Vauxhall Workshop Service and Repair Manuals

  Remove

Remove visco-fan – see operation "Visco-fan, Remove and Install".

Remove injection lines – see operation "Injection Lines, Remove and Install".

Remove wiring harness plugs (2) and (3).

Detach cable terminal (1) from fuel injection pump.

Remove closure plug (3) from cylinder block and insert Test Drift KM-813 (2).

  Adjust

At torsional damper hub, turn crankshaft in direction of engine rotation to "1st cylinder TDC".

  Inspect

Test Mandrel KM-813 must engage in flywheel and/or drive disc – for vehicles with automatic transmission, ensure that the test mandrel does not engage in indentation in fastening bolts of converter.

Remove oil filler cap and check position of 1st cam (1) – in TDC position, 1st cam must point upwards.

  Remove

Remove ribbed V-belts – see operation "Ribbed V-belts, Remove and Install".

Remove cover (3) for ribbed V-belt tensioner and remove fastening nut from injection pump shaft.

  Install

Attach Remover KM-825 (1).

  Remove

Remove fastening nuts (arrows) for injection pump.

Tighten bolt (2) of KM-825 until injection pump is released from sprocket.

Caution

Do not remove KM-825 from sprocket.

Remove injection pump.

Remove disc spring (1) from injection pump and check that it is in good condition.

Remove injection pump seal (2).

Note:   When replacing fuel injection pump, transfer all attaching parts.

  Install

Insert new seal ring (3) into injection pump.

Insert disc spring into injection pump shaft.

  Remove

Remove bolt from KM-825 – KM-825 must not be removed from sprocket.

  Install

Set injection pump shaft to sprocket position using Adjustment Lever KM-826 (1).

Insert injection pump with injection pump shaft into sprocket. Disc spring must engage in groove (arrow) of sprocket – ensure correct seating of injection pump.

Attach fastening nuts for injection pump, do not tighten.

Detach Removal Tool KM-825.

Attach fastening nut to injection pump shaft – tightening torque 48 Nm / 35 lbf. ft.

Install cover for ribbed V-belt tensioner with new gasket – tightening torque 20 Nm / 15 lbf. ft.