Vauxhall Workshop Service and Repair Manuals

Remove simplex chain tensioner (3) and duplex chain tensioner (2) – note installation position. Remove fastening bolt for camshaft sprocket from camshaft – counterhold with open-ended wrench on hex of camshaft.

  Install

Insert new bolt for camshaft sprocket and tighten hand-tight – ensure that the camshaft sprocket is not tilted on the camshaft. Camshaft sprocket must lie plane on the camshaft.

  Remove

Remove fastening bolts (1) and loosely screw in new fastening bolts (ensure that bolt strength is 10.9) - 5 fastening bolts for Y 20 DTH as of MY 2003 and Y 22 DTR.

Turn fuel injection pump sprocket until arrow (1) on simplex fuel injection pump sprocket aligns with recess in fuel injection pump flange and lock bore (2) in fuel injection pump.

  Install

Insert Injection Pump Lock Pin KM-927 (3) to stop in lock bore fuel injection pump.

Insert Duplex chain tensioner (4) into timing case – closed side of chain tensioner must point to tensioner blade. Install Duplex chain tensioner screw plug (2) with new seal ring (3) – tightening torque 60 Nm / 44 lbf. ft.

Caution

A distinction must be made between versions with and without release bolts (1). In versions with release bolts the chain tensioner must be untightened using the release bolt after installation!

  Inspect

Press in the release pin with a hammer shaft until a click is heard.

It must be possible to push in release bolt up to stop with thumb and for it to slide back to its original position automatically – the release bolt can no longer be pushed in once the oil pressure has built up.

Tighten fastening bolts (1) with bolt strength of 10.9 for Simplex injection pump wheel (tightening torque 28 Nm / 20.6 lbf. ft.) - 5 fastening bolts for Y 20 DTH as of MY 2003 and Y 22 DTR.

Insert Injection Pump Lock Pin KM-927 into fuel injection pump lock bore again.

Apply Test Gauge KM-932 (3) to cylinder head – pin (2) must engage in bore (1) of camshaft – if necessary, turn camshaft at hex (short path).

Caution

Turn camshaft carefully and smoothly.

Insert carrier (1) of Adjuster KM-933 (4) vertically into camshaft sprocket. Install Adjuster KM-933 on cylinder head.

  Adjust

Use handle (2) to exert slight pressure on the carrier in the direction of arrow (counter engine rotational direction) and fix in place with holder bolt (3).

Injection Pump Lock Pin KM-927 must be able to be installed and removed under suction. If this is not the case, decrease the pressure on the carrier disk slightly via the holder bolt.

Insert Simplex chain tensioner (4) into cylinder head – closed side of chain tensioner must point to tensioner blade. Install Simplex chain tensioner screw plug (2) with new seal ring (3) – tightening torque 60 Nm / 44 lbf. ft.

Caution

A distinction must be made between versions with and without release bolts (1). In versions with release bolts the chain tensioner must be untightened using the release bolt after installation!

  Inspect

Press in the release pin with a hammer shaft until a click is heard.

It must be possible to push in release bolt up to stop with thumb and for it to slide back to its original position automatically – the release bolt can no longer be pushed in once the oil pressure has built up.

  Adjust

At fastening bolt of torsional vibration damper, turn crankshaft two turns (approx. 720°) in engine rotational direction to just before "1st cylinder TDC" – mark (3) on torsional vibration damper is just before lug (2) on timing case.

  Inspect

In this position, the cams (1) of the 1st cylinder are just before TDC (both cams point upwards).

Insert Crankshaft Lock Pin KM-929 (1) in aperture for crankshaft pulse pick-up and simultaneously slowly turn crankshaft further in engine rotational direction at fastening bolt of torsional vibration damper until crankshaft lock pin engages to stop in cylinder block or crank web.

  Inspect

In this position, marks (2) must align.

Arrow (1) on simplex fuel injection pump sprocket must align with recess in fuel injection pump flange and lock bore (2) in fuel injection pump.

  Install

Insert Injection Pump Lock Pin KM-927 (3) in lock bore of fuel injection pump.

Apply Test Gauge KM-932 (3) to cylinder head – pin (2) must engage in bore (1) of camshaft.

Remove simplex chain tensioner (1) – note installation position.

Remove fastening bolt for camshaft sprocket from camshaft – counterhold with open-ended wrench on hex of camshaft.

  Install

Insert new bolt for camshaft sprocket and tighten hand-tight – ensure that the camshaft sprocket is not tilted on the camshaft. Camshaft sprocket must lie plane on the camshaft.

Arrow (1) on simplex fuel injection pump sprocket must align with recess in fuel injection pump flange and lock bore (2) in fuel injection pump.

  Install

Insert Injection Pump Lock Pin KM-927 (3) in lock bore of fuel injection pump.

Apply Test Gauge KM-932 (3) to cylinder head – pin (2) must engage in bore (1) of camshaft – if necessary, turn camshaft at hex (short path).

Caution

Turn camshaft carefully and smoothly.

Insert carrier (1) of Adjuster KM-933 (4) vertically into camshaft sprocket. Install Adjuster KM-933 on cylinder head.

  Adjust

Use handle (2) to exert slight pressure on the carrier in the direction of arrow (counter engine rotational direction) and fix in place with holder bolt (3).

Injection Pump Lock Pin KM-927 must be able to be installed and removed under suction. If this is not the case, decrease the pressure on the carrier disk slightly via the holder bolt.

Insert Simplex chain tensioner (4) into cylinder head – closed side of chain tensioner must point to tensioner blade. Install Simplex chain tensioner screw plug (2) with new seal ring (3) – tightening torque 60 Nm / 44 lbf. ft.

Caution

A distinction must be made between versions with and without release bolts (1). In versions with release bolts the chain tensioner must be untightened using the release bolt after installation!

  Inspect

Press in the release pin with a hammer shaft until a click is heard.

It must be possible to push in release bolt up to stop with thumb and for it to slide back to its original position automatically – the release bolt can no longer be pushed in once the oil pressure has built up.

  Adjust

At fastening bolt of torsional vibration damper, turn crankshaft two turns (approx. 720°) in engine rotational direction to just before "1st cylinder TDC" – mark (3) on torsional vibration damper is just before lug (2) on timing case.

  Inspect

In this position, the cams (1) of the 1st cylinder are just before TDC (both cams point upwards).

Insert Crankshaft Lock Pin KM-929 (1) in aperture for crankshaft pulse pick-up and simultaneously slowly turn crankshaft further in engine rotational direction at fastening bolt of torsional vibration damper until crankshaft lock pin engages to stop in cylinder block or crank web.

  Inspect

In this position, marks (2) must align.

Arrow (1) on simplex fuel injection pump sprocket must align with recess in fuel injection pump flange and lock bore (2) in fuel injection pump.

  Install

Insert Injection Pump Lock Pin KM-927 (3) in lock bore of fuel injection pump.

Apply Test Gauge KM-932 (3) to cylinder head – pin (2) must engage in bore (1) of camshaft.