Solenoid valve replacement

The solenoid valve cuts off the fuel supply as soon as the engine is shut off.

■ Remove the power cable from the solenoid valve.

■ Unscrew the valve.

■ Screw in the valve with a new gasket and tighten to torque 2,5 Nm.

■ Overtightening may cause the valve to short out.

■ Connect the electric cable.

Injection pump replacement

A Bosch injection manifold pump is used in the supply system. Proceed as follows to remove the injection pump:

■ Remove the V-belt

■ Remove the upper and lower toothed belt covers.

■ Remove the cover on the coupling housing.

■ Remove the vacuum pump

■ Unscrew the camshaft housing cover.

■ By turning the crankshaft, set the plunger 1. cylinder in position ZZ; the timing marks on the valve timing and the injection pump must match

■ Loosen the bolts securing the coolant pump, turn the pump housing and remove the slack toothed belt.

■ Block the injection pump drive gear with a screwdriver. Remove three bolts and one wheel nut.

■ Slide the drive wheel off using the special puller (Opel-KM –532), previously marking the previous location.

■ Disconnect the injection and return lines from the pump.

■ Pull off the electric wire that powers the solenoid valve.

■ Remove the three screws securing the pump.

■ Remove the injection pump.

The sequence of steps when assembling the injection pump is as follows.

■ Insert bolts into injection pump drive sprocket.

■ Turn the pump hub against the drive wheel, counterclockwise, until the bolts stop in the oblong holes.

■ Lightly tighten the screws.

■ Install the injection pump and drive sprocket.

■ Put the pump on 1 cylinder, i.e.. turn the drive wheel, so that the arrow is pointing vertically up. The pump connection will then be at the "D."”.

■ Connect the injection and return pipes.

■ Connect the electric wire to the solenoid valve.

■ Loosen the camshaft sprocket fixing bolt, holding the shaft with a spanner.

■ Put on the toothed belt and tighten it

■ Check the setting of the control marks on the handwheel and correct if necessary

■ Tighten the camshaft sprocket, trying not to allow it to rotate in relation to the shaft.

■ Check valve timing and adjust

■ Install the vacuum pump

■ Install the camshaft housing cover

■ Set injection pump discharge start, as described below

■ Tighten the bolts on the pump wheel

The rest of the steps are in the reverse order to that for dismantling