Valve Timing Adjust Opel Agila B

Remove

1. 1. Before performing ANY work on fuel system or its components, switch OFF ignition and wait until pressure has dropped sufficiently (approximately 30 seconds). This waiting period is absolutely essential for fuel rail to be depressurised
2. 2. Raise vehicle
3. 3. Release 2x protective panelling from front panelling • Remove 4x clip (1)

4. 4. Lock crankshaft • Insert EN-46785 (1) through bore in transmission housing • Turn crankshaft carefully at bolt for torsional vibration damper flange until EN-46785 engages in flywheel

5. 5. Lower vehicle
6. 6. Disconnect battery negative lead • Release nut
7. 7. Disconnect hose (5) from mass air flow (MAF) meter (6) • Release clip
8. 8. Disconnect harness connector (3) from MAF meter
9. 9. Disconnect hose (1) from air cleaner assembly • Release from clip
10. 10. Remove air cleaner assembly (2) from vehicle • Remove 2x bolt (4) • Release 2x locator from battery tray – Pull up

11. 11. Remove cover (1) from engine • Remove 4x bolt

12. 12. Remove engine cover bracket and camshaft cover insulation (1) from engine • Remove 2x bolt (2)

13. 13. Remove intercooler outlet pipe (2) from engine • Release clip (1) • Remove 5x bolt

14. 14. Disconnect brake servo vacuum hose (1) from vacuum pump • Release clip
15. 15. For DPF vehicles only. Disconnect DPF vacuum hose (2) from vacuum pump • Pull off
16. 16. Release fuel return pipe mounting bracket from vacuum pump • Remove bolt
17. 17. Remove vacuum pump (3) from cylinder head • Remove 2x bolt

18. 18. Remove high pressure fuel pipe (2) from high pressure pump and fuel rail • Place collecting basin underneath. • Release 2x pipe union (1) • Install 4x new blanking plug
19. 19. Remove 4x injector pipe (3) from 4x fuel injector and fuel rail • Release 8x union • Install 16x new blanking plug

20. 20. Remove high pressure pump (1) • Disconnect wiring harness connector (3) • Unscrew 3x bolts (2)

Note. Note carrier

21. 21. Disconnect 4x harness connector (1) from 4x fuel injector
22. 22. Disconnect 4x glow plug connector (3)
23. 23. Disconnect harness connector (2) from camshaft sensor

24. 24. Disconnect harness connector from fuel rail pressure regulator (1)

25. 25. Disconnect harness connector (2) from fuel rail pressure sensor (1)

26. 26. Release engine wiring harness (1) from camshaft cover • Remove 3x bolt (2)

27. 27. Remove fuel rail (2) from fuel rail mounting bracket • Remove 3x bolt (1), then release fuel return hose from fuel return pipe • Release clip
28. 28. Remove engine cover bracket from fuel rail bracket • Remove, bolt
29. 29. Remove fuel rail mounting bracket (3) from engine • Remove 3x bolt

30. 30. Remove 2x blanking plug from camshaft housing

31. 31. Clean 4x threads • From closure bolts, camshaft housing
32. 32. Install Camshaft Positioning Tool EN-46781 (1) to intake side • Ensure correct installation position

Note. Fixing for Camshaft Positioning Tool must be installed in the horizontal position. To do this, apply marking to Camshaft Positioning Tool as an aid (arrow).

33. 33. Latch Camshaft Positioning Tool in intake camshaft • Rotate exhaust camshaft drive gear camshaft on bolt until the locking slots in camshaft are lined up with camshaft cover apertures and the Camshaft Positioning Tool fixing points audibly latch in intake camshaft

Note. Ensure that the Camshaft Positioning Tool does not twist.

34. 34. Remove blanking plug (1) from timing case

35. 35. Release intake camshaft sprocket • Release bolt (1), intake camshaft sprocket – Counterhold on camshaft drive wheel

Note. Use a second person

36. 36. Adjust exhaust camshaft • Rotate exhaust camshaft approx. 15° opposite to direction of engine rotation • Install Camshaft Positioning Tool EN-46781 on the exhaust side • Turn the exhaust camshaft on the camshaft drive pinion screw in direction of engine rotation until the Camshaft Positioning Tool latches into exhaust camshaft

Important. Counterhold exhaust camshaft drive wheel camshaft on bolt

37. 37. Fasten intake camshaft sprocket • Tighten bolt 150 Nm

Note. Use a second person

38. 38. Raise vehicle by its full height
39. 39. Remove crankshaft locating pin EN-46785
40. 40. Lower vehicle by its full height
41. 41. Remove 2x Camshaft Positioning Tool EN-46781
42. 42. Rotate engine • Turn crankshaft approx. 680° in the direction of engine rotation by the bolt on the torsional vibration damper flange
43. 43. Check position of camshafts, see Valve Timing Check

Install

44. 44. Install 2x blanking plug 15 Nm to camshaft housing • Apply suitable locking compound

45. 45. Install high pressure pump (1) • Replace seal • Tighten 3x bolt (2) 17 Nm • Connect wiring harness plug (3)

Note. Note carrier, bevelled side points towards camshaft.

46. 46. Install vacuum pump (3) to camshaft housing • Install 2x bolt 23 Nm
47. 47. Secure fuel return pipe bracket to vacuum pump • Install bolt
48. 48. Connect 2x hose (1), (2) to vacuum pump • Push on

49. 49. Install fuel rail mounting bracket (3) to engine • Install 3x bolt 28 Nm
50. 50. Install engine cover bracket to fuel rail bracket • Install bolt
51. 51. Install fuel rail (2) to fuel rail mounting bracket • Install 3x bolt (1), do not tighten at this stage

52. 52. Install 4x new high pressure pipe (4) to fuel rail and 4x fuel injector • Remove 16x blanking plug • Install 8x union, do not tighten at this stage
53. 53. Install high pressure pipe to common rail and high pressure fuel pump • Remove 4x blanking plug • Install 2x union, do not tighten at this stage
54. 54. Secure fuel rail (1) to cylinder head • Secure 3x bolt (2) 25 Nm
55. 55. Secure 4x high pressure pipe union to 4x fuel injector • Secure 4x pipe union 27 Nm
56. 56. Secure high pressure pipe union to high pressure pump • Secure pipe union 27 Nm
57. 57. Secure 2x high pressure pipe union (3) to fuel rail • Secure 2x union 29 Nm
58. 58. Secure 3x high pressure pipe union to fuel rail • Secure 3x union 32 Nm

59. 59. Secure engine wiring harness (1) to camshaft cover • Install 3x bolt (2) 11 Nm

60. 60. Connect harness connector (2) to fuel rail pressure sensor (1)

61. 61. Connect harness connector to fuel rail pressure regulator (1)

62. 62. Connect 4x harness connector (1) to 4x fuel injector
63. 63. Connect 4x glow plug connector (3) to 4x glow plug
64. 64. Connect harness connector (3) to camshaft sensor

65. 65. Install intercooler outlet pipe (2) to engine • Secure clip (1) • Install 5x bolt

66. 66. Install engine cover bracket and cylinder head cover insulation (2) to engine • Install 2x bolt (1) 11 Nm

67. 67. Install cover (1) to engine • Install 4x bolt 8 Nm

68. 68. Install air cleaner assembly (2) to vehicle • Push down to secure 2x locator to battery tray • Install 2x bolt (4)
69. 69. Connect hose (5) to mass air flow (MAF) meter (6) • Secure clip
70. 70. Connect harness connector (3) to MAF meter
71. 71. Connect hose (1) to air cleaner assembly • Secure to clip

72. 72. Secure 2x protective panelling to front panelling • Install 4x clip (1)

73. 73. Lower vehicle