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Condition Value
expand_moreAir intake system
expand_moreIntake manifold
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 3.0 L ZD3 200 134 HP at 3600 RPM, 320 N⋅m at 1800 RPM 16.23 lbf⋅ft
G9T 750 engine 8.85 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 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 2.5 L G9U 754 113 HP 32.45 lbf⋅ft
Opel diesel straight-4 2.5 L G9U 750 113 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
All Opel diesel straight-4 3.0 L ZD3 200 engines 33.19 lbf⋅ft
All Opel diesel straight-4 3.0 L ZD3 202 engines 33.19 lbf⋅ft
All other modifications 15.49 lbf⋅ft
Air-conditioning compressor bracket 33.19 lbf⋅ft
expand_moreAir-conditioning compressor pressure line
All other modifications 5.9 lbf⋅ft
expand_moreAlternator
All Opel diesel straight-4 2.2 L G9T 720 engines 15.49 lbf⋅ft
All Opel diesel straight-4 2.2 L G9T 722 engines 15.49 lbf⋅ft
All Opel diesel straight-4 2.2 L G9T 750 engines 15.49 lbf⋅ft
expand_moreAll Opel diesel straight-4 3.0 L ZD3 200 engines
Lower screws 33.19 lbf⋅ft
Upper screws 16.23 lbf⋅ft
All other modifications 22.13 lbf⋅ft
Generator bracket 22.13 lbf⋅ft
Hydraulic lines at the servo-steering pump 15.49 lbf⋅ft
expand_moreServo pump pulley
All Opel diesel straight-4 3.0 L ZD3 200 engines 8.11 lbf⋅ft
All Opel diesel straight-4 3.0 L ZD3 202 engines 8.11 lbf⋅ft
All other modifications 7.38 lbf⋅ft
expand_moreServo steering pump
All Opel diesel straight-4 3.0 L ZD3 200 engines 16.23 lbf⋅ft
All Opel diesel straight-4 3.0 L ZD3 202 engines 16.23 lbf⋅ft
All other modifications 15.49 lbf⋅ft
expand_moreVacuum pump
All Opel diesel straight-4 3.0 L ZD3 200 engines 16.23 lbf⋅ft
All Opel diesel straight-4 3.0 L ZD3 202 engines 16.23 lbf⋅ft
All other modifications 16.96 lbf⋅ft
expand_moreCarburetion
expand_moreFuel-distributing pipe
G9U 750 engine 18.44 lbf⋅ft
Otherwise 16.96 lbf⋅ft
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 2.2 L G9T 750 89 HP 16.23 lbf⋅ft
Opel diesel straight-4 2.2 L G9T 720 89 HP 16.23 lbf⋅ft
Opel diesel straight-4 2.2 L G9T 722 89 HP at 3650 RPM, 260 N⋅m at 1500 RPM 16.23 lbf⋅ft
G9U 750 engine 18.44 lbf⋅ft
Otherwise 16.96 lbf⋅ft
All other modifications 18.44 lbf⋅ft
High-pressure pump pulley 66.38 lbf⋅ft
expand_moreInjection hoses
expand_moreAll other modifications
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
expand_moreAll other modifications
expand_moreFlywheel side
First stage 4.43 lbf⋅ft
Second stage 330390°
Front side 4.43 lbf⋅ft
expand_moreInjection pump
High-pressure pump 22.13 lbf⋅ft
expand_moreInjection pump pulley
Nuts 73.76 lbf⋅ft
Screws 28.03 lbf⋅ft
All other modifications 66.38 lbf⋅ft
expand_moreCharging
expand_moreTurbo charger
All Opel diesel straight-4 3.0 L ZD3 200 engines 22.13 lbf⋅ft
All Opel diesel straight-4 3.0 L ZD3 202 engines 22.13 lbf⋅ft
All other modifications 20.65 lbf⋅ft
expand_moreCooling system
expand_moreCoolant pump
expand_moreAll Opel diesel straight-4 3.0 L ZD3 200 engines
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
expand_moreCoolant pump pulley
All Opel diesel straight-4 3.0 L ZD3 200 engines 8.11 lbf⋅ft
All Opel diesel straight-4 3.0 L ZD3 202 engines 8.11 lbf⋅ft
expand_moreRadiator mounting
Opel diesel straight-4 3.0 L ZD3 200 134 HP at 3600 RPM, 320 N⋅m at 1800 RPM 14.75 lbf⋅ft
Opel diesel straight-4 3.0 L ZD3 202 134 HP at 3600 RPM, 320 N⋅m at 1800 RPM 14.75 lbf⋅ft
All other modifications 15.49 lbf⋅ft
expand_moreCylinder head
expand_moreCamshaft bearing
expand_moreAll Opel diesel straight-4 3.0 L ZD3 200 engines
First stage 8.85 lbf⋅ft
Second stage 15.49 lbf⋅ft
All other modifications 13.28 lbf⋅ft
expand_moreCylinder head screws
expand_moreAll Opel diesel straight-4 3.0 L ZD3 200 engines
Figure 1. Cylinder head, Cylinder head screws, Opel diesel straight-4 3.0 L ZD3 200.
Figure 1. Cylinder head, Cylinder head screws, Opel diesel straight-4 3.0 L ZD3 200.
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°
expand_moreAll other modifications
First stage 22.13 lbf⋅ft
Replace screws.
Second stage 294306°
Rocker bridge 9.59 lbf⋅ft
expand_moreValve cover
All other modifications 8.85 lbf⋅ft
expand_moreEngine block
expand_moreConnecting rod bearing
All Opel diesel straight-4 3.0 L ZD3 200 engines 59 lbf⋅ft
All Opel diesel straight-4 3.0 L ZD3 202 engines 59 lbf⋅ft
expand_moreAll other modifications
First stage 18.44 lbf⋅ft
Replace screws.
Second stage 4961°
expand_moreCrankshaft central screws
First stage 36.88 lbf⋅ft
Second stage 8496°
Opel diesel straight-4 3.0 L ZD3 202 134 HP at 3600 RPM, 320 N⋅m at 1800 RPM 280.27 lbf⋅ft
Opel diesel straight-4 3.0 L ZD3 200 134 HP at 3600 RPM, 320 N⋅m at 1800 RPM 280.27 lbf⋅ft
First stage 36.88 lbf⋅ft
Second stage 8496°
expand_moreAll other modifications
First stage 36.88 lbf⋅ft
Replace screws.
Second stage 8496°
expand_moreFlywheel
expand_moreAll Opel diesel straight-4 2.2 L G9T 720 engines
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
All Opel diesel straight-4 3.0 L ZD3 200 engines 125.39 lbf⋅ft
All Opel diesel straight-4 3.0 L ZD3 202 engines 125.39 lbf⋅ft
expand_moreAll other modifications
First stage 14.75 lbf⋅ft
Second stage 3951°
expand_moreMain bearing
First stage 14.75 lbf⋅ft
Replace screws.
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
expand_moreCamshaft timing gear
All Opel diesel straight-4 3.0 L ZD3 200 engines 44.25 lbf⋅ft
All Opel diesel straight-4 3.0 L ZD3 202 engines 44.25 lbf⋅ft
All other modifications 18.44 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.
expand_moreToothed belt guard
All other modifications 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 other modifications 18.44 lbf⋅ft
Toothed belt tightener 18.44 lbf⋅ft
expand_moreEngine lubrication
expand_moreOil drain plug
G9U 750 engine 18.44 lbf⋅ft
Replace the sealing ring and the oil drain plug.
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 3.0 L ZD3 202 134 HP at 3600 RPM, 320 N⋅m at 1800 RPM 25.08 lbf⋅ft
G9T 720 and G9T 722 engines 16.23 lbf⋅ft
G9T 750 engine 18.44 lbf⋅ft
G9U 750 engine 18.44 lbf⋅ft
Replace the sealing ring and the oil drain plug.
All other modifications 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 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
First stage 3.69 lbf⋅ft
Replace sealing rings.
Second stage 6.64 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
Opel diesel straight-4 3.0 L ZD3 202 134 HP at 3600 RPM, 320 N⋅m at 1800 RPM 5.16 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
expand_moreAll Opel diesel straight-4 2.2 L G9T 720 engines
G9T 720 and G9T 722 engines 11.06 lbf⋅ft
G9T 750 engine 8.11 lbf⋅ft
All Opel diesel straight-4 3.0 L ZD3 200 engines 12.54 lbf⋅ft
All Opel diesel straight-4 3.0 L ZD3 202 engines 12.54 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 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
expand_moreAll Opel diesel straight-4 3.0 L ZD3 200 engines
At the turbocharger 16.23 lbf⋅ft
On the engine block 33.19 lbf⋅ft
All other modifications 15.49 lbf⋅ft
expand_moreExhaust manifold
All Opel diesel straight-4 3.0 L ZD3 200 engines 30.98 lbf⋅ft
All Opel diesel straight-4 3.0 L ZD3 202 engines 30.98 lbf⋅ft
All other modifications 22.13 lbf⋅ft
expand_moreExhaust pipe
All other modifications 19.91 lbf⋅ft
expand_moreStart system
expand_moreStarter
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 3.0 L ZD3 200 134 HP at 3600 RPM, 320 N⋅m at 1800 RPM 25.81 lbf⋅ft
Opel diesel straight-4 2.2 L G9T 750 89 HP 32.45 lbf⋅ft
Opel diesel straight-4 2.2 L G9T 720 89 HP 32.45 lbf⋅ft
Opel diesel straight-4 2.2 L G9T 722 89 HP at 3650 RPM, 260 N⋅m at 1500 RPM 32.45 lbf⋅ft
Opel diesel straight-4 2.5 L G9U 754 98 HP 32.45 lbf⋅ft
All other modifications 33.19 lbf⋅ft

Please be noted that all capacities listed here are approximate. Check fluid levels when adding or refilling as recommended in your 2004 Opel Movano Kipper 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 Kipper 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 2004 Opel Movano Kipper you're not only saving money, but also also improving your technical skills and learning something new.

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