Do not allow dirt and moisture to enter the power supply system!
Some adjusting elements and connectors of the pump can be sealed by the manufacturer by painting over or installing wire protection, the removal of which leads to a violation of the warranty.
Engines 1.7 l SOHC
The fuel injection timing is calculated by the ECM based on the analysis of information from various sensors. The check can only be carried out with the use of special diagnostic equipment and its implementation should be entrusted to car service specialists.
Engines 1.7 L DOHC
Although the injection timing is set by the ECM on these engines, replacing the injection pump entails setting the injection timings to base values. A complete check can only be carried out with the use of special diagnostic equipment and its implementation should be entrusted to car service specialists.
1. If you haven't done so already, remove the intake duct with the air cleaner (see Removal and installation of components of an inlet air path). Also remove the top timing cover (see chapter Engine).
2. Turn out fixing bolts and remove fuel tubes of atomizers. The compilers of this manual believe that it is necessary to unscrew the mounting bolt (see chapter Engine) and move the oil cooler assembly back to provide adequate access to the high pressure pump - prepare to catch spilled fuel.
3. Bring the crankshaft to a position of 45°before TDC of the piston of the first cylinder (see chapter Engine).
4. Turn out the central screw of prorolling located between unions of connections of four fuel tubes in a back part of TNVD.
5. Screw the nozzle into the back of the pump and install a plunger type dial gauge - these tools (Opel KM-798) should be available to every diesel operator. Zero the meter at the plunger stroke position, and securely tighten the nozzle lock nut/bolt.
6. Slowly rotate the crankshaft in both directions, using the gauge readings, determine the bottom point of the stroke (NMT). After achieving the desired result, reset the meter.
7. Slowly turning the crankshaft clockwise, achieve alignment of the alignment mark of the crankshaft pulley with the counter pointer (TDC position of the end of the compression stroke of the piston of the first cylinder - see Chapter Engine).
8. Check the value of the plunger stroke taken by the meter against the requirements of the Specifications. If necessary, loosen the front nuts and rear pump mounting bolts and slowly turn the pump housing to achieve the desired result. Turning the pump towards the engine leads to a decrease in readings, from the engine - to an increase. Once satisfactory, tighten the front nuts and rear bolts to the correct torque.
9. Rotate the crankshaft one or three quarters of a turn in the normal direction (clockwise), install the pump plunger at BDC (see paragraph 7 above), then zero the meter.
10. Slowly rotating the crankshaft clockwise, achieve alignment of the installation mark on its pulley with the pointer (TDC of pistons of the 1st and 4th cylinders). Re-check the stroke value of the injection pump plunger stroke value.
11. If adjustment is required, loosen the pump mounting nuts and bolts and repeat the procedure (see paragraphs 9-10 above).
12. Having determined the exact value of the stroke of the pump plunger (and, therefore, the moment of injection) unscrew the nozzle and remove the meter.
13. Install the central bleed screw.
14. Restore the original connection of the fuel lines - make sure that the union nuts are tightened with the required force. If removed, reinstall the oil cooler housing and tighten its mounting bolt.
15. Install the top timing cover, air cleaner and intake ducts.
16. «pumping» the fuel system is automatic, although the engine start procedure may take a little longer than usual. Check the engine for signs of leak development.
Engines 2.0 l
The fuel injection timing is calculated by the ECM based on the analysis of information from various sensors. The check can only be carried out with the use of special diagnostic equipment and its implementation should be entrusted to car service specialists.
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