2. Raise the car and remove the bottom trim of the engine compartment.
3. Unscrew the cylinder head.
4. Set 1 cylinder to TDC. To do this, turn the crankshaft so that the TDC mark on the flywheel coincides with the protrusion on the clutch cover, and the mark on the camshaft wheel matches the mark on the guide rail.
5. Do not pull out the cold start acceleration cable.
6. Unscrew the screw plug in the pressure pump cover (see illustration).
7. Insert nozzle (OPEL KM-226) and a small dial indicator (value range 0-30 mm) in place of the screw plug (see illustration).
8. Slowly turn the crankshaft counterclockwise until the arrow on the indicator stops.
9. Set the indicator scale to position «0».
10. Turn the crankshaft in the direction of engine rotation (clockwise) so that the TDC mark on the flywheel coincides with the mark on the casing. The measuring device should show the amount of travel.
- For models without turbocharging - 0.93-1.03 mm.
- For turbocharged models - 0.85 mm.
Note: If the crankshaft has overshot the TDC mark, rotate it in the opposite direction, and then set it to TDC again.
11. If the meter reading is out of tolerance, loosen the injection pump mounting nuts and turn it until the desired value is reached.
12. Tighten the fixing nuts of the injection pump.
13. Check the installation again. To do this, turn the crankshaft in the direction opposite to the rotation of the engine until the arrow of the device stops moving (position «ABOUT»).
14. Slowly turn the crankshaft in the direction of engine rotation until the gauge shows the desired value.
15. In this position, check whether the mark on the clutch cover matches the TDC mark on the flywheel. Otherwise, repeat the installation.
16. Remove the dial indicator.
17. Install the lower trim of the engine compartment.
18. Lower the car.
19. Install the cylinder head cover.
20. Rotate the crankshaft ¼ turn.
21. Blow out and wash the fuel filter.
22. Press the hand pump until it fills with fuel.
23. Tighten the ventilation bolt with a new gasket ring.
24. Start the engine. If the engine does not start, bleed the pressure pipes at the nozzle holders, if necessary, bleed the air from the charge pump again.
25. With the engine running, check the tightness of the ventilation unit, tighten if necessary.
Visitor comments