Vauxhall Workshop Service and Repair Manuals

Fuel Injection Pump, Remove and Install

Important:   For Y 20 DTH as of MY 2003, Y 22 DTR: Security code must be reset using TECH2 before removal when replacing or swapping injection pump - see relevant test instruction

  Remove

1.	Remove inlet manifold upper section •   For X 20 DTL, Y 20 DTL, Y 20 DTH up to MY 2003 •   For Y 20 DTH as of MY 2003, Y 22 DTR

2.	Remove intake manifold lower part

3.	Remove air cleaner housing with hot film mass air flow meter and air intake hose •   X 20 DTL and Y 20 DTH •   Y 20 DTH up to MY 2003 •   Y 20 DTH as of MY 2003 and Y 22 DTR

4.	Lock engine on no. 1 cylinder "Ignition TDC"

Important:   To avoid bending the pins and thus replacing the injection pump, protective caps KM-6154 must be fitted on the injection pump immediately after removing the wiring harness plug and removed again just before attaching the wiring harness plugs 6.   For Y 20 DTH from MY 2003, Y 22 DTR engine: Detach wiring harness plugs (2) and attach KM-6154 (1) to injection pump

7.   Remove Simplex chain tensioner (3) •   Note installation position. Important:   Use sheet metal plate or suitable heat shielding to avoid damaging the guide rails 8.   Heat fastening bolts (1) intensively with hot air blower and remove 9.   Remove guide rail for simplex timing chain upwards •   Note installation position. 10.   Clean thread for the fastening bolts (1) in cylinder head 11.   Remove duplex chain tensioner (2) •   Note installation position.

14.   Remove fastening bolts (1) and simplex injection pump gear Note:   For Y 20 DTH from MY 2003 and Y 22 DTR: 5 fastening bolts 15.   Remove simplex timing chain upwards from cylinder head

16.   Remove fastening bolts (1) from injection pump with MKM-604-D 17.   Detach fuel injection pump bracket (2) from cylinder block and fuel injection pump. Remove fuel injection pump towards rear out of cylinder block and remove upwards out of engine compartment

  Install

Important:   The spacer disc (1) on the fuel injection pump flange (3) must not be removed, as this disc compensates for manufacturing tolerances and therefore corresponds to a precisely defined axial dimension 18.   Replace gasket (2) 19.   Insert injection pump in cylinder block •   Ensure that the duplex sprocket sits straight on the injection pump flange without tilting

23.   Guide simplex timing chain through timing case, and insert simplex injection pump gear in simplex timing chain •   Arrow (2) must align with recess in injection pump flange and retaining bore (3) in injection pump 24.   Loosely hand-tighten new fastening bolts (1) with bolt strength 10.9 of the simplex injection pump gear Note:   For Y 20 DTH from MY 2003 and Y 22 DTR: 5 fastening bolts 25.   Insert injection pump locking pin KM-927 (4) in retaining bore of fuel injection pump 26.   Insert camshaft sprocket in simplex timing chain and fasten hand-tightened to camshaft with new fastening bolt •   Ensure that the camshaft sprocket is not askew on the camshaft •   Camshaft sprocket must lie flat on the camshaft

Important:   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 27.   Insert duplex chain tensioner (4) in timing case •   The closed side of chain tensioner must point to tension rail. Install duplex chain tensioner closure bolt (2) with new seal ring (3) •   Tightening torque 60 Nm / 44 lbf. ft. 28.   Press in the release pin with a hammer shaft until a click is heard 29.   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

31.   Tighten fastening bolts (1) for simplex injection pump gear Note:   For Y 20 DTH from MY 2003 and Y 22 DTR: 5 fastening bolts •   Tightening torque 28 Nm / 20.6 lbf. ft. 32.   Re-insert injection pump locking pin KM-927 into injection pump retaining bore

33.   Position test gauge KM-932 (3) on cylinder head •   Pin (2) must engage in hole (1) of camshaft

34.   Insert and install simplex timing chain guide rail (1) Note:   Check installation position •   Use new fastening bolts (2) •   Tightening torque 8 Nm / 6 lbf. ft.

35.   Insert carrier (1) of adjuster KM-933 (4) vertically into camshaft sprocket. Mount adjuster KM-933 on cylinder head 36.   Use toggle (2) to exert slight pressure on the carrier in the direction of arrow (counter to direction of engine rotation) and fix in place with locking bolt (3) 37.   Injection pump locking pin KM-927 must be able to be installed and removed under suction. If this is not possible, decrease the pressure on the carrier disc slightly using the locking screw. 38.   Fasten camshaft sprocket to camshaft •   Tightening torque 90 Nm / 66 lbf. ft. + 60° + 30°

Important:   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 39.   Insert simplex chain tensioner (4) in cylinder head •   The closed side of the chain tensioner must point to tension rail. Install simplex chain tensioner closure bolt (2) with new seal ring (3) •   Tightening torque 60 Nm / 44 lbf. ft. 40.   Press in the release pin with a hammer shaft until a click is heard 41.   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

43.   At fastening bolt of torsional vibration damper, turn crankshaft two turns (approx. 720°) in direction of engine rotation to just before "1st cylinder TDC" •   The mark (3) on the torsional vibration damper is located just before the lug (2) on the timing case 44.   In this position, the cams (1) of the 1st cylinder are just before TDC (both cams point upwards)

45.   Insert crankshaft locking 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 46.   Insert fuel injection pump locking pin KM-927 (2) into injection pump retaining bore and test gauge KM-932 (3) into cylinder head Note:   If a tool cannot be inserted, then the adjustment procedure must be completely repeated

49.   Apply an approx. 2 mm (Dimension I) thick bead of silicone sealing compound to timing case cover. Note:   The silicone sealing compound must be applied and the timing case must be installed (including torque checking) within 10 minutes

53.	Install ribbed V-belt tensioner

56.	Install air cleaner housing with hot film mass air flow meter and air intake hose •   X 20 DTL and Y 20 DTH •   Y 20 DTH up to MY 2003 •   Y 20 DTH as of MY 2003 and Y 22 DTR

58.	Install intake manifold lower part

59.	Install inlet manifold upper section •   For X 20 DTL, Y 20 DTL, Y 20 DTH up to MY 2003 •   For Y 20 DTH as of MY 2003, Y 22 DTR