Note: Before you begin, see. Chapter 2. Use new gaskets when installing the carburetor. A tachometer and exhaust gas analyzer are required to check the idle speed and mixture.
Removal
1. Disconnect the negative cable from the battery.
2. On early models, remove the air cleaner. On later models, disconnect the main air duct from the air cleaner, then disconnect the vacuum pipe and breather hose from the air block. Remove the three mounting screws, remove the air block together with the main air duct.
3. On 1.4 liter models, disconnect the fuel supply hose from the carburetor, and on 1.6 and 1.8 liter models, disconnect the fuel supply and return hoses from the vapor separator. Plug the ends of the hoses to prevent dirt from entering and causing further fuel leakage.
4. Remove the clip from the throttle cable end in the bracket on the carburetor, then pull the sealing ring off the bracket, disconnect the end of the cable from the throttle lever.
5. Disconnect the coolant hoses from the automatic air damper housing; note their location to make installation easier. Plug the hoses or secure them with the ends pointing upward to prevent further loss of coolant.
6. Disconnect the vacuum tubes from the front of the carburetor, remembering their location and direction so as not to mix them up during installation (see illustration).
7. Disconnect the damper heater wire and other electrical wiring.
8. Unscrew the three mounting nuts and remove the carburetor from the mounts on the intake manifold.
9. Remove the gaskets and the seal block installed between the carburetor and the intake manifold.
Bulkhead
11. Blow out the jets and holes with compressed air, under no circumstances use a wire for cleaning. If it is necessary to remove the jets, unscrew them carefully with a well-suited tool.
12. Remove the fuel filter gauze from the inlet connector using the Chapter 21. Opel recommends replacing it every time the carburetor is cleaned.
13. Clean the float chamber. Replace the float, needle and seat if they are worn or if the float is punctured or otherwise damaged. Check that the float regulator needle is completely closed before the float reaches the upper position. To check the upper position of the float, see. Chapter 15.
14. Replace the diaphragms in the part load enrichment valve and in the accelerator pump. If the repair kit includes parts for the accelerator pump or enrichment valve, replace those parts as well.
15. Further disassembly is not recommended. Pay special attention to the location of the throttle opening mechanism if you decide to disassemble it.
16. Reassemble in reverse order. Use new gaskets and seals everywhere; lubricate the rods with molybdenum grease.
Installation
17. Before starting work, perform the following procedure.
- a) Place the fast idle adjusting screw at the highest notch of the fast idle cam.
- b) Use a drill bit of the diameter specified in the Specifications to measure the primary throttle valve opening.
- c) Adjust the fast idle screw if necessary.
- d) Please note that all this is preliminary adjustment; the final adjustment of the increased idle speed must be made with the engine running.
18. Installation is carried out in the reverse order, replace the gaskets.
19. After installation, perform the following checks and adjustments.
20. Check the throttle cable free play, adjust if necessary as described in Chapter 11.
21. Check the coolant level and top up if necessary as described in Section 3.
22. Check and, if necessary, adjust the idle speed and mixture as described in Chapter 14.
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