Cars built before 6/84
Remove air filter.
Remove the camshaft cover see point 1.6.
Remove clutch cover see point 9.1.
Remove upper and lower toothed belt guards.
Check toothed belt tension.
Put 1 cylinder at TDC. The mark on the flywheel must match the mark on the clutch housing (Pic. B4738).
The marking on the gear wheel of the injection pump must match the marking on the bracket.
Shine the vacuum pump.
Instead of the pump, install KM-537, blocking the camshaft, in the TDC position, if there is no KM-537, then the adjustment can be made using a micrometer.
Attention: KM-537 must be installed without voltage, so as not to change the TDC position.
If the KM-537 tool is installed with tension, then it is necessary to adjust the position of the camshaft / camshaft wheel.
Remove the camshaft wheel by holding it by the flats between the intake and exhaust cams of cylinder 4 with a wrench.
Block the KM-537 camshaft. Turn the camshaft with a wrench so that the tool can be installed without tension.
Check the coincidence of all TDC markings, otherwise adjust.
Attention: The deviation of the mark on the flywheel from the index mark should be no more than±1.0 mm.
Tighten camshaft wheel screws to 90 Nm.
Remove KM-537
Check again the rose adjustment. To do this, rotate the crankshaft but 90°back and again to TDC.
Install vacuum pump.
Check toothed belt tension see point 6.6.
Check the delivery moment of the pressure pump, see clause 7.11.
Install the clutch cover.
Install the upper and lower toothed belt guards.
Install and tighten the camshaft cover.
Install the air filter.
Adjusting the valve timing in cars manufactured after 6/84
Adjustment of the valve timing, until now, was carried out by blocking the camshaft with the KM-537 OPEL blocker. Since June 1984, there are no more holes in the camshaft housing for installing the KM-537. Blocking the camshaft in this way is not possible.
The valve timing is now adjusted using the KM-537 OPEL measuring strip and a micrometer.
If there is no measuring bar at hand, then the measurement can be made using a micrometer and a crossbar placed on the camshaft housing. This adjustment method can also be used on cars manufactured before June 1984.
Turn the crankshaft so that the marking on the flywheel matches the pointer on the clutch housing (photo). The piston of the 1st cylinder in this case is at TDC, the valves of the 4th cylinder overlap.
The marking on the gear wheel of the injection pump matches the marking on the water pump bracket (left photo).
Attention: Check the tension of the toothed belt using KM-510 A, if necessary, adjust, see paragraph 6.6.
Install the measuring bar KM-238 with a micrometer so that the leg of the micrometer ∅ 7-10 mm is at the base of the 2nd cam of the inlet valve of the 1st cylinder. Set micrometer to 0.
Move the micrometer together with the tire towards the top of the cam by 10 mm.
Using a 22 mm wrench, turn the camshaft clockwise until the micrometer foot rises 0.56 mm.
While holding the camshaft in this position, tighten the wheel screws to 90 Nm.
Check the adjustment again. Also check the adjustment of the pressure pump. Adjust.
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