Keep dirt out of the pump and fuel lines.
Models 1.7L SOHC
1. Disconnect the negative cable from the battery.
2. Remove the pump drive gear (see chapter Engine).
3. Turn out nuts of union connections and remove fuel pipes (see Removal and installation of fuel injectors).
4. Release the latch (1) fastening the contact connector of the injection pump control module to the engine, disconnect the connector.
5. Thoroughly clean and mark fuel lines to be disconnected. Remove the sealing rings of the nipple connectors, plug the open ends of the tubes immediately after disconnection with suitable plugs.
6. Turn out bolts of fastening of a back arm of fastening of the pump to an arm on the block of cylinders.
7. Turn out forward fixing nuts and remove the pump from the engine.
Do not attempt to disassemble the injection pump! In the event of signs of a violation of the functioning of the pump, seek advice from a car service specialist.
8. Install the pump in its original place, screw in the front and rear mounting bolts and tighten them to the required torque.
9. Restore the original wiring connection, make sure that the connector is securely fixed by the locking element, - press the latter to the left along the car.
10. Connect the fuel supply and return lines to the pump, tighten the union connections with the required force.
11. Make sure that the elements of the union connectors are absolutely clean and dry and restore the connection of the fuel lines to the injection nozzles - make sure that the nuts of the union connectors are tightened with the required force.
12. Reinstall the gear wheel of the high-pressure fuel pump and tighten its fastening bolt by hand - it should be possible to turn the wheel by hand.
13. Putting an open-end wrench on the mounting nut, turn the pump mounting flange until its mark is aligned with the risk on the gear wheel and the lock drilling in the pump. Pass the Vauxhall KM-6011 tool through the flange and insert it into the drilling, thereby fixing the pump assembly. In the absence of a special tool at hand, you can use a piece of bar with a diameter of 9.5 mm and 75 mm in length.
14. Install the timing belt (see chapter Engine).
15. Further installation is carried out in the reverse order to the dismantling of the components. Pay attention to the following points:
- Make sure that all fasteners are tightened with the required force;
- Make sure that the laying is correct and the electrical wiring is securely fixed, if necessary, replace the connectors;
- After starting the engine, check the union connectors for signs of leaks.
Remember that starting the engine will take a little longer than usual, due to the need for automatic bleeding of the fuel path in order to remove air pockets from it.
Models 1.7L DOHC
1. Disconnect the negative cable from the battery.
2. Remove the pump drive gear (see chapter Engine).
3. Remove the inlet pipeline (see Removal and installation of the inlet pipeline).
4. Remove the injection pump control module (see Removal and installation of electrical components of the power system).
5. Disconnect the electrical wiring and two vacuum tubes, unscrew the two mounting bolts and remove the boost pressure control solenoid valve (see Removal and installation of electrical components of the power system).
6. Disconnect the electrical wiring from the atmospheric pressure sensor, remove the sensor from the mounting bracket (see Removal and installation of electrical components of the power system). Turn out two fixing bolts and remove an arm. Remove the mounting bracket for the injection pump control module.
7. Disconnect the fuel supply and return lines from the pump.
8. Pull off the insulation of the high-pressure fuel pump, disconnect the contact connectors of the information sensors on the pump, release the harnesses from the intermediate clamps - try to remember the order of laying the wires.
9. Turn out two fixing nuts and take TNVD from the case of the gas-distributing mechanism. Remove the sponge insulation laid between the pump and the cylinder block.
In no case do not attempt to disassemble the high-pressure fuel pump; if necessary, contact a car service specialist for help.
10. Lay a new sponge seal between the pump and the cylinder block, achieve the required engagement of the pump shaft with the gas distribution mechanism, then screw on two new fixing nuts - at this stage, tighten the nuts only by hand.
11. Install the injection pump support bracket on the cylinder block, screw in the fixing bolts and tighten them with the required force. For now, hand-tighten the bracket-to-pump bolts only. Lay sponge insulation around the pump. Connect the wiring to the pump memory before installing the rear (PROM) on the side of the assembly.
12. Replace the pump drive gear (see chapter Engine).
13. Install the timing belt (see chapter Engine).
14. Perform injection timing procedures (see Checking and adjusting fuel injection timing settings).
15. Further installation is carried out in the reverse order to the dismantling of the components. Pay attention to the following points:
- Make sure all fasteners are tightened to the correct torque.
- Make sure that the laying is correct and that the electrical wiring is securely fixed; if necessary, replace the connectors.
- After starting the engine, check the union connectors for signs of leaks.
Remember that starting the engine will take a little longer than usual, due to the need for automatic bleeding of the fuel path in order to remove air pockets from it.
2.0 liter models
Since the dismantling of the pump is associated with the need to remove the upper timing chain and sprockets, the installation will require special Opel tools, or their self-made counterparts, to be sure, without the use of which the installation of the valve timing is not possible (see chapter Engine). If it is not possible to use special tools, contact a car service specialist for help. If, due to circumstances, the pump has to be removed without the use of special tools, first mark the relative position of the sprockets and flanges. It will not be superfluous to purchase a special head MKM-604-30, which will be needed to unscrew the front bolts for fastening the injection pump.
When installing, you will need a new camshaft sprocket bolt and upper chain guide bolts.
1. Remove the inlet pipeline (see Removal and installation of the inlet pipeline).
2. Thoroughly wipe the surfaces around the fittings, then remove the bolts, remove the sealing washers, disconnect and lay aside the fuel supply and return lines.
3. Remove the upper timing chain and sprockets.
4. Remove the front bolts through the holes in the lower chain sprocket (1) injection pump mountings.
5. Turn out fixing bolts and remove an arm of fastening of the pump.
6. Remove the pump from the seat assembly with the sealing ring - during assembly, the ring must be replaced without fail.
In no case do not attempt to disassemble the high-pressure fuel pump; if necessary, contact a car service specialist for help.
7. Before installation, make sure that the markings on the pump flange are correctly aligned with the fixing hole in the casing. Check the correct position of the crankshaft and camshaft.
8. Install the pump in place - make sure that the sprocket is correctly aligned with the pump flange. Screw in the front pump mounting bolts and tighten them to the required torque.
9. Install the support bracket on the back of the pump and tighten the pump mounting bolts to the required torque.
10. Install the upper timing chain and sprockets (see chapter Engine).
11. Install new sealing washers on both sides of the nipple connections of the fuel supply and return lines, screw in the nipple bolts and tighten them to the required force.
12. Install intake piping (see Removal and installation of the inlet pipeline).
13. Connect the negative cable to the battery and start the engine.
Visitor comments