them how basic machinery works. It's really hard to screw something up and damage your car permanently if you use right tools, follow Opel Movano Box Van service manual and use right parts and fluids in prescribed amounts. Even modern cars stuffed with electronics can be serviced in your garage or even in your driveway. Changing engine oil, brake fluid, ATF, replacing brake pads, and etc. It's all may be done by yourself in a mater of a couple of hours.

Doing basic service for your 2009 Opel Movano Box Van you're not only saving money, but also also improving your technical skills and learning something new.

Units:
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